Tuesday, 25 August 2015

Basics of Pattern Making

The development of a garment comprises of different process. Fit is the most important factor leading to the final acceptance or rejection of a garment. Fit must be designed into the original pattern through subtleties in the pattern that provide fullness unobtrusively at appropriate locations to accommodate body bulges in a flattering manner (Hudson). Good customized fit is dependent on the pattern drafting incorporating various shapes and proportions of the individual customer. With the onset of the Industrial Revolution, standardized patterns were essential to the success of ready-to-wear clothing.

Pattern making is an art. It is the art of manipulating and shaping a flat piece of fabric to conform to one or more curves of the human figure . Pattern making is a bridge function between design and production. A sketch can be turned into a garment via a pattern which interprets the design in the form of the garment components.

A pattern is flat while the body is not. The body has height, width and depth. With in this roughly cylindrical framework there are a series of secondary curves and bulges, which are of concern to the pattern maker. Darts are the basis of all pattern making. They convert the flat piece of cloth into a three dimensional form, which fits the bulges of the body.

A patternmaker typically makes a pattern from a flat sketch with measurements or a two dimensional fashion illustration. The basic pattern is the very foundation upon which pattern making, fit and design are based. The basic pattern is the starting point for flat pattern designing. It is a simple pattern that fits the body with just enough ease for movement and comfort (Shoben and Ward).

Methods of Pattern Making

Pattern making involves three methods-

  • Drafting
  • Draping
  • Flat paper patternmaking


Drafting: It involves measurements derived from sizing systems or accurate measurements taken on a person, dress or body form. Measurements for chest, waist, hip and so on, and ease allowances are marked on paper and construction lines are drawn to complete the pattern. Drafting is used to create basic, foundation or design patterns.

Draping: It involves the draping of a two dimensional piece of fabric around a form, conforming to its shape, creating a three-dimensional fabric pattern. This muslin is transferred to paper to be used as a final pattern (Armstrong). Ease allowances for movement are added to make the garment comfortable to wear. Advantage of draping is that the designer can see the overall design effect of the finished garment on the body form before the garment piece is cut and sewn. However, it is more expensive and time consuming than flat pattern making.


Flat Pattern Making: It involves the development of a fitted basic pattern with comfort ease to fit a person or body form. A sloper is the starting point for flat pattern designing. It is a simple pattern that fits the body with just enough ease for movement and comfort (Shoben and Ward). Five basic pattern pieces are used for womens clothing. They include a snug-fitting bodice front and bodice back with darts and a basic neckline, a sleeve and a fitted skirt front and back with darts. However, as fashion changes frequently womens styles fluctuate frequently. These basic slopers are then manipulated to create fashions.

A basic sloper has no seam allowances, which facilitates its manipulations to various styles. It has no design interest, only construction lines are marked on it. It is necessary that the basic structure of a sloper should be such that adjustments can be introduced easily. For a good pattern making, accurate measurements are of utmost importance.

The flat patternmaking method is widely used in the ready-to-wear market because it is fast and accurate.



Pattern making in today's world

Pattern making today has become an easy job with the use of the computers. Now-a-days different softwares are available in the market to meet the needs of the manufacturers. The different softwares used are Gerber, Lectra, Tukatech , OptiTex etc. These softwares has made the job of the Pattern master easier. They have made the process of pattern making more economical and less time consuming.

Pattern-making softwares enables you to input your measurements and draft out a pattern. These softwares draft patterns to fit your measurements specifically, eliminating much fitting trial and error in the sewing room.

A pattern can be made from a 3D form in just a few steps by using these softwares. An individual's measurements are collected from 3D body scanner. The measurements are used to create a virtual 3D model of the individual's body. The 3D to 2D software allows the user to define a garment surface in relation to the 3D body model. Once the garment surface is defined, the application automatically unwraps and outputs a 2D flat pattern in .dxf format.

MEASUREMENTS 
  • Bust – measure just under the arms around the fullest part of chest. 
  • Waist – measure around narrowest part of torso. 
  • High Hip – measure 6 inches [15.5 cm] below waist around the hips. 
  • Back-waist length – measure from nape of neck to waist level 
  • Shoulder length – measure shoulder from ball socket to side of neck. 
  • Armhole depth – measure from nape of neck to under arm level. 
  • Back width – measure from armhole to armhole across shoulder blades. 
  • Neck – measure around base of neck. 


Tools use for Drafting 

Tape Measure :- This is likely something you already have in your stash, because if you have been making clothing you should have been measuring your body along the way! If not, pick up a good quality fiberglass tape measure today so you can start your pattern making off right with correct body measurements. 

Seam Ripper :- Like the tape measure, you probably have a seam ripper. You will use this in patternmaking for taking out your basting stitches when you move from the muslin fitting to the pattern drafting stage. 

Fine Point Sharpie Marker :-Muslin versions are always ugly because they are marked up, but you want to make your markings with a permanent and fine point. I like these push-button fine point sharpie pens as the cap always seems to get lost in my studio! These are quick and easy to use. 

Tracing Wheel :-To take your markings from the muslin stage to the patternmaking stage, this tool will pierce through the paper and leave behind marks to draft with a mechanical pencil. 

Rotary Cutter :-I like using my rotary cutter for the big broad strokes of cutting muslin. Make sure to use a cutting mat beneath your item to protect the cutting surface of the table underneath! 

Fabric Scissors :-Sharp, high-quality scissors are used for all your fabric cutting in sewing and patternmaking. These will shape the muslin down to the proper size after you have cut it big and broad with the rotary cutter. 

Tracing Paper :-I personally do not use this, but many designers like it for leaving marks behind on their muslins. I like a sharpie or tracing wheel, but try these sheets out and perhaps you will love them! Many people do. 

Scotch Tape :-It is inevitable that you will need to tape pattern pieces together and I find that basic Scotch tape is the best for this. 

Clear Rulers :-Having a variety of clear rulers in different shapes and sizes is essential in your kit for patternmaking. I like having a little one for marking in tiny areas, long ones for making marks for pin tucks, side seam lines, and other parts of the patternmaking process that call for something longer than average. I also have a quilting square with diagonal lines for helping square up corners and creating angles. 

Right Angle :-This is also a huge help in creating perfect 90 degree angles on your pattern. These are also available in clear plastic, which most people prefer. I have had this black one since art school and still use it. 

Curved Rulers :-To shape arm holes, hip curves, hems and other lines that are not straight in patternmaking, it is essential that you have a few different curved rulers to get the proper slope in your pattern


Standard pattern symbols
Sewing patterns typically include standard symbols and marks that guide the cutter and/or sewer in cutting and assembling the pieces of the pattern. Patterns may use:


  • Notches, to indicate: 
    • Seam allowances. (not all patterns include allowances)
    • Centerlines and other lines important to the fit like the waistline, hip, breast, shoulder tip, etc.
    • Zipper placement
    • Fold point for folded hems and facings
    • Matched points, especially for long or curving seams or seams with ease. For example, the Armscye will usually be notched at the point where ease should begin to be added to the sleeve cap. There is usually no ease through the underarm.
  • Circular holes, perhaps made by an awl or circular punch, to indicate:
    • A dart apex
    • Corners, as they are stitched, i.e. without seam allowances
    • Pocket placement, or the placement of other details like trimming
    • Buttonholes and buttons
  • A long arrow, drawn on top of the pattern, to indicate:
    • Grainline, or how the pattern should be aligned with the fabric. The arrow is meant to be aligned parallel to the straight grain of the fabric. A long arrow with arrowheads at both ends indicates that either of two orientations is possible. An arrow with one head probably indicates that the fabric has a direction to it which needs to be considered, such as a pattern which should face up when the wearer is standing.
  • Double lines indicating where the pattern may be lengthened or shortened for a different fit
  • Dot, triangle, or square symbols, to provide "match points" for adjoining pattern pieces, similar to putting puzzle pieces together
Many patterns will also have full outlines for some features, like for a patch pocket, making it easier to visualize how things go together.


Saturday, 22 August 2015

APPAREL PRODUCTION SYSTEMS


             The production process involves myriad steps and depends on the talent and skill of many individuals. It is a team effort.
             Apparel making is not conductive precision mass production. Frequent style changes and varying degrees of fabric work ability force continual adjustment in the manufacturing process standardized equipment is difficult to design and implement and production is there fore dependent on skilled workers.
An apparel production system is an integration of material handling, production processes, personnel and equipment that direct work flow and generates finished product.
       Three types of production systems that are commonly used to mass produce apparel or are:
  1. 1.    MAKE THROUGH SYSTEM,
  2. 2.    MODULAR PRODUCTION SYSTEM,
  3. 3.    ASSEMBLY LINE SYSTEM.




Each system requires different types of:
·         management philosophy
·         material handling arrangement
·         floor layout
·         employee training
·         Companies may combine the systems or use only one depending on their need.

1.    Make through system :-
    It is the traditional method of manufacture in which an operator makes right through one garment at a time. That is one operator will do all the stages of the sewing operations of one garment and after completing it he will go for the next garment
The advantages of the make through system are:
·         Quick throughput time
·         Easy to supervisor.

The disadvantages of the make through systems are:
·         low productivity
·         high labor cost
·         only very experienced operator can be used
·         it is a system only suitable in couture and sample making



2. Modular system :-
     "An organized group of individuals working together in a co-operative manner to accomplish a common purpose"
   “A group of people who working together to accomplish individual goals effectively and efficiently while simultaneously accomplishing goals of the team or organisation"
   “A team is a small number of people with complimentary skills who are committed to common purpose, set of performance goals, and approach for which they hold themselves mutually accountable".
Working in modular system:
·         The line layout is U -shaped with garments progressing around the line.
·         Each operator is cross trained on a different portion of line (i.e. continuous operation) depending on skills and operation complexity. Ideally all the operators are cross trained on all the operations.
·         Thus operators work to predominantly predetermined adjacent tasks.
·         Each operator is assigned at least one operation.
·         Operatives work on standing workstations.
·         The first and last operations are uniquely assigned to the first and last operator respectively
·         Work In Progress (WIP) is kept to a minimum.

3.    Assembly Line System :-

Each operator is assigned to one operation only,
·         Bundles of garment components are moved sequentially from operation to operation
·         Bundles consist of garment parts needed to complete a specific operation or garment component.
·         Some companies work with varied bundle sizes others with standard bundle sizes
·         Bundles are assembled in cutting room where cut parts are matched.
·         Bundle tickets consist of a master list of operations and corresponding coupons for each operation.
·         Each bundle receives a ticket that identifies style#, size , shade and list of operations  (is some cases)
·         Bundles are assembled is cutting room where cut parts are matched
·         Bundle receives a ticket that identifies style#, size, shade and list of operations.

               There are two variations of the assembly line system being followed in the industries namely
·         Progressive Bundle systems and
·         Unit production system.

a. Progressive Bundle system: -
·         Machines and operations are organized into sections according to basic functions, which produce sub components.
·         Within each sections works is balanced according to time required for each sub-functions.
·         The disadvantages of progressive bundle system are:
·         Machine investment costs are high.
·         The system is not very adaptable for short-run production and frequent style changes, as these require rearrangement of the workstation.
·         It involves high handling costs for bundle handling and transportation.
·         It requires a high level of work in progress and therefore a high capital commitment.
·         It requires a high level of management skills to arrange the workflow and decide on the number of operators for each operation.
·         Individual performance can be monitored and incentives offered.
·         The advantages of the progressive bundle systems are:
·         High productivity
·         A high level of labour utilization can be achieved
·         Training time and costs can be reduced
·         Semi-skilled labour can be used.

b .Unit Production systems (UPS) :-
Similar to a relay race, each production operator has a task and passes that garment on to the next person. Normally there is only one garment between operations.
     As a mechanical system this has been in use for many years, but a major advance was made in 1983 when computers were first used to plan, control and direct the flow of work through the system.
  The essential features of this system are:
1.    The unit of production is single garment and not bundles.
2.    The garment components are automatically transported from work station to work station according to pre-determined sequence.
3.    The work station are so constructed that the components are presented as close as possible to the operator's left and in order to reduce the amount of movement required to grasp and position and component to be sewn.

All the components for one garment are loaded into a carrier at a work station specially designed for this purpose. The carrier itself is divided into sections, with each section having a quick - release retaining clamp which prevents the components from falling out during movement through the system. When a batch of garments has been loaded into carriers they are fed past a mechanical or electronic device which records the number of the carrier and addresses it to its first destination.
COMPARISION OF VARIOUS APPAREL PRODUCTION SYSTEMS
Comparative analysis of various production systems is presented in table 1, in terms of various common inputs required. Points 1 to 5 indicate relative significance of the input such that 1 indicates "Very difficult or complex" or "too much" and 5 indicates "very easy or simple" or "very less"





INPUTS
MTS
ALS
PBS
UPS
Investment cost
5
3
3
1
Operator skill
1
3
3
2
Supervision
5
3
2
1
Style change
4
2
3
4
Flexibility
4
2
4
5
Repair control
2
3
4
5
Quality control
2
5
4
5
Balancing
5
2
3
1
Throughput time
5
4
2
4
Labour cost
1
3
4
3
Output /sq. meter
1
3
4
3

Sewing

History of Sewing

The first sewing process was very simple; the two layers of fabrics are attached with the help of sharp edge stone with some type of thread then the hole at the back is developed in needles which makes the sewing process easy.

Later on metal needles are developed. In year 1760 the Saint Thomas of England observed how the shoemakers prepare shoes and invented simple type of sewing machine. In 1834 Sir Isaac Singer of U. K. invented the domestic sewing machine and in 1900 the Singer Company developed industrial sewing machines.

Difference between domestic and industrial sewing machines:

 

Domestic

Industrial

1. Low speed (500spm)

1. High speed (up to 5000spm)

2. Less Production

2. More Production

3. Manual operation

4. Poor quality

3. Power operation

4. Good quality

Types of industrial machines:

  1. Juki Sewing machines
  2. Brother Sewing machines
  3. Puaff Sewing and finishing machine
  4. Pegasus Knitwear machine
  5. Nagi Shing Fusing machine
  6. West man Cutting machine
  7. East man Cutting machine
  8. Kansai special Waistband stitching machine
  9. Durkop & Adler Sewing machines
  10. Barudan & Tazima Embroidery machine


Type of fabrics:

1. Light weight (60gsm) Silk, rayon, and any thin fabric

2. Medium weight (60-240gsm) Cotton, terry cot, polyester etc.

3. Heavy weight (240-340gsm) Denim, Jeans

4. Extra duty (above 340gsm) Leather, Rexene etc.

Functions of sewing department

The objectives of sewing are the construction of seams which combine the required standard of appearance and performance with an appropriate level of economy in production. The performance of sewing means the achievement of strength, appearance, and aligned properties with an economical way. Assuming that the fabric is sew able and suitable for garments, this is related to five factors during manufacture.

1. The seam type which is a particular configuration of fabric

2. The stitch type which is a particular configuration of thread in the fabric

3. The sewing machine feeding mechanism which moves the fabric past the needle and enables a succession of stitches to be formed.

4. The needle which insert the thread into the fabric

5. The thread which forms the stitch which either holds the fabric together neatens it or decorates it.

The main objective of sewing department is to produce or assemble the garments in the required manner with required quality particulars and with low production cost and in achieving the required production within the period of requirement.

General and Specialised sewing Machines.

The garment industry is rest on sewing operations, which convert the fabric to garment. The sewing department needs skilled and trained operators as well as new and advanced machineries for its high productivity and quality.

In the RMG it uses a variety of sewing machines and accessories for the reduced work content and increased productivity. Some of the sewing machines which are used in are as follows,

Single needle lock stitch machine.

It produces a stitch type of Single Lock Stitch with fine quality in high speed of 5000 rpm

1. Type of machines: Single needle lock stitch

2. Type of feed: Drop feed

3. Sewing speed: 2500 to 4500 SPM

4. Needle: DB´1 or DA´1

5. Stitch length 0 – 5

6. Type of motor Clutch, 1/3 HP or 270 W

7. Lubrication Automatic with centralized pumping system

8. Pressure foot lifter 5 mm by hand, 13 mm by Knee

9. Hook set position Horizontal

10. Needle bar stroke 30.7mm

11. Type of belt V belt (41” or 42”)

12. Pulley 90mm

Double needle Lock stitch machine DNLS (LH-3168)

This is a two needle, needle feed lock stitch machine with organized split needle bar. LH-3128 & LH3168 everything are same but only corner stitching facility is in LH – 3168.

Specification:

Sl. No.

Particular

LH –3128

LH – 3168

1

Application

A-S.G

ASG

2

Swing speed

3000 SPM

3000 SPM

3

Stitch length

0 – 5 mm

0 – 5 mm

4

Needle

DP´5

DP´5

5

Needle bar stroke

33.4mm

33.4mm

6

Lubrication

Automatic vertical axis

Automatic vertical axis

7

Hook set

Regular hook

Regular hook

8

Pressure foot

5mm by hand

12mm by knee

5mm by hand

12mm by knee

9

Split needle bar

Not provided

Provided

10

Motor type

Clutch motor – 400W

Clutch motor 400W

11

Belt type

V belt 42”

V belt 42”

12

Pulley size

70mm (Max)

70mm (Max)

13

Hand wheel

90mm

90mm

14

Thread take up

Slide type

Slide type

Some of the advanced sewing machines used (by JUKI)

Sl No

Model No.

Purpose

Type of stitches

Needle system

Approximate price in Rs

1.

DDL – 5530

Single needle

Lock stitch

DB´1 or DA´1

24,000

2.

DDL – 5530

(cp – 330)

Single needle with ATT & computer unit

Lock stitch

DB´1 or DA´1

50,000

3.

LH – 3168

Split – bar

LH - 3128

Double needle

Double needle

Lock stitch

DP´5

95,000

85,000

4.

LBH - 781

Button Holing

Lock stitch

DP´5

1,25,000

5.

MB – 372

Button stitch

Chain stitch

TQ´1 or TQ´7

75,000

6.

LK – 1850

Bar tacking

Lock stitch

DP´5

11,000

7.

MS – 1190

Fee off the arm

Chain stitch

TV´1

TV´64

110,000

8.

MO – 3616

Over lock

Chain stitch

DC´1

DC´27

55,000

9.

DLM-5200

Edge cutting

Lock stitch

DB´1 or DA´1

45000

10.

LZ - 2288

Zig – Zag

Lock stitch

DB´1 or DA´1

45000

11.

MH - 380

Double needle

Chain stitch

TV´1

45000

12.

MH - 480

Single Needle

Chain stitch

- Do -

40000

13.

MB - 373

Button stitch with ATT

Chain stitch

TQ´1

TQ´7

80000

14.

MB - 377

Button stitch with knoll system

Chain stitch

TQ´1

TQ´7

80000

15.

BR - 10

ATT & Button feeder

Chain stitch

TQ´1

TQ´7

200000

16.

LK - 1851

Button stitch

Lock stitch

DP´17

150000

17.

BR - 20

Button stitch with button feeder

Lock stitch

DP´17

250000

18.

LK - 1900

Computer system

Lock stitch

DP´5

150000

19.

MFB Series

Eyelet button hole

Chain stitch

DO´558

150000

20.

APW Series

Automatic pocket welting

Lock stitch

DP´5

600000

21.

MS - 210C

Single needle embroidery

Lock stitch

DP´5

500000

22.

CB – 641

Hemming

Chain stitch

LW´6T

45000