Operator Evaluation in Garment Industry - IE & Textiles

 

A sewing operator needs to be evaluated regularly to dynamically update his rating on the skill matrix chart. However, current practices refer to its output quantity and quality as parameters for updating efficiency, as stitched output is the only visible evidence of the operator's output. The supervisor has no or little information about the sewing procedure; How was the exercise? What is the average sewing speed? How many stitches burst? How much was the needle running time and how much was the handling/pivoting time?

 

Computerized evaluation of sewing operators can usher in a new era of remotely distributed testing frameworks, eliminating subjectivity altogether.

 

Even in any training setup, only output quality is evaluated; The evaluator can best stand in front of an operator and observe the procedures. Logically the evaluator cannot measure all these method related parameters as they have to be collected during stitching. This explains the need for an operator evaluation system where all important parameters of any sewing operation such as average speed, number of stitch bursts, needle movement time, handling/pivoting time etc. are analyzed to evaluate each trainee sewing operator. A computerized sewing operator evaluation system can capture data as operations are performed, analyze the data, and determine operator ratings. Real time sewing data capture equipment includes Hall sensors and Profibus technology to network sewing machines with computers

The two graphs shown below demonstrate the stitch speed characteristics of pocket mouth hemming and pocket attachment. The stitch speed characteristic for pocket mouth hemming shows short bursts of stitch cycles with a momentary pause between each stitch cycle.  The sewing speed characteristics of the pocket attachment reflect a very interesting result, where the average speed is only 60% of the previous operation at 534 SPM. Analysis of the above two operations also shows the role of a stitch burst in an operational cycle. 16 cycles of pocket mouth hemming were done in only 18 stitch bursts, six pocket attaching cycles required 67 stitch bursts. Since each stitch burst involves acceleration and deceleration, the average speed is automatically reduced. Also, the pause between bursts of stitching adds to the sewing cycle time. Likewise, all sewing features are included to develop the operators final skill rating. Various sewing characteristics such as speed, sewing burst, quality variations are then calculated as an integral numerical score as the sewing operator's rating.

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