Textiles Industrial processespowerpoint

7/30/2019 Textiles Industrial processespowerpoint

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Focus:

The ways in which textile

products are manufactured inindustry.


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Processes and Manufacture

Content

The production systems and their

processes.

The range of hand tools, equipment and

machines used in textile production.

CAD/CAM Production Flowcharts

Quality Control and Quality Assurance


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The production systems and their

processes

There are three main types of production

system.

One-off

Batch

Mass ObjectivesUnderstand what is meant by one-off, batch, and mass production.

Understand line production and

subassembly systems

Consider cost implications when

selecting method of production


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One-off

One-off production is designing andmaking a single textile product to a client's

specification. The garment design is

developed from a basic block pattern,with a prototype made from inexpensivefabric to test the drape, fit and assembly

of the garment.
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One-off

Haute-couture fashion: models at London Fashion Week

TaskLook in magazines and cut out

pictures to make a collection of

designer outfits from catwalk shows.

Why are these garments made by

one-off production? How much do

these clothes and accessories cost

to buy?


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Batch Production

Batch production is manufacturing setquantities of a textile product to order. The

prototype is made up in a medium size from the

intended fabric. The prototype is checked forquality of design and manufacture, then put into

production in a range ofstandard sizes. Thequantity of products can vary from a set of four

cushions made by a designer-maker, to 20,000jumpers made for a department store.
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Systems and sub-systems

In a production system, a number of differentdesigning and manufacturing processes or sub-

systems take place at the same time. Examples

of sub-systems are:

Lay-planning is the laying out of patternpieces of a fabric to work out the quantityand cost of material required for a product.

Costing is working out how much eachproduct costs in terms of includingmaterials, labour, rent and energy costs.


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Just-in-time stock control (JIT)

This is a cost effective method of ordering

components and sub-assemblies to arrive

just before they are needed. Stock storage

time is reduced but any mistakes anddeliveries will hold production up.

SummaryHand-crafted, exclusive products are made individually using the one-off production system.

For a fixed number of identical products, batch production is cost effective.

Mass production usually includes production lines

Subassemblies are made separately before they are joined to the main product.


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The range of hand tools, equipment and

machines used in textile production.

ObjectivesHave an understanding of the

variety of machines used in

textile manufacture

Appreciate the difference

between sewing and the

embroidery machines.

Plotter/Cutting machinesComputers are used for producing Lay plans whichwork out exactly where to place each pattern piece tobest use the fabric. Remember wasted fabric is wastedmoney!A plotter would mark out the pattern pieces and any

construction instructions such as darts.A CAM cutting machine automatically cuts out thepieces following the lay plan. It cuts the fabric quicklyand accurately using vertical knives, high pressurewater jets or lasers. Many layers can be cut out atonce which means less labour costs and more

efficiencyA Band saw can be used by a skilled operator. It isused for cutting through multiple layers of fabricquickly. Metal chain mail gloves are worn to protectthe workers hands.


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Sewing machines.

These range from simple machines to ones that do specialist taskssuch as buttonholes, overlocking fabric edges or CAD CAMmachines that stitch out motifs

Lockstitch Used for sewing seams (Straight stitch)

Over locker

Stitches, cuts and finishes seams in one process Seam coverUsed for sewing belt loops

Automatic buttonholeUsed for sewing buttonholes

CAD/CAMMultihead embroidery machine
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Hand tools and equipment

Tools & equipment for Designing, colouring and embellishing

Measuring and marking

Cutting

Heating and pressingIdentify and make a list of all the tools and equipment in your

textiles classroom

SummaryAppropriate tools and equipment should be selected, used correctly and safely, and stored in the

designated place.

A wide variety of tools and equipment are required when designing and making

Efficient and accurate use of tools and equipment will help ensure that high-quality products are

made.


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Industrial MachineryBelow are some of the maintypes of machines used in themanufacture of textile products.

ObjectivesHave an understanding of the variety of machines used in textile manufacture

Appreciate the difference between sewing and the embroidery machines.

Digital jet printer Knitting machine Band saw Multi-headembroidery machine

Machinery can be

operated by hand, besemi-automatic fullyautomatic and canalso be computercontrolled
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SummaryMachines speed up the process of making and can be used to ensure high-quality products

Many machines have fast moving parts and sharp needles. Great care must be taken to follow

safety rules to avoid injury while operating such a machine.

Machinery can be operated by hand, semi-automatic or fully automatic and can also be computercontrolled.

Industrial sewing machinesIn industry a range of different sewing machines are used for stitching seams,embroidery, buttonholes etc. The main ones are listed in the table below :

Industrial machineMethod of control Joining process Used for

Lockstitch Electric Lockstitch Straight seams

Lockstitch Electric Zigzag stitchStretchy knits; finishingedges

Overlocker ElectricStitches, cuts and finishesseams in one process

Non-fraying seams;stretchy seams

Seamcover Electric Flat seamKnitted hems; belt loopson jeans

Linking Electronic; CAMJoins knitted fabric stitchby stitch

Knitted seams

Automatic buttonhole Electronic; CAM Lockstitch; chainstitch Buttonholes

Computer NumericallyControlled (CNC) Computer software;Electronic; CAM Lockstitch; zigzag;embroidery Making collars; labels;logos; embroidery


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CAD USING COMPUTERS TO DESIGN AND PRESENT

Computers are used by designers for:

Writing documents and creating display boards,including artwork, text, spreadsheets, graphs and tables

Putting together slide show presentations

Digital photography and video making

Designing and sampling

Supplementing drawing and colouring with use ofspecialist fashion software, e.g. Speed Step.

ObjectivesUnderstand the benefits of using computers in manufacturing.

Appreciate the link between CAD & CAM


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PROGRAMMES USED BY DESIGNERS

These include:

Microsoft Office - Word, Excel,

PowerPoint, Publisher

Drawing packages Paint, Adobe

illustrator, CorelDraw

Image editing

Photoshop Specialist Fashion software, e.g. Speed

Step


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DRAWING USING SOFTWARE

Drawing software can be used to design, illustrate and showworking drawings. Drawn lines and shapes or photographic imagescan be imported and edited, or scanned to manipulate and developideas. Collections with a range of coordinating products can bedeveloped from one initial idea.

With some specialist software it is possible to get a 3D impression ofthe design by rotating the design and seeing it from differentviewpoints. The designer can use the computer to simulate drapingand shadowing to create a realistic image of the design. Also, ideasfor different colourways can be tested and a variety of printed,knitted or woven fabric designs can be trialled on screen, to see the

effect of each different combination of colour and texture.


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USE OF ICT FOR PRESENTATION

The designer can present ideas to the client on screen orprinted on to presentation boards, or via e-mail, and

then quickly modify them according to client feedback.Promotional material developed from design work can beadapted for use on websites, business stationery andadvertising and marketing materials, such as point ofsale literature and display posters. Computers make this

development of related design work a quicker process


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DESIGNING AND SAMPLING USING COMPUTERS

Computers can be used to pass detailed design information to machineryquickly so that samples can be made during the design and developmentstages, often without the designers even leaving their workstations.

Designers can use computers to design new woven or knitted fabrics onscreen and then show the new fabric in use on a drawn model, on screenor on printed copy.

Printed fabric design developed on screen can be digitally printed on to

actual fabric for sampling. Embroidered motifs and patterns can be designed on the computer and

then stitched directly onto fabric. A design process that previously took weeks or months can now take less

than 24hrs. The images on colour monitors and those reproduced by colourprinters are so realistic that they can be used to present ideas to fashionbuyers. In the past buyers have demanded to see and touch actual sample

garments, before deciding to place orders, but with the new computertechnology they now have the confidence to buy from screened or printedpresentations.


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ICT and CAM

ICT and computer-aided manufacture (CAM)

ICT and CAM play a vital role in modern textiles production. Forexample, they enable :

designs to be sent electronically to the print manufacturer and storedon computer to ease repeat printing orders.

colours to be matched to the design, dyes weighed and dispensedand the fabric printed automatically

ICT makes possible the just-in-time ordering of materials andcomponents so they arrive at the factory as they are needed, ie just-in-time for production to start.

ICT enables companies to transmit information between plants, and

manufacture on a global scale

ObjectivesUnderstand the benefits of using computers in manufacturing.

Appreciate the link between CAD & CAM


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SummaryComputers can be used to increase efficiency and accuracy in manufacturing

Costs can be reduced if efficiency is increased

Health and safety of workers can be monitored and working conditions made safer using

computersFlexibility is increased as changes in production can be made more rapidly

Mass-produced clothing: jeans in a clothes shop window


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CNC

Computer-numerical control

Computer-aided manufacturinginvolves the use ofCNCmachines for printing, cutting,

joining and many other textiles

processes. CNC-automatedmachines can repeatprocesses with accuracy andreliability, and are easily re-programmed when changes todesign or production run are

needed. The graphic showssome of the uses of CNCmachines.
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CIM

Computer-integrated manufacturing(CIM) systems integrate or link CAD andCAM systems. These combined systems

link design development, productionplanning and manufacturing systems

together. Companies that use CIM are

able to design a product in one countryand manufacture it overseas where labour

costs are lower.


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Production Plan

Production planning

Production plans and work schedules are

important planning tools in batch and

mass production.

The production plan should set out

information about all the stages of

production, so that every product is made

to the same quality. See example below:


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Each production plan should include the following stages:

The preparation stage details the amount ofmaterials to buy-in, preparation ofgarment

patterns, templatesand lay plans. The processing stage details the fabric spreading,

cutting, labelling and bundlingof the fabricpieces.

The assembly stage contains instructions forfusing,joiningandpressingthe separate productparts.

The finishingstage gives instructions fordecorative/functional finishing and final pressing.

The packaging stage explains how to label, hang,fold, and cover the product ready for transport tothe retailer.

Some manufacturers use computer software to handle the detailed information in theproduction plan. Any changes made to the plan are quickly available to each member of the

production team
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Work schedule

A work schedule sets out instructions

about the order ofassembly, the stitchtype, the processes to be used, the time

each process will take and the seamallowance. See the example of a workschedule below:

Work schedule below for a skirt


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Work schedule below for a skirt

Order ofassembly

Stitch type Process Process timein minutes

Seamallowance

1 Lockstitch Stitch pockets 2.00 1.00cm

2 Lockstitch Stitch pockets tofront

2.00 1.00cm

3 Overlock Join back seam 1.00 1.00cm

4 Lockstitch Insert zip 2.00 0.20cm

5 Overlock Join side seams 1.50 1.00cm

6 Lockstitch Join waistband totop

2.50 0.60cm

7 Blindhemming

Turn up hem 1.50 0.20cm

N/A N/A Total process time 12.50 N/A

Documents

Textiles Industrial processespowerpoint