What is the Operation Bulletin in Apparel Industry?
An Operation Bulletin (OB) is a Critical Document used in the apparel industry to manage and optimize the Production Process for a Specific Garment or style.
It serves as a comprehensive guide that outlines every step involved in manufacturing a garment, detailing the sequence of operations, the time required for each task, the machinery to be used, and the Skill level required for each Operation.
The Operation Bulletin is essential for ensuring that Production is Efficient, Consistent, and meets Quality Standards.
The Key Components of an Operation Bulletin:
Style Information:
- Includes details about the garment style, such as the style number, description, and sometimes a sketch or image of the garment.
Operation Breakdown:
- Lists all the individual operations or tasks required to assemble the garment. Each operation is described in detail, such as "sew side seam," "attach collar," or "hem sleeves."
Sequence of Operations:
- The order in which the operations should be performed is specified. This ensures that the production process flows smoothly without interruptions or bottlenecks.
Standard Minute Value (SMV):
- The time allocated for each operation is calculated using time study methods, usually expressed as Standard Minute Value (SMV) or Standard Allowed Minutes (SAM). This helps in estimating production capacity and planning workloads.
Machine and Equipment:
- Specifies the type of machinery and equipment needed for each operation, such as lockstitch machines, overlock machines, or specialized sewing equipment.
Work Aids and Attachments:
- Details any special attachments, guides, or tools required for specific operations to improve efficiency and accuracy.
Skill Level:
- Indicates the skill level or grade of the operator required to perform each operation, which helps in assigning the right workers to the right tasks.
Manpower Allocation:
- Suggests the number of operators needed for each operation based on production targets and efficiency levels.
Quality Checkpoints:
- Lists specific points in the operation sequence where quality checks should be performed to ensure the garment meets required standards.
Production Targets:
- Provides production targets, such as the number of pieces expected to be completed per hour or day, helping in monitoring and controlling the production process.
Work Layout:
- Sometimes includes a layout of the production line or workstation arrangement, indicating where each operation should be performed and how the workflow should proceed.
Purpose and Benefits of an Operation Bulletin:
- Standardization: Ensures that all workers follow the same procedures, leading to consistent product quality and reduced variations.
- Efficiency: Helps in identifying and eliminating bottlenecks or inefficiencies in the production process by optimizing the sequence of operations.
- Time Management: Provides a clear understanding of the time required for each task, aiding in accurate production planning and scheduling.
- Labor Allocation: Assists in assigning the right number of workers with the appropriate skills to each task, ensuring that production targets are met.
- Cost Control: By optimizing operations and reducing waste, the Operation Bulletin helps in controlling labor costs and improving overall profitability.
- Training and Supervision: Serves as a reference for training new operators and for supervisors to monitor and guide the production process.
Example of an Operation Bulletin:
For a simple T-shirt, the Operation Bulletin might look like this:
Use in Production Planning:
- Line Balancing: Helps in distributing tasks evenly across the production line, ensuring that no workstation is overburdened or underutilized.
- Performance Monitoring: Enables supervisors to track whether operators are meeting the expected SMVs and identify areas where additional training or adjustments might be needed.
- Cost Estimation: Facilitates accurate costing of the garment by providing detailed information on labor and machine usage.
