2 min readMar 1, 2022


How to solve bottleneck problem in the Garment Industry?

What is a Bottleneck?

A bottleneck is an event in which the capacity of the entire system is limited by a single or limited number of components or resources. The narrow part at the top of the bottle is called the neck (open direction), and it prevents the larger part of the bottle from passing through the narrow part of the neck. The apparel sector is a manufacturing sector, where barriers are used as general production barriers. A bottleneck is simply a loss of production and a loss of profit that is minimum capacity.

In the production line minimum or lowest output is called bottleneck.

Why do bottlenecks arise in the production line?

There are many reasons for bottleneck in a production line, which are explained below:

Bottleneck before input in production line:

  • If the issue is not supplied in time from the Merchandiser and sub-store as per order quantity or allocated quantity.
  • Wrong issue supply.
  • Pattern problem. etc
  • Folder not available / Adjustment issues
  • Cutting mistake by Cutting
  • Bundling mistake by Cutting.

Bottleneck in line production:

  • Layout is not properly balanced
  • Selection of the Operator is wrong.
  • Bundle sequence of works is not followed.
  • Lack of Skill Operators
  • Works negligence by workers.
  • Absence or illness of the workers.
  • Machine breakdown or adjustment issues.
  • Supply is not enough
  • wrong supply
  • Color shading
  • Quality problem
  • Lack of Supervisor’s monitoring

How to find the Bottleneck?

  • By checking booking and inventory in-house as per order quantity
  • By checking quality before supply in the line
  • By observing serial number of supplied issues:
  • By perfuming cycle time check

How to solve bottleneck problem in the Garment Industry?

  • To make size set samples minimum 7 days before input.
  • Selection of the critical processes.
  • To arrange pre-production meetings in time.
  • To prepare a layout sheet before input in the line.
  • To submit the layout sheet to the maintenance section minimum 5 days before.
  • By checking the pattern before supply in the line.
  • By checking fabrics and accessories before issuing in the line
  • To keep sufficient supply in time..
  • To select the right workers for the right works.
  • To maintain a serial number.
  • Awareness on defects of garments
  • By improving methods.
  • By improving workers’ performance.

Visit here to know what is operation breakdown. You can visit my website to learn more about the bulletin or breakdown of garments.

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I am Mohammad Shorab. I am sharing information about apparel production and process through this platform.