Work queues before the zipper station while the station after it is often idle. What likely limits sewing output?
A Pressing area lighting
B Final carton width
C Zipper station capacity
D Marker paper strength
Answer: C. Zipper station capacity. A persistent queue ahead of the station and starvation after it point to insufficient capacity there.
If the pattern pieces use 10.2 m² of a 12 m² marker, calculate marker efficiency.
A 75%
B 102%
C 15%
D 85%
Answer: D. 85%. Divide used pattern area by total marker area and multiply by 100.
If two fabric roll groups differ slightly in shade, what practice helps prevent mismatched matching panels?
A Raise needle speed only
B Mix all cut plies randomly
C Use deeper cutting notches
D Separate and trace bundles
Answer: D. Separate and trace bundles. Keeping panels from compatible shade groups together prevents shade differences within a garment.
During a 460-minute shift, 230 garments are required. What is customer takt time?
A 0.5 min/garment
B 230 min/garment
C 2 min/garment
D 4 min/garment
Answer: C. 2 min/garment. Takt time is available production time divided by required output.
On a knit edge that stretches while being overlocked, what machine adjustment may reduce wave formation?
A Smaller bobbin case only
B Lower fusing temperature
C Wider paper marker
D Differential feed adjustment
Answer: D. Differential feed adjustment. Differential feed adjusts the relative advance of feed dogs and can compensate for stretch-induced distortion.
Fabric length per ply is 9.6 m and the marker contains eight garments. What is length per garment before other losses?
A 1.60 m
B 1.20 m
C 0.83 m
D 76.80 m
Answer: B. 1.20 m. Divide 9.6 m of fabric length by eight garments per ply.
Operator time totals 2,000 min and the line earns 1,500 standard minutes. Find line efficiency using earned time divided by labour time.
A 75%
B 25%
C 50%
D 133.3%
Answer: A. 75%. Efficiency is 1,500/2,000 × 100%.
Fabric grainlines are tilted inconsistently across pieces of the same leg panel. Which issue can appear after assembly and washing?
A Higher marker width
B More stitch holes always
C Less sewing thread use
D Twisted garment panels
Answer: D. Twisted garment panels. Off-grain pieces may relax asymmetrically and cause apparent garment twisting.
Observed sewing time is 0.80 min at a performance rating of 125%. What is normal time before allowances?
A 1.00 min
B 1.25 min
C 0.64 min
D 0.80 min
Answer: A. 1.00 min. Normal time is observed time multiplied by the rating as a fraction.
Four operators work 7.5 h each and complete 180 garments. What is output per labour hour?
A 24 garments/h
B 6 garments/h
C 45 garments/h
D 3 garments/h
Answer: B. 6 garments/h. Total labour input is 4 × 7.5 = 30 hours. Divide 180 garments by those labour hours.
Calculate total area for a marker that is 1.50 m wide and 8 m long.
A 5.33 m²
B 9.5 m²
C 12 m²
D 120 m²
Answer: C. 12 m². Marker area equals width multiplied by length.
Where many garments show the same skipped stitch defect, what is a useful first check on the machine?
A Needle condition and timing
B Pressing table colour
C Marker plot scale
D Carton label placement
Answer: A. Needle condition and timing. Needle damage or incorrect timing can prevent the hook or looper from catching the thread loop.
Daily demand cannot change, but available working minutes fall. What happens to customer-demand takt time?
A It equals seam allowance
B It gets longer
C It gets shorter
D It remains unchanged
Answer: C. It gets shorter. Takt time is available time divided by demand, so less time requires a faster pace.
If a sewing operation takes 48 seconds per garment, what is its theoretical hourly capacity?
A 48 garments/h
B 75 garments/h
C 125 garments/h
D 60 garments/h
Answer: B. 75 garments/h. An hour has 3,600 seconds. Divide by 48 seconds per garment.
Fusible interlining peels even though the press meets target temperature. Which two settings also need review?
A Bottle volume and shade
B Cone shape and colour
C Marker length and width
D Dwell time and pressure
Answer: D. Dwell time and pressure. A sound bond depends on temperature, contact time and pressure. A correct temperature alone may not achieve sufficient bonding.
If an operator turns out 20 accepted garments with a 6 minute standard each, how many standard minutes are earned?
A 20 min
B 26 min
C 3.33 min
D 120 min
Answer: D. 120 min. Each acceptable garment earns its assigned standard minutes. Multiply 20 by 6.
Why record machine work time separately from waiting time in a sewing study?
A Make every station identical
B Distinguish processing from delay
C Remove checking activities
D Increase the seam length
Answer: B. Distinguish processing from delay. Separating active time from waiting helps identify whether flow delays or sewing work cause a long cycle.
With six garments per marker and 45 usable plies, how many garment sets can be cut?
A 270
B 51
C 45
D 7.5
Answer: A. 270. Each ply yields six garment sets, so output is 6 × 45.
The operator switches to a thicker fabric without changing the needle. Which compatibility should be checked before bulk sewing?
A Package and loom size
B Floor colour and trim
C Roll label and carton
D Needle, thread and fabric
Answer: D. Needle, thread and fabric. Needle size and point, thread size and material must work together for reliable stitch formation.
If normal time is 2 min and allowance is 15% of normal time, what is the standard time?
A 2.15 min
B 1.70 min
C 2.30 min
D 2.35 min
Answer: C. 2.30 min. Add 15% of 2 min to the original 2 min.
Video shows an automatic sewing attachment needs a long setup but stitches quickly. Which time category rises most per garment for small batches?
A Setup time per garment
B Marker length per ply
C Needle count per seam
D Machine speed per stitch
Answer: A. Setup time per garment. A fixed setup is spread over fewer units in a small batch, increasing setup time per unit.
Forty plies each require 5 m plus 0.10 m end loss. How much fabric is spread?
A 204 m
B 240 m
C 200 m
D 201 m
Answer: A. 204 m. Each ply uses 5.10 m including end loss. Multiply by 40.
At finishing, one garment has measurements within tolerance but the zipper will not close. Which separate check captures the issue?
A Carton weight check
B Yarn count confirmation
C Functional inspection
D Fabric width inspection only
Answer: C. Functional inspection. A functional check operates closures or other features. Dimensional checks can pass even when a component fails.
Among sequential stations with hourly capacities 90, 80 and 100, what maximum steady output can the line sustain without added parallel capacity?
A 90 garments/h
B 80 garments/h
C 270 garments/h
D 100 garments/h
Answer: B. 80 garments/h. The least capable station limits sustainable output to 80 per hour.
At 4 stitches/cm, how many stitches are needed along a 180 cm seam?
A 45
B 720
C 184
D 180
Answer: B. 720. Multiply stitch density by seam length: 4 × 180.