The world is changing rapidly and becoming more and more challenging. There is a very close connection that exists between product and production. Every minute counts and is very important in the production sector because time is considered as money.
Production is therefore a well-known term for any production-oriented organization.
It is not a healthy practice to seek production only in the production department. Better productivity is the result of the overall effort of any organization. In short, we can say that it recommends productivity in all business activities. It is a chain reaction in the organization to pay close attention to getting a high-quality product.
Do you have an idea about production and production? Production means other actual actions or steps that can combine all resources into a product or service on the other hand a product emphasizes the process of producing a particularly high-quality product or service.
Processes used to convert material inputs (materials, finished goods, sub-assemblies) and intangible inputs (plans, ideas, information, information) into goods or services. The resources used in this conversion process are to create goods or services that are valuable and that contribute to the use of individuals or groups.
Productivity Improvement Techniques
1. Conducting Learning Work
There is a saying “Even the best can be improved”. Prepare a checklist for best practices and movements. During the movement, the study looks at the conductor’s movements and compares them to your checklist.
If you find incorrect movements or unnecessarily additional movements are in the operating cycle fix it.
By doing this you can reduce the working cycle time and can improve labor productivity by up to 100% * in each operation. Also, it will help to reduce operator fatigue.
2. Hourly Performance Testing
There should be a system in place to monitor operator performance on an hourly basis so that effective remedial action can be taken to ensure efficiency and productivity.
If it is not guaranteed that there should be technological advances.
3. Production Research and Development
A non-value-added (NVA) process but with a strong Research and Development (R&D) team at the factory brings many benefits.
4. Tracking Systems like 5S and Kaizen
The 5S is also a well-known waste minimization, product enhancement, and clear visibility
Consistency at work.
Kaizen Chinese and Japanese “continuous improvement” when used in the workplace and used in a business sense, kaizen refers to activities that continue to improve all functions and include all staff from CEO to Assembly line staff.
5. Select the correct line format
Line arrangement means placing equipment and a table in the center (wheelbarrow) according to the needs of each style. The main purpose of choosing the best make-up is to reduce the travel time on the line as much as possible.
6. Reduce Time Line
Reason – a lot of time is lost while repairing a new style line. This reduces overall machine production and line efficiency. There can be several production lines in the production process. It is also the job of the engineer to use that type of line structure that not only ensures less time in the set-up process but also increases productivity by reducing the time spent assigning work to each component of the production line.
7. Improve Line Ratings
The purpose of line balancing is to reduce operator idle time or to increase operator usage. In the balance line, the work will go smoothly and no time will be lost waiting for work. Always select operators with a history of operator skills and performance required. Following this method, you will select the most experienced operators for high content performance. One line is set to conduct a power study at regular intervals and you will find issues within the line. You have to think about how to reduce WIP (Work in Progress) to box performance.
8. Use Utilities
Utilities are additional devices that can be integrated into basic sewing machines such as folders, guides, and compression feet. If resources are used effectively the working cycle time can be reduced by more folders than the existing cycle time.
9. Continuous Feeding Sewing Line
It is not the fault of the production department if they do not get the cut to be sewn. All production plans and efforts will fail. Once the operators have acquired the rhythm, they should be given continuous feed until the style has changed to continue production.
10. Error Feed the Dress of the Parts Going To the Line
Inspect the parts of each garment and accessories before starting production. It will help protect defective clothing.
11. Leadership Training for Line Directors
Line directors play an important role in the production. Their main function is to provide instructions, to convey information.
12. Skill Provider Skills Training
Operators are the main equipment in the production of clothing. They are the most important resource in the company. Therefore, the factory should work on building operator skills where needed. “Training is not expensive but it is an investment,” say many experts. Production from the operator depends on his level of skills in the job. The low-skilled user will use the higher resources (time) and provide less output. You will find quality-related issues with low-skilled and untrained providers. As the level of operator skills is increased through the training lines the exit will improve. Training means more time and more money.
13. Adjusting Each User Target
Instead of giving an equal target to all line operators, give each target a level of operator skills and capabilities. Set a goal that is accessible to each operator to try to reach the target. This will help improve the performance of each operator.
14. Remove Active Time
Use the operator time as much as possible. If there is a period of inactivity in the production process, this idle time will delay the operation of the whole process. And performance delays reduce productivity. So to ensure efficient use of the time you must work to eliminate idle time.
15. Using the UBT Sewing Machine (Under Under Trimmer)
Just think how many pieces the operator produces per day? Each time the operator cuts the cord using a trimmer or scissors it consumes at least 10% of the cycle time (approx). Even a machine that does not have a car grinder uses more sewing thread.
16. On-Line Quality Checks Regular
Functional testing will help reduce feature production in the source. A small amount of incomplete stitching is done in less time which will be lost in repairing it. The on-line inspection system will inform operators to focus on their work. It helps to identify quality issues in advance and prevent them from happening.
17. Provide a Fun Workplace
It may sound impossible, but some research shows that setting up an office with good things – like plants – can increase productivity by up to 15 percent. Jazz your office space with pictures, candles, flowers, or anything else that puts a smile on your face.
18. Facilitator Operator
Employee motivation often depends on a variety of factors such as work culture, HR policies, incentives, a bonus in extra effort, or achieving the target. In the case of clothing promotion, there may be financial and non-financial benefits, but financial benefits are highly recommended because of their tangible benefits.
19. Edit the Operator’s Incentive Scheme
Depending on the efficiency of the operator incentives should be assigned to the operator.
+ Operating efficiency 70% – 1 $
+ Operating efficiency 80% – 2 $
+ Operating efficiency 85% – 3 $
+ Operator efficiency 90% – 4 $
+ Operator efficiency 95% – 5 $
20. Take Regular Vacations
It sounds inconsistent with accuracy, but taking regular breaks can help improve concentration. Some studies have shown that taking short breaks during long work helps you to keep your level of activity at bay. While working on a break without leave leads to a steady decline in performance.
21. Use ERP Software’s
It will help reduce communication time, easier monitoring of production data, and be able to easily identify issues and balance that.
The suggested techniques developed by Dony Garments Company in this article cover a wide range of factors in reducing recurrence in the sewing industry in the garment industry by ensuring that quality products also help to improve productivity.
Production assistance to reduce product costs and quality ultimately provide customer satisfaction. Good quality increases the value of a product or service, establishes a brand name, and builds a good reputation for the sender of clothing, which also leads to customer satisfaction, high sales.
Research clearly shows that eliminating unproductive jobs will improve the productivity of the garment industry.
About the author
Dony Garment is a clothing manufacturer based out of Vietnam. We create top-quality apparel products for clients in developed countries for a less than average price.
Passion, Quality, Expertise. These are just a few of the things that go into ensuring DONY garments remain one of the go-to places in Vietnam for high-quality clothing manufacturing.
We craft garments for clients in developed countries that are looking for that extra bit of wow factor with their service. Our mission is to prove to the world that this lovely country can do great things by offering unmatched service for companies big and small.
Productivity Strategies to Improve Apparel Manufacturing
Productivity improvement is a sought-after point in the clothing fabricating area. Typically, the creation group and mechanical designing group think and get things done for improving the current productivity level and keep up the benchmark productivity. Everybody should consider productivity improvement in their shop floor for some reasons. A portion of the advantages incorporate
- Expanded overall revenue
- Diminished assembling cost
- Better creation arranging
- Expanded limit
- Diminished lead time
Anyway, how would you be able to deal with improve the productivity level on the shop floor? You ought to build up a productivity improvement procedure and follow up on that to meet your productivity objective.
According to Dony, the accompanying techniques of activities ought to be sent by a manufacturing plant to improve shop floor productivity. He follows these means to his shop floor.
1 Survey the style being referred to be stacked, 3 weeks ahead of time.
2 Survey accessibility of machines for the style according to design.
3 Unite activities and machines according to design.
4 Audit strategies for assembling for every activity of the style.
5 Conceptualize whether it tends to be improved better hypothetically.
6 Set all the necessary hardware and connections according to quality prerequisites expressed by the purchaser including best professionals/best mechanics/best IEs. This action to be finished fourteen days ahead of time of stacking the style.
7 Set up a reproduced design and orchestrate apparatus according to recreated format with all work helps or potentially connections and so on
8 Plan standard worksheets in nearby dialects so administrators can comprehend and adhere to the directions and strategies.
9 Set up an ability network of the arranged line for the arranged style for a portion of administrators to each operation(s).
10 Get administrators from the showing lines to supplanting them with floaters and enlist them in the new style which is set in the Pre-Production zone.
11 All the specialists include in teaching administrators concerning dealing with/technique/quality to be followed and polished on the genuine texture (around 100 laptops cut in real creation texture) to get the certainty of live creation.
12 Screen every single administrator on regular routine for quality, productivity and plotted on a diagram as a visual instrument to follow up on for additional activities to improve.
13 All administrators ought to be prepared to required abilities and quality levels to accomplish productivity (proficiency and viability).
14 All the 100 pieces are checked toward the stopping point and offered for AQL.
15 Whenever passed for AQL, all the passed pieces ought to be asked to take a hike for shipment.
16 These whole advances are begun 3 weeks ahead of time of the creation start date and complete the speedy changeover measure and are prepared to run creation as the administrators and machine are getting moved individually as and when old-style tasks get finished one over the other.
By the time the last operation of running style completed, the last operation of the new style gets started soon after it and by the time it comes out of the last machine to the end table for checking, quick changeover happens automatically.
Quick changeover team handed over the process to production teams (planned lines) and works with them for 3 more days to settle if any minor issues.
Now the next step is the ramp-up of each operation from the start date of the production in the planned line starts from day -1 and monitored to improve further to set targets.
The above process is suitable for both high volumes and low volumes since the process is set externally 3 weeks before the start of production and cost-effective as it reduces the changeover time drastically by quick changeover principle, facilitates skill development to operators, boosts confidence in operators on actual fabric as it is shippable, quality improvement takes place which in turn reduces reworks and rejects on planned lines.
Overall leads to cost-effective and productive lines.
Henry Pham (Pham Quang Anh), CEO of DONY Garment
This year, we have found that many international buyers are seeking new suppliers based in nations outside of China and Thailand to purchase many goods and products, including uniforms, workwear, reusable cloth face mask, and protective clothing.
At DONY Garment, we are proud to welcome international customers, especially those based in the US, Canada, the Middle East, and the EU market to discover the professional production line at our factory in Vietnam.
We guarantee our products are of the highest quality, at an affordable cost, and easy to transport across the world.