A business with higher productivity will have a greater margin. An Increase Productivity in Garment Production will reduce the cost of clothing manufacturing. A factory can therefore make more profit by increasing productivity.
This article will discuss the top 10 productivity improvement methods that factories can use to increase current labor productivity. You can implement most of the methods that have been described here. When a factory produces more pieces using the available resources (Manpower and time), both machine productivity and labor productivity increase.
During my factory visits, I see improvement potential in all areas. However, you may not initially be able to find and measure the potential areas. Using the following steps can help you Increase Productivity in Garment Production.
Here are ten ways you can be more productive. A few links are provided to help you further your knowledge on some of these steps. The majority of the tips in this article focus on time-saving, discipline, and proper planning. External support and recommendation may be necessary to achieve an outstanding result. However, even without external assistance, you will see measurable improvements once you begin your journey.
It is important to realize that the steps you follow will differ depending on the production system. This article is focused on the progressive bundle system Increase Productivity in Garment Production.
If you’re new to the productivity discussion, I suggest that you read how to Measure Labor Productivity before starting the next steps. It will allow you to better understand the discussions.
10 Ways to Increase Productivity in Garment Production
1. Hourly operator capacity checks:
If you don’t already have work-study staff, start checking the operator’s capacity hourly or bi-hourly, comparing the actual operator’s hourly production to their capacity. Ask them why their production is lower.
This helps in two ways. First, it ensures that the operator’s ability is tested at regular intervals. They will also be put under pressure. Work-study staff begins to think about ways to reduce cycle time. You can balance the line by using the capacity data Increase Productivity in Garment Production.
2. The layout of a scientific workstation:
This layout identifies where the operator will pick up (garment components) as well as where she will dispose of the garment. A scientific layout refers to the minimum distance required for components to be picked up or disposed of. Each component and tool (trimmer) must be within reach of the operator. Engineering must adhere to fundamental principles when designing workstations.
It is important to position components as close to the needle as you can.
The components must be positioned in the right direction on the track or table so that they do not have to be turned when moving from one point to another Increase Productivity in Garment Production.
Place work on the same plane as the machine table so the operator can slide it to the needlepoint.
A good layout for a workstation is important to reduce material handling time. This will reduce the operation cycle time. A good workstation also allows operators to work at the same speed without feeling fatigued. Remember ergonomics when designing your workstation layout Increase Productivity in Garment Production.
3. Reducing line setting time:
Lines reach their pick productivity level within 6-7 days after the order is loaded. Thus, the average labor productivity of the entire style is reduced by the time spent learning in the beginning days.
This is because a lot of time goes into setting up a new style. As a result, it decreases machine productivity and reduces line efficiency. To maintain your line productivity, you must reduce line setting time and throughput time.
Engineers must study the garment carefully and prepare an operation bulletin detailing the machine requirements and a plan for the machine layout before cutting the fabric. This will reduce line setting time.
You can read another article to learn how to decrease line setting time. Engineers must coordinate with the maintenance department and line supervisors to discuss their plans and needs. It will allow supervisors and maintenance to be proactive in allocating resources.
4. Balance the line:
The purpose of balancing a wire is to minimize operator idle time and maximize operator utilization. In addition, a balanced line will allow for smooth workflow and will eliminate the need to wait for work.
Line setting involves selecting operators who have the required skill and experience to perform the operation. It will allow you to select highly skilled operators who can perform higher work content operations. Conduct a capacity study every other week once the line has been established.
To find bottlenecks in the line, use the pitch diagram method. It is important to consider how you can reduce WIP levels at bottleneck operations. For more information, see another article on online balancing.
You will see an increase in operator utilization by line balancing. It will allow you to get more pieces from the same resources over a defined period.
5. Continuous feeding of the sewing machine:
If they don’t have cuttings to sew, it is not their fault. However, if the sewing line is not fed regularly, all plans and efforts to increase productivity will be ruined. Poorly managed factories are more likely to have lower productivity because they don’t get enough or not enough food.
Ineffective cutting departments, poor production plans, and incorrect product selection in seasons are all reasons for stopping continuous feeding. To maintain productivity, operators should continue to be fed continuously until they get into the rhythm. Plan accordingly if you are certain that there will be no cutting in the near future. Don’t call all of your operators.
6. Setting individual operator target:
Instead of giving an equal target to all operators working in a line, give individual targets as per the operator’s skill level and capacity. Each operator should be given a realistic target so they can reach it.
This will help to improve the operator’s individual efficiency. You can use tricks to increase the target’s accuracy step by step. Operators who are not on target should be taken care of. They may need skill training.
7. Better equipment:
It is unacceptable to have a low-performing machine in the same place as your other machines. Make the most of what you have. If machines or equipment don’t perform, well operator motivation goes down.
Machine failures can lead to increased loss time, which in turn reduces line efficiency and labor productivity. I’ve seen lines with UBT machines being used for extended seam operations but comparable work content. However, when shorter seams are being sewn, the majority of time is spent on thread trimming to remove work. Normal lock stitch sewing machines are used.
8. Regular inline quality inspection:
The most efficient inspection tool to reduce defect production at the source is the Traffic Light System. The time spent repairing a defective seam will be reduced if there are fewer of them. In addition, operators will be able to concentrate their work with the help of an inline inspection system.
It can also be used in another way. For example, operators may not be able to understand the specifications at the beginning of the style. However, interaction with quality inspectors will help them to understand the quality requirements.
9. Shop floor data tracking system in real-time:
It is essential for continuous improvement and quick action when there is a problem. In addition, you will need important information such as the hourly production, line balance, WIP, tracking bundles, and line quality performance.
Failure to take corrective action quickly can lead to more problems. For example, RFID-based real-time systems allow for quick access to shop floor information.
10. The motivation of the operator:
An essential part of productivity improvement is the operator’s will. They will work hard if they feel motivated. Motivation for employees is dependent on many factors, such as work culture, HR policies, and bonus incentives.
Extra money is a key factor in motivating garment manufacturers’ operators. You can increase operator motivation by sharing a percentage of the operator’s extra work.