Conduct Motion Study
Identify and eliminate unnecessary motions during sewing operations. Optimise operator movements to reduce operation cycle time. Do Method Study or analyse the operation to record the motion, motion sequence and required time needed for those each motions, re-sequence, eliminate and rearrange the motion therefore do and adjust anything from the findings in your analysing to reduce the process time actually.
2.
Use Work
Aids and Attachments
Incorporate folders, guides, and attachments to simplify operations and minimize
manual adjustments, reducing the time required for stitching.
3.
Adopt
Automation
Use automated machines such as auto-trimmers, computerized sewing machines, and
robotic cutters to complete repetitive tasks more quickly and accurately.
4.
Optimize
Line Balancing
Balance the sewing line by aligning task assignments with operator skills to
ensure smooth workflow and avoid bottlenecks from first to last process which
can be the great to gain exact Target.
5.
Redesign
Garment Construction
Modify garment construction to simplify complex operations without compromising
design or quality. For example, replace multiple seams with a single stitch
line but remember about the required strength of the joining.
6.
Improve
Workstation Layout
Design ergonomic workstations with components placed within easy reach,
reducing handling time and operator fatigue, less quantity gathering in hand.
Here we can use 5S method also in every workstation which influences to
minimize the process time.
7.
Implement
Modular Production
Use modular layouts for complex garment styles to divide operations into
smaller, manageable sections for faster assembly.
8.
Streamline
Cutting and Marking
Ensure precision in fabric cutting and marking to eliminate the need for
post-sewing corrections, reducing wasted time.
9.
Pre-plan
Operations
Use operation bulletins and Standard Operating Procedures (SOPs) to streamline
workflow, ensuring operators know exactly how to perform each task. Supervisor
must maintain and follow the Operation Bulletin.
10.
Train
Operators
Provide task-specific training to enhance operator efficiency, enabling them to
complete operations faster with fewer errors.
11.
Use Lean
Manufacturing Techniques
Apply lean principles such as value stream mapping to identify and eliminate
non-value-adding activities in production.
12.
Optimize
Thread and Needle Selection
Choose the right thread and needle combinations to reduce thread breakage and
improve stitching speed.
13.
Minimize
Handling Time
Reduce the number of times a garment is handled during production by
grouping tasks or using automated material handling systems.
14.
Perform
Real-Time Monitoring
Implement real-time tracking systems to identify inefficiencies and
bottlenecks, allowing for immediate corrective actions.
15.
Improve
Quality at the Source
Use inline quality checks to catch defects early, avoiding rework that
increases production time.
16.
Simplify
Styles during Design Phase
Collaborate with designers to create styles that are easier and faster to
produce without compromising aesthetics.
17.
Use
High-Efficiency Equipment
Replace outdated machinery with modern, high-speed machines to increase
output and reduce cycle times.
18.
Standardize
Processes
Establish standardized methods for recurring operations to ensure
consistency and minimize variability.
19.
Implement
Continuous Feeding Systems
Ensure a steady supply of materials to sewing lines to prevent idle time
and maintain production flow.
20.
Analyze
Historical Data
Review past production data to identify best practices for reducing
standard times in similar garment styles.
By implementing these techniques, garment manufacturers can significantly reduce SAM, improve productivity, and enhance overall operational efficiency.
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