Are you ready to press to the max every hour of every day? Here are 10 ways for manufacturers to speed up and boost efficiency in their garment production process
1. Create an efficient production schedule
Determine the proper sequence of operations for each garment style. Integrate all steps of your manufacturing process into a streamlined flow so that nothing is repeated, and everything is done in as few steps as possible. Make sure you have enough time to make any necessary alterations to get it all done in time for shipping.
2. Optimize your floor plan
Reduce movement on the factory floor for optimal task efficiency. Organizing equipment, tools, and materials properly will not only improve manufacturing productivity but will also help to keep the workplace a safe environment for employees to do their jobs. Make sure your sample room is well organized. Use a dedicated warehouse for incoming materials and outgoing finished goods.
3. Commit to scheduled maintenance
The fastest way to slow things down is by ignoring regular maintenance. Downtime for maintenance costs much less than downtime due to broken and worn equipment. With new technologies, it’s easy to keep track of your maintenance schedule. There are many smart machines and systems to help you track every machine’s performance.
4. Use the latest software tools
Invest in software that helps with capacity planning, scheduling, customer relationship management, inventory and order tracking, data collection and analysis. Automation is a powerful tool for increasing efficiency and reducing errors. Your factory staff should not be wasting time on email updates and manual progress reports. New software solutions like the WFX ERP and Smart Factory can help with real-time alerts, scheduling, inventory, and monitoring workflow.
5. Active collaboration is key
Improve communication between departments so everyone is aware of what is happening at each stage of the production process. In garment manufacturing, each stage requires the input and approval of different people in different departments. The more coordinated they are, the smoother things will run. Instead of manual approvals, invest in software tools that allow line supervisors to be more proactive. Communication must be crystal clear so everyone knows exactly what to do on what day and the next.
6. Use data to get better
Factories can and should collect data using IoT sensors and web-based monitoring devices. This data can be used to optimize the manufacturing process by reducing defects and increasing productivity by predicting machine failure beforehand. You should also set aside time for failure analysis and improvement planning. Identify where product-line rationalization can help, and use benchmarking and analytics tools to see how your performance compares with others in your sector.
7. Provide performance training
Training at factories should be based on the real-life needs and challenges individual workers face, rather than a tick-box exercise. Schedule training sessions for operators when new equipment is installed. Keep accurate records of training and schedule refresher if needed. Create ‘learning moments’ tailored to the practical requirements of staff on the shop floor.
8. Keep alternate shipping options
Don’t let your production get delayed due to shipping problems. Have a network of multiple carriers. So that if one shipping company experiences issues or is too busy, you have more options to fall back on. It’s also wise to choose a carrier who will work with you regardless of changes in schedule because these situations can be hard to avoid.
9. Outsource or automate
When it comes to garment production, the more automated your system is, the quicker you can get garments out of your factory. That’s why it’s so important to increase automation whenever possible. Automation can also help reduce production costs and improve product quality. Another strategy you can use is outsourcing, especially during peak season when demand temporarily rises. They may be able to help with any temporary rise in demand but won’t require training or long-term commitment from your company.
10. Maintain a material stock
Invest in building a good inventory of fabric stocks, popular trims, hardware and other materials. This will help cut down on lead times for these items by reducing the need to place new purchase orders every time production begins for a new style. Work closely with suppliers who are willing to make quick deliveries if you order small quantities, but also offer discounts for larger volumes of raw materials like zippers or buttons. If you place repeat orders with suppliers who have longer lead times, consider asking them if they can deliver sample quantities ahead of time so that you can begin production faster.
