How to Improve Efficiency of a Sewing Line ?

How to Improve Efficiency of a Sewing Line ?

Today I'm share to you more detailed breakdown of the factors that can lead to a sewing line falling short of production goals:

Efficiency improvement of a sewing line is a probably the most important performance indicator of garment industry but it is also one of the trickiest. The reason for that is that all the factors that affect increase in efficiency are interrelated.

We know that Efficiency is measure of how well a line is run. It is a combined measure for performance of operators(Performance) and Utilization( how well working hours of operators are used). To learn more about efficiency , performance and utilization read this post today I'm sharing.👉

Efficiency is the responsibility of managers and not operators alone because performance of operators can only be improved marginally but to achieve increase in sewing line efficiency utilization needs to be improved as well. operator performance should be improved only when utilization is corrected .

To improve the efficiency of a sewing line you need to adopt a sequential approach. Below is the step by step approach to improve the efficiency of a sewing line .These steps can be applied to not just sewing but to increase efficiency of any assembly line

🛑Look 3 Months lording plan

🛑RM update on time

🛑Sampling process 

🛑 Finalize OB

🛑Lay out Finalize 

🛑Define of Skill Gaps

🛑Pre Training required efficiency + Quality

🛑SMED

🛑Strong Pre -Production 4P,4M,

🛑Improve the line layout with GSD pattern 

🛑Improve the Line Balance :

🛑Identify and remove bottlenecks

When production Start You have to follow and analyzing process improvement follow 👉

🛑How to remove bottleneck from an operation ? Time line progress (What, When, Who)

🛑Method Study go to the operation and observe it carefully and find out the problems (Standards work Sheets Cycle )

🛑Method improvement: Improve the method and train the operator in the right method. Don’t forget to document the changed method as standard( Kizan )

🛑Work aid development: Design and develop work aids that will help in operations like stacker, drop box, folders, zigs (VSM)

🛑Quality improvement: find out the defects that the operator is producing, this could be one of the reason for bottleneck as most of the time is taken doing rework . Do root cause analysis and find out the solutions to reduce the defects.(JIT+RTF)

🛑Change the operator: Maybe the handling or skill of the operator is causing the bottleneck . If that’s case its good to change the operator ( 4M+OEE)

🛑Improve the Performance of operators:

Once all the other factors are improved only then individual operator performance should be monitored and improved. Low performers should be identified and method study need to be carried out to find out the reasons for low performance.

(Skill Metrics Currant Update)

Let us know if you have anything to add regarding how to improve efficiency add your valuable Ideas 👉