Visionary Textile Expert | Weaving | Towel Jacquard | Denim | Spinning | Dyeing | Sustainable Solutions | HVAC | Research & Innovation | Garment | Industry 4.0 | MS | MBA Textile Apparel Manufacturing | PGD Weaving JAPAN
Major reasons for higher style changeover time in garment manufacturing. The approach in which we work to minimize COT is called QCOT Approach. Before we discuss how to reduce COT, I would like to discuss the causes of COT. To be frank cause of Changeover Time is Changeovers but what I meant earlier was, causes of High Duration Change Over Time. SMED – The Lean Method of Reducing Style Changeover Time SMED stands for Single Minute Exchange of Dies. In simple terms any change over time should be in single digit (minutes). Now we will discuss, how to apply SMED approach in a sewing line. For this, we need to list down all the elements of a line change over along with time. External elements are those elements that are independent of your sewing line. For example, you need a special machine for next style. You can arrange that machine before the line change over starts. Internal elements are those elements for which you need to stop the line, or you have to wait till the last piece is out. For example, you want to set that new special machine in your line for next style. This activity can’t be performed till the old style is out of line. Now our approach will be converting internal activity into external activity and reducing time duration of both activities. Here is another example, mechanic is setting that special machine after placing that machine in line. Now you say that this setting can be done before start of changeover outside the line. Here you have converted internal activity into external activity. Now there can be another condition where mechanic does not have a proper toolbox and for each tool, he is going back to the tool room. In this case, time consumption will be higher. Conclusion Some key points in consideration before style changeover: The new style needs to be allocated to that line only where there is a minimum style variation. The batch Supervisor and QC along with the COT team should be there at pre-production meetings to judge critical operations and operator availability. New Style Requirement (NSR) to be made and discussed. It will ensure the availability of trims, machines, skilled operators, cutting before the line setting. Supervisors/IE need to analyze the skill-matrix prior to the style changeover; the concerned Floor Manager must ensure the availability of operators along with the skill. The spare machines should be allotted before the start of the process to stimulate the offline batch setting. The mechanic needs to ensure the availability of templates, guides, attachments with settings. Low COT has numerous benefits, the most eminent and visible one is that it increases Available Time thus increasing floor OEE.
Quality /QA at Changhong Ruba Pakistan
3moi learing garment manufacuring