The question “Difference Between Standard & Standardised work?” has been a confusion for quite a few people and I have seen people particularly pressing on the point that “Do not confuse Standard work with Standardised work”. I googled the difference and what I could understand from many blog posts was that Standard work means the work will not change whereas Standardized work means there is a scope of improvement. Continue reading “Difference Between Standard & Standardised work ?”
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Process standardisation- A silver bullet for lean Manufacturing.
“Where there is no standard, there is no Kaizen” . Effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S .
Process Standardisation is a simple technique but with high impact. It is more underestimated than misunderstood. Lean strategy in Garment industry is mainly centered around 5S & Kaizen but an effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S . Taichi Ohno, The father of Toyota Production System himself has famously quoted :
“Where there is no standard, there is no Kaizen”
What is Process Standardisation in garment industry?
Continue reading “Process standardisation- A silver bullet for lean Manufacturing.”
A secret useful excel formula for merchandisers, planners and buyers
In this post I am going to tell you a useful excel formula for merchandisers, planners and buyers ( or every garment professional) which is going to save you a lot of time and will let your boss wondering about your speed and efficiency.
Many a times garment professionals have to copy a style information from one excel sheet to other. To do this, the normally adopted method is to open both the sheets, search the style number , select the style colour then copy the relevant data and paste it into the other sheet. Continue reading “A secret useful excel formula for merchandisers, planners and buyers”
Industrial Engineering Calculations in garment production factory
Industrial engineering calculations in garment production factory is the most powerful waste quantifying and reduction tool.
These calculations are important because without setting up a target it is highly unlikely that you will be able to achieve what is expected. Once the target is set and we know what is expected we can take steps to achieve the target production. It gives industrial engineers clear picture about the performance of sewing operators, supervisors and the sewing line. The things that an industrial engineer needs to calculate are: capacity, efficiency, performance and utilization.
Continue reading “Industrial Engineering Calculations in garment production factory”Doing things right the first time – literature review
Quality is free, what costs money is defects- all the activities resulting from not doing things right the first time. It is always cheaper and efficient to do things right the first time
Doing things right the first time(DRIFT)/Zero defect(ZD)
Doing things right the first time (DRIFT)/Zero defect(ZD) was coined was Philip Crosby in his book Quality is free. According to him Quality is free, what costs money is defects- all the activities resulting from not doing things right the first time. It is always cheaper and efficient to do things right the first time[1] Crosby’s response to the quality crisis was the principle of “doing things right the first time” (DRIFT). Continue reading “Doing things right the first time – literature review”
5S implementation challenges in garment factory
5S implementation challenges in garment factory
5S implementation challenges in garment factory stops the improvement journey before it even starts.. 5S is a slow and gradual process as it involves the support of entire garment factory workforce. There isn’t any magical solution with which you can do it within few months and gain the results. Even if you are able to notice improvements, it won’t sustain for long unless efforts are put to strengthen the 5th S – Sustain Continue reading “5S implementation challenges in garment factory”
Ink Numbering garments panels in assembly sewing line – An efficiency and quality improvement tool
How to implement number sealing on garments in a factory ?
Ink numbering garments is called Number Sealing. Number sealing or Ink numbering refers to printing number on the garment pieces by means of ink and stamping machine to identify the garment panels to be stitched together. It replaces the traditional method of pasting a numbered Sticker on garment pieces Continue reading “Ink Numbering garments panels in assembly sewing line – An efficiency and quality improvement tool”
How to identify a good Cut order plan for optimum fabric utilization
Identifying a good cut order plan can be critical in saving fabric while cutting an order and increasing the efficiency of cutting floor. There can be hundreds of combinations of a cut order plan so identifying the best one is an important skill.
A good fabric cut order plan will require less time and effort for spreading and will use lesser fabric per garment. But there are many factors which make cut order planning efficient as mentioned below , However if you want to understand the basics of how to make a cut order plan , please read this post first.
Characteristics of an efficient Fabric cut order plan :
1. Maximum number of garments on a marker –
Number of garments on marker (G’s ) should be maximum depending on Continue reading “How to identify a good Cut order plan for optimum fabric utilization”
What is a cut order plan and how it is made ?
Guide to the art of making a fabric saving cut plan !
A cut order plan is a logical division of an order quantity into lays (spread) of fabric such that desired number of garment pieces can be cut in the required size ratio. Cut order plan is made to minimize time and effort in cutting as well as to utilize fabric efficiently.
Cut order plan is also referred as lay plan or cut plan in apparel industry. A good cut order plan will require less time and effort for spreading and will use lesser fabric per garment
A cut order plan is made by following these steps :
Continue reading “What is a cut order plan and how it is made ?”Cutting process in garment industry
Cutting process in garment industry can be tricky and many people are perplexed on how this magical feat of matching every check/stripe is achieved by the factories. Here is the step by step, brief explanation on cutting process in garment industry and the cutting process flowchart at the end of the article.
1. Spreading or laying
To cut many garments simultaneously, fabric is spread in layers one over the on a long table. This process in called spreading or laying.
Plies – Fabric is spread in layers one above the other and every layer is called a ply. Number of plies that can be laid is decided based on the height of the knife, thickness of fabric and type of cutting method being followed.
Lay– End product of spreading/ laying is a lay which is nothing but desired number of plies laid.
Spreading can be done by manual as well as automated spreaders.
Note: while spreading checks and stripes fabric, every line of a ply will not overlap exactly over each other hence if garments are cut directly line matching will not be achieved in every garment. Pinning table is used as solution to this problem. If pinning table is not used then panels are cut as a block as explained below.