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| Efficiency |
What is a Short Run Order?
An order of small order quantity that runs on the production line for 3-5 days. The order quantity for a short-run order may be different depending on the style design. Garment factories set their own criteria for considering the order short-run or a long-run order
It is true that for short-run orders when the line reaches its
pick performance, stitching get completed. When a factory compares the line performance
of a short-run against a long-run order, it gets less efficiency.
Normally, on the first 1-3 days of production loading (depending on the style
or production system), a line builds its performance day by day (learning
curve) and line works at optimum efficiency level after the learning curve. If the line gets a long
run order (that normally runs more than 15 days), the average efficiency of the
order comes higher as after learning most of the days, the line works on the
higher level.
On the other hand, when an order gets finished by 4th to 5th day of loading,
the average line efficiency remains low due to initial days' learning curve.When
a line gets 4-5 short run orders in months, they lost the productive time
on production line set-up (style changeover). This results in lower line
performance during the month.
In this post, I have shared few tips that can be useful in
achieving maximum efficiency in shorter run orders. Though these tips are
applicable for long-run orders too to achieve better performance.
Get Maximum Efficiency in Shorter Run Orders
- ·
By loading the new style back to back. This means when the
previous style getting completed from the one operator, load the new style
without waiting for completing style from all operations.
- · Prepare the line layout and
process workflow on paper in advance and follow that one during line
set-up.
- ·
All you need to be better prepared. Keep continuous feeding
to the line. Before loading the cuttings in the line, keep everything
ready- all approvals related to the style, trim, and complete cutting of
the order or at least two day's cutting WIP should be there.
- ·
Train employees (sewing operators) separately, how to do the
operation they are going to assign to the style.
- · Supervisors need to be prepared and need to complete line set-up
as quickly as possible (no waiting of operators should be there), including
machine changing, an instruction to operators, quality specification, approval
etc,
- ·
Reduce bundle size. Single piece flow would better for small runs.
·
If possible use a shorter sewing line for small qty orders. This
change will also make difference in achieving line's overall efficiency.
