Now a day competition is increasing in the garments industry. In past, factories rely on few buyers with huge order volumes. Now, because of huge competition, factories have to work with lots of buyers with short volume orders. If one style is running in a garments line continuously, productivity should be increased gradually and after few days it reaches maximum productivity (There is always a scope to increase productivity).
But for short order quantity, we need to achieve maximum productivity from the very first day. Otherwise, the targeted profit may not be achieved.
Here are a few tips for the garments manufacturer who is dealing with small orders:
- Identify the pattern of that style: Yarn count, the requirement of line setup and balancing, requirement of the multi-skill operator, requirement of a special machine.
- Take a calculative risk: Buffer yarn stock, flexibility in line arrangement, contract manufacturing option evaluation, small lines, similar product in a similar line, small dyeing machine, matching knitting Dia, etc.
- Adjust risk with premium: Absorb it into the price, where possible.
- Reduce red tape barriers: Order to sample, sample to bulk lead-time needs to reduce by prompt decision making backed up by proper and transparent information.
- Automation: Replacing some manual machines to enable efficient production and reduced DHU (Defect per hundred units).
- Efficiency: Marker efficiency, No shortcutting, no helper.
- Quality: End line quality and establishing proper QMS (Quality Management System), so that operators can maintain line quality.
- Communication with buyer: Clear and timely communication will help.
- Management: Management should be on the toe with a thinking mind.
- SCM: Proper supply chain integration with logistics support.
- Changeover pre-activities: For short order quantity, style changing happens frequently. Before any style change, some precautionary actions are necessary. By doing these activities properly, change over time may be reduced. I have discussed this topic in my previous article “Pre-activities for a quick successful changeover”