Without pre-planning task of change-over, we are losing a lot of production during the learning curve period (Usually 3-5 days from style change). At the same time, due to the lack of monitoring in pre-planned activities and unawareness of several departments task about maintaining quick changeover are responsible for the failure in achieving learning curve target. So that there are some pre-activities for different departments to handle changeover smoothly and to achieve the learning curve periods target on time.
Team for changeover
There are two teams in every unit/floor, one is for implementation in the floor and another is for reviewing the activities which is done by the implementation team. Review team monitors the pre-activities progress which is done or not. Each department has a leader to monitor all his departments’ task. They are also responsible for giving decisions from his department side about any issues which is related to changeover and will attend all the meetings which is about the changeover.
Changeover pre-activity monitoring mechanism
Changeover pre-activity under implementation teams are given below:
Technical team
Risk Analysis meeting with all head of the department.
Complete pilot-A (Methods and construction has to be finalized during Pilot-A run)
Preparation of the comparison report on the current and upcoming style
Sent folder, foot, and gauge requirement to the maintenance
Complete Pilot-B & identify critical operations of the style
Ensure availability of finish board and pattern board
Actual fabric cut panel need to handover to maintenance team to adjust the machine
Preparation of mock-ups of the critical operations
IE team
Send M/C and thread requirement for that style to the maintenance
Update GSD SMV based on an approved sample and finalize OB based on GSD SMV
Select the operators for critical operations and set back up a plan for training
Ensure operator allocations for training are done as per requirement
MP allocation list with their replacement MP Plan provides to technical, production & ME team
Maintenance team
Machine arranging for pilot
Adjust special machines and cross check with technical.
Ensure machine availability physically
Preparation of machinery and attachments based on the I.E requisition.
Ensure that physically needle, throat plate, feed dog and bobbin available
Ensure machine working condition with stitching quality
Utility team
Arrange Chair, Table, Machine light physically
Production team
Line selection for Pilot-B run
Line manager needs to involve in Pilot-B stage & make 1 sample which is approved by a quality
Ensure inputs, CPU parts, and trims (threads, zipper, Label etc.) availability before 1 day
Quality team
Attend during Pilot-A run time and feedback with review comments
Deployment of quality inspectors based on the critical operations of the new
Provide guideline to QI about checking procedure and DHU target
Verification of patterns
Learning curve target will be depended on the Standard Minute Value (SMV) and the difference between the construction of the garments.