Manufacturing Excellence: A Roadway for Garment Industry in This Current Situation
Khurram Bahadur
IE Executive
Remi Holdings Limited
Email: khurramtakbir@gmail.com
Our readymade garment industry have been evolved with dynamic changes getting net increased of demand. The dynamic product demand issues the impact on some operational risks like high inventories, excess manpower and underutilization of machines. Due to consequence of Russia- Ukraine conflict, the inflation of currencies result adverse impact on global supply chain in garments industry. Most of European buyers reverse their order quantities in order to remain sustained. But in this current situation, our most of garment manufacturers are worried to set aims to different lead times.
Manufacturing excellence in the garment industry refers to the implementation of best practices, techniques, and systems to achieve the highest level of efficiency, productivity, and quality in the production of clothing and textile products. It involves the use of advanced technologies, streamlined processes, and a skilled workforce to optimize production, reduce waste, and improve overall performance.
BGMEA President Faruque Hossain told a press conference, “The buyers are changing their sourcing strategy and placing work orders in small slots. As a result, our production at factory level is facing difficulties”.
Now this is the situation our leading manufacturers have to push through their strategy with maximum quality assurance. Now the term “Manufacturing Excellence” is the loud topic as it is now outmost strategy to cope up with the current situation.
Manufacturing Excellence is a broad term continuous term of your operations to reduce minimum waste of resources. Day by day establishing some principles can make progress better for management. Production management, general management and systems management are again in focus with numerous approaches towards improving the bottom line. Planning department set the plan to make cut, make and trim action according to shipment date. To estimate the line loading plan, the production department’s carried out the statistics have been shown on Follow-up forecast meeting. According to the previous result, critical and semi – critical style is allocated on better responsible line.
To get deep understanding in Manufacturing Excellence, we have to observe where we push through daily activities.
At first, an enterprise has to look for rules with restrict in attendance time to time. The first rules of productivity to get the employees in time and continue to monitoring with right strategies. Most of manufacturers’ management system set the polis gesture on dress of garments employees thus they get positive hive in their self esteem. This hive give them confidence.
Low productivity always bring in a vicious cycle in an enterprise. The vicious cycle continues and becomes more and more complex until right management technique is launched and pursued.
The cycle of low productivity continues like –
Overwork → Migration → Illness → Job dissatisfaction → Failure in social audit and scientific management.
To close the door of vicious productivity cycle, specially IE & Production department has to balance and work with those problems such as operator abseentism checklist, capacity utilization and distribute the operator in right processes.
The key components of productivity improvement role in Production Planning department. Number of man, machine ratio have to be set up with followed the takt time.
During their assessment of production planning team in operations, the team are daily in hassle the following:
- Capacity was never considered when doing planning (many of the planners could not even hazard a guess at the capacity of their system).
- All production scheduling was done manually on a large, vinyl-coated metal board. Many of the items updates are noted in the boards system daily efficiency, production, DHU℅ that did had varying levels of accuracy.
- Routings for many parts were missing (people depended on the memory of certain key individuals; as how many sewing overlock, single needle machine should be distributed on the floor really believed in the proposed system or even understood it.
- Expediting was the norm, rather than the exception. This was a system in which the “squeaking wheel” really did get all of the attention. After spending time in reviewing the system and its operation.
In this current economic situation, business firms or companies get impacted financially due to the dynamic product demand with issues like rising finish goods, raw material, and in-process stocks or inventories, inefficient usage of resources like machines, water, and people, and excess or less manpower or job cuts.
To sustain in this situation our manufacturers’ balance the practical common thing which ensure future sustainability.
Some common ways of regular practice in manufacturing excellence:
- Implement Lean Manufacturing Principles: Lean manufacturing is a systematic approach to eliminating waste and maximizing efficiency. By implementing lean principles, the garments industry can improve its processes, reduce production time, and enhance the quality of its products.
- Improve Workforce Training: Investing in the training and development of the workforce can improve the quality and efficiency of production. Workers need to be trained in the latest technologies and best practices to perform their jobs efficiently.
- Invest in Automation: Automation can significantly improve the efficiency and productivity of the manufacturing process. Investing in automated machinery and robotics can help reduce labor costs and improve quality.
- Enhance Supply Chain Management: The garments industry’s supply chain is complex, with multiple stakeholders involved, including suppliers, manufacturers, distributors, and retailers. Improving supply chain management can help reduce lead times, improve quality control, and reduce costs.
- Focus on Sustainability: Customers are becoming increasingly conscious of the environmental and social impact of the products they buy. The garments industry needs to focus on sustainability, including the use of environmentally friendly materials, reducing waste, and improving social and labor practices.
To ensure sustainable future, focusing on manufacturing excellence and implementing the above strategies, the Bangladesh garments industry can improve its competitiveness, attract more business, and continue to grow and contribute to the country’s economy.
References:
- https://www.textileschool.com/amp/4405/the-blueprint-to-attain-manufacturing-excellence/
- https://www.fibre2fashion.com/industry-article/9144/best-practices-manufacturing-excellence
- Making Common Sense Common Practice: Models for Manufacturing Excellence by Ron Moore
Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. Mr. Kiron is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.
