Fu Dongliang: How Do Garment Enterprises Achieve Lean Production?

How to achieve lean production in garment enterprises -- Analysis of preparation before preparation and promotion of single piece production system

In recent years,

The core of the concept of lean production is to eliminate all useless labor and waste. It aims at perfection in terms of reducing costs, improving quality, enhancing production flexibility, realizing no waste and zero inventory and so on to ensure enterprises' advantages in market competition.

At the same time, lean production puts responsibility under all levels of the organizational structure, fully mobilizes the enthusiasm and intelligence of all the staff, and eliminates defects and waste in every post.

Fu Dongliang, general manager of Nan Bo Wan Business Management Consulting Co. Ltd. and chief researcher of China Brand Strategy Research Institute, explored the future direction of garment industry and enterprise through the preparation of pre production preparation and the promotion of single piece production system. These two important contents of lean production were discussed.

Prenatal preparation requires cooperation.

The so-called prenatal preparation is to meet the smooth progress of mass production and ensure the smooth development of the production process.

The production of samples is the responsibility of technicians.

In order to make the production of large goods smooth, technicians make strict rules according to the general rules of the customers, and simplify the complicated processes as far as possible without changing the appearance of the samples. Try to design special auxiliary tools or replace the manual work with special machines, so as to reduce the difficulty of the work.

When making samples, technicians must record any problems encountered in the production process, including cutting pieces, materials, cardboard, sewing methods and quality, as well as special procedures and operation skills that need special attention.

The production of mould is responsible for technicians. In the process of sample production, it is suggested that special vehicles and special tools should be improved instead of flat cars and manual operations to save time and efficiency, and provide special vehicle and special tools information for large production, so as to make timely preparations.

The process allocation table is responsible for the IE department.

We should consider the relevant conditions such as time, process flow, machinery, method, cloth characteristics, operator's technical proficiency, order quantity, quality standard and so on.

We must grasp the key points in the process combination: the balance of time and the smooth flow of the process, and other conditions as auxiliary reference.

And we need to train multi skilled workers to facilitate different types of process combinations.

The combination and splitting of process is the most difficult task in process assignment.

The machine layout plan is made by the IE department according to the storage and process allocation table, making the layout map of the parking lot and arranging the appropriate time parking spaces, so as not to affect the normal production.

The head of the field is responsible for arranging the corresponding man's parking spaces. When the field is laid out, the power supply should be cut off and all mechanical plugs should be removed to ensure safety so as not to damage the electrical equipment.

After the machine is finished, the staff should be instructed to plug in the power supply for trial run. If there are any problems, the mechanic will solve them on the spot.

In addition, the IE department must prepare the equipment before commissioning and adjust it.

The arrangement of personnel is responsible for the group leader, and determines the personnel needed according to the process allocation table and sub division table.

The team leader should arrange the operation process according to the skill level of the staff, and at the same time, find out other possible bottleneck processes according to the style characteristics and the practical skills of the staff.

The team leader should check the correctness of the main and auxiliary materials in advance, and whether the inventory is consistent with the list.

Improvement must be carried out before shipment.

Before the big cargo, try to finish the improvement that should be done, and do not need too much improvement when the goods are actually opened.

Fu Dongliang said: "in a Chinese proverb, prenatal preparation is" preventive measures ".

Before big cargo, try to solve all possible problems in large cargo, such as personnel, machine, cutting, process, process, management and so on, and take preventive measures in time to ensure the smooth launch of large cargo.

At the beginning of garment enterprises, a pfer team should first be established, consisting of technicians, IE (Industrial Engineers), QC (quality inspectors), supervisors and team leaders.

Team members are flexible, depending on the degree of difficulty in the style and the skill level of the staff.

When the technician makes the sample, the supervisor should take part in it to understand the difficult process and find out the corresponding solutions.

The leader should clearly inform the employee of the process that he is responsible for in the new payment, and tell the process requirements clearly.

Technicians, IE and team leaders must clearly tell each employee what he has done during the convening of their antenatal meeting, and make sure that the employee is competent.

If an employee is not sure about the process that he is going to produce, the technician should carry out prenatal training ahead of schedule.

If the employees feel confident that their production processes are confident in skills and quality, technicians will no longer make corresponding guidance, only when the quality is confirmed when they are newly opened.

At present, the first process of a project is completed, and the first process of the new type will start to be put into operation. When the first process is put into operation, it will be paid at the same time by other departments, which will shorten the time of the pfer.

Limit samples should be made in every difficult process.

Antenatal training is especially important for employees. The mark of prenatal training is the "acceptable quality standard" physical sample.

This sample is personally completed by the sewing workers under the guidance of technicians and during prenatal training.

After completion, the physical samples are uniformly placed under the machine as the quality standard for large cargo.

Prenatal preparation is the cornerstone of success.

Prenatal preparation requires standardized operation and compliance with the rhythm requirement of production.

In terms of materials, Fu Dongliang said that because of the particularity of the garment industry, each employee should not have more than 2 semi-finished products.

In addition, Kanban should be used to strengthen visual management.

The production line can drive the whole production line to flow rapidly through the process of the preceding process, so as to reduce the WIP, increase output and efficiency.

In manufacturing and manufacturing, there is often a case of forced shutdown due to machine failure, which wastes a lot of valuable time.

If the machine can operate at a rate of 100%, first of all, it is necessary to cultivate the awareness of prevention.

On the other hand, use the light box alarm system, once the situation occurs, notify the mechanic immediately to repair.

Adequate prenatal preparation requires the cooperation of all departments to succeed.

Fu Dongliang, for example, in order to carry out prenatal training, the first 20 pieces of film in place in advance is 4 days in place, so as to ensure that the learning curve of the difficult process is completed before the pfer, so as to achieve seamless pfer (prenatal training as far as possible in overtime).

In addition, in order to make every workstation staff have a good idea of the new quality standard when pferring money, technicians and QC should complete the determination of the quality standard of workstations 1 days ahead of time (the quality standard of each workstation has been determined) when the antenatal training is completed, and the employees do not need to slow down the operation speed because of the inaccuracy of the quality, and affect the efficiency.

Fu Dongliang said: "the purpose of prenatal preparation is to eliminate the impact of learning curve on production, improve production efficiency, reduce costs and achieve the pfer within a quarter of an hour.

With sufficient prenatal preparation, we can achieve seamless pfer, achieve smooth production process and achieve quality stability.

Only with adequate prenatal preparation can we improve our efficiency. "

Targeted training is the core of the system.

Before the establishment of a single piece production system, the first task is to train personnel.

The purpose of training at this stage is only one: the reform of the consciousness of the whole staff.

Fu Dongliang said: "because the change of thought is the beginning of all changes, and also the foundation of all changes."

So, how to train the personnel at different levels before the promotion of single piece flow is the most serious problem facing every promoter.

For this reason, Fu Dongliang proposed training methods with pertinence and applicability for different levels of personnel in the enterprise.

In view of management training, Fu Dongliang believes that the best way is to set up an independent research association.

In this way, managers can find the superiority of single piece flow and accept the idea of single piece flow voluntarily, so that they can yearn for this mode of production, so that they can set up a new production mode in their minds and improve their production efficiency.

Managers' participation in the "independent research council" and subsequent actions are the best targets for evaluating the training results.

Those who have great interest in the single piece flow system and those who have great hopes will actively express their views during the discussion and take corresponding actions after the meeting.

Middle managers are very busy with their work.

In the process of popularization, we should also consider normal production.

Training can be conducted through a combination of centralized teaching and seminars.

Training results can be carried out by written examination.

But Fu Dongliang said: "this kind of assessment is often very inaccurate, which requires managers to evaluate their performance in practical work."

Team leaders and technicians are people who deal directly with employees. Their attitude towards and work style of single flow will directly affect their work enthusiasm and improvement attitude, which will affect the success or failure of promotion.

Most of them have received secondary or higher education, and have good skills and management skills.

But it is easy to rely on experience to do things.

Therefore, the theory, technology and management tools of single piece flow can be used in a combination of centralized teaching and practical learning.

It will change the traditional passive management concept, actively manage and establish the confidence that the new production method will be successful.

To this level of training workers, Fu Dongliang stressed that this is often the most critical, because sewing workers are the direct creator of company wealth.

Therefore, we must first establish an attitude of respect for them.

But on the other hand, because of the uneven education level of the sewing workers, uneven development of skills, fear of standing production, lack of confidence in the new production system, and the influence of non-standard action habits.

Therefore, we must train staff's team consciousness through training, help employees overcome difficulties and build up confidence, quality concept and equipment preservation concept.

Fu Dongliang said that in fact, training methods for employees are flexible.

All the promotion personnel, management cadres and technicians have the responsibility and obligation to train their employees and influence their employees with their own correct behaviors and attitudes.

And staff confidence can be established through the excellent performance of the model line and the high income and no overtime motivation.

In addition, he believes that the focus of staff training should be on the daily maintenance of training results.

This is more important than training itself.

Single flow adds a lot of specific requirements.

The difference between single line production line and traditional production line also leads to different selection of equipment.

Fu Dongliang said that the biggest difference between the two forms is standing mode of production, and it is necessary to choose vertical clothes cars.

In addition, the pfer of workstations is bound to happen when the workstation is mobile.

The single piece production line strictly distinguishes the operation time of manual operation and clothing truck. Improving the efficiency of manual operation is an important way to improve the productivity of a single employee when the speed of the equipment is constant.

The movement of the hand can be reduced by controlling the stitching, lifting the foot and cutting the thread through the pedals.

The single piece production system requires the standardization of sewing workers' movements, and the standard clothing car is conducive to the realization of standardized actions.

Easy to retrofit clothes and cars, table tops and lengthened clothes cars are also optional devices.

Compared with the traditional production line, the single piece flow production line has increased many control tools for production rhythm, products, film distribution and quality, such as electronic Kanban, chip release timer, quality warning light, first process warning light, bottleneck process warning lamp, etc.

Among them, Fu Dong Liang selects several control tools to introduce the requirements and functions of his control personnel.

IE is responsible for setting the rhythm time and target output of the electronic Kanban when each payment is made and the production efficiency changes.

The timers are used to control the release of cutting pieces. Keeping the rhythm of the chip input mode will not affect the production rhythm due to the insufficient input of the cutting film, nor will it cover the problems in production because of the excessive input of the cutting piece.

The quality warning lamp is controlled by QC. When serious or continuous quality problems occur, QC can turn on the quality warning lamp.

At this point, the whole line should be shut down, waiting for technicians to solve the quality problems before resuming production.

Process lights can also be controlled by QC. When more than a few rhythmic time still does not have finished products to reach the final inspection table, it indicates that the production process is defective. QC can turn on the process lights and require the whole line to stop production.

The visual Kanban is completed by the head of the group (style / quantity, standard time / delivery time, rhythm / number) filled by IE, and IE is responsible for supervision.

Visual Kanban is also a very important visual management tool. Even a layman can see how the production line completes the online style: how much to produce, how much it has been produced, and what kind of day it has been made since it was opened.

Managers' grasp of these information helps to predict and adjust the production plan of the production line in order to meet the delivery date.

Process balancing diagram is an important tool for IE in balancing process. It also provides many useful information for managers: the type of products, how to allocate processes, whether the processes are balanced or not, target rhythm time, actual rhythm time and so on.

IE to draw up the first process balance map within two hours after the new payment is made, balance the work processes in four hours, and draw second process balance diagrams.

IE eliminate the daily bottleneck process and test the process and modify the process balance chart, and improve the result on the process balance diagram.

Build a mature and perfect production line

Fu Dongliang believes that the role of the single site flow control form is to create a mature production line.

First, set up a series of objectives for the mature production line, and achieve this goal, which requires managers to make continuous improvement, reduce the production line pause caused by accidental factors, maintain stable production line and quality stability, and reduce the production line's rhythm time and improve production efficiency through action improvement, equipment improvement and standard action formulation.

One piece flow theory

The single piece stream is also called onepieceflow, or OPF.

The single piece flow operation system has laid the foundation for the realization of JIT goals in garment production. It is the application of lean production theory in garment operation. It also brings new topics and practical contents to IE activities in garment industry, and it also creates conditions for achieving 5S management goals more smoothly.