To stop work in a garment factory is a waste.Do you agree? time： 2018/7/7 9:06:21 TIMES：3459 BACK
There are many ways to improve the site, and the most important thing is to reduce waste. In the management thinking of garment factories, there is a saying that "all operations that do not produce added value are wasted" and waste can be divided into the following eight categories:
Overproduction of waste;
Waste of unqualified products;
The waste of waiting;
The waste of action;
Waste of transportation;
Waste of processing itself;
Waste of inventory;
Waste of management.
There are many ways to improve the site, and the most important thing is to reduce waste. In the management thinking of garment factories, there is a saying that "all operations that do not produce added value are wasted" and waste can be divided into the following eight categories:
Overproduction of waste;
Waste of unqualified products;
The waste of waiting;
The waste of action;
Waste of transportation;
Waste of processing itself;
Waste of inventory;
Waste of management.
Although there will be other kinds of waste in the specific field situation of enterprises, but this intolerable waste is very dangerous if it is not stifled in the cradle! Therefore, the on-site improvement of enterprises should start with these wastes.
First, eliminate waste from overproduction.
"Waste of overproduction" is considered to be the root cause of all waste. If this waste is allowed, the remaining six kinds of waste will occur at the same time. If this waste is discovered and started to improve, the other six kinds of waste that were concealed before will show up.
Overproduction of waste is divided into excessive overproduction and excessive overproduction.
Excessive overproduction refers to the number of production exceeding the production plan (or delivery plan). Some people think that if the hands are over, continuous production can generate profits. But production is good. If it can't be sold out, then there will be a surplus, and this part will be completely lost. In addition, even products that can be sold sooner or later will be moved to warehouses for storage and management before the day they are sold, which will result in a lot of work that is totally unnecessary.
Too fast overproduction is due to the increase of manpower and the completion of production tasks ahead of schedule. Some people think that it is necessary to produce anyway. However, because in the time before delivery, the products can not be put in place and need to be temporarily transported to other places, so there will be all kinds of redundant work like this, and there will be quality risks.
Over production of waste can be caused by the following reasons:
Do not understand customers and market needs.
A production plan based on personal experience and way of thinking.
Overstaffing.
Overequipment.
Mass production.
Changes in production load.
Problems arise during the production process, such as substandard products, equipment failures, etc.
Production speed increased.
Solving the problem of over production waste can be considered from the following angles:
Use data to understand customers and market needs.
Standardization of production plan.
Balanced production.
A process.
Small batch production.
Flexible use of Kanban management technology to organize production.
Quick change of operation procedure.
Introduce production rhythm.
Two, eliminate the waste generated by unqualified products.
In the process of eliminating waste, waste caused by substandard products is the most far-reaching waste that should be paid attention to. This waste will affect the development of brands and the survival of enterprises.
Let's first take a look at what kinds of garments do not have.
Poor appearance, stains, breakage and ironing.
Poor sewing, many threads, slanting lines, small track density, low turnover and lack of fastness.
Bad size, size beyond tolerance range.
Physical and chemical properties are not qualified, harmful substances exceed standard, fiber content is not consistent, and color fastness is not enough.
The unqualified items shown above are mainly concentrated on the last physical and chemical properties.
What are the reasons for producing unqualified products?
Lack of necessary fabric accessories inspection, fabric accessories inspection not only includes the appearance of color defect inspection, but also should do the relevant physical and chemical properties of the spot test.
Lack of necessary quality control links, such as poor size, is mainly due to the lack of appropriate positioning, template size errors and other reasons.
Lack of awareness of the quality of employees, unclear understanding of the process quality requirements of operators, lax control, and lack of basic quality judgment ability for the semi-finished products delivered from the upper channel will lead to the continuing flow of defective products. For staff skills training and responsibility awareness, standard awareness should be appropriate. Training and assessment.
Lack of necessary quality inspection and supervision, the unqualified garment products should be detected in the production and intermediate inspection links or the final pre-packaging inspection links, and handled promptly. If the inspectors are careless, the inspection is not comprehensive and meticulous, or the lack of inspection of the corresponding items, it will result in the omission of inspection. Our current service Inspection capability of assembly and processing enterprises is generally weak, lacking of internal quality inspection links. If there is no internal quality control of facial accessories in the early stage, it is easy to appear the phenomenon of internal quality unqualified in the pictures above.
In order to eliminate the waste caused by unqualified products, we should strengthen management from the following aspects:
Establish a comprehensive quality management supervision and control system.
From the quality supervision and management of fabrics and accessories to a series of processes of cutting, sewing, finishing and inspection, there are relevant quality managers, relevant inspection and supervision systems, data records, specific implementers and execution methods. Some enterprises introduce ISO9000 quality management system, and quality control should be carried out in accordance with the requirements of this system. Don't just hang out.
Train staff's quality consciousness and standard consciousness.
For the training of employees, we also have a series of special topics before. Clothing production is completed by labor-intensive production, which requires the cooperation of human, machine, environment, facial materials and process methods. The final foothold is human, equipment depends on human maintenance, environment depends on human. Maintenance, technological methods are also carried out by people, and the selection of material inspection and judgment depends on people. How to respect the physiological and psychological characteristics of employees, give full play to their strengths, and stimulate employees'conscious awareness of maintaining product quality is the embodiment of enterprise human resources management level.
Pay attention to the details of clothing production, the quality of clothing is reflected in details.
Clothing is a product that can be easily copied and copied. The key to its quality lies in its details. High-quality clothing is more meticulous and stricter in the standard-setting of products. It has low tolerance or even zero tolerance for non-conforming products. Some low-quality products have loose standards for products. They can only meet the requirements of national standards, or even can not meet the requirements of national standards. Our national standards are low when they are formulated. If enterprises want to eliminate unqualified products, they can not achieve it by lowering standards and requirements. Instead, they should gradually improve standards in line with their own production conditions and strive for excellence. Only in this way can they produce products higher than national standards or even world-leading standards under strict requirements and inspection conditions and withstand external inspection.
The details of garment production begin with design, then with strict requirements of raw materials, followed by precise tailoring, fine sewing, fine ironing and final meticulous inspection and packaging. High-quality clothing can obtain higher brand praise, thereby gaining more brand added value. China's clothing production will inevitably develop towards a higher level in the future. Therefore, enterprises must strictly control and manage unqualified products, strictly require high standards in production, zero tolerance for unqualified products, and quality control. Preventive measures should be done well.
Three, eliminate waiting waste.
In clothing production line, it is often seen that some employees are in a state of inactive waiting, which not only wastes human resources, but also causes some temporary absence, chat, mobile phone playing and other phenomena that are not in harmony with the production rhythm, and even affects the working mood of employees who work normally. The main reason for waiting is caused by pipeline imbalance, but there are many kinds of performance.
To eliminate such disharmony, we should first look at the manifestations of waste waiting on the pipeline.
Human and other machines
Machines and others
People and others
Stop work to wait for material
Unplanned downtime
The reasons for these kinds of waiting are:
Machine failure, unreasonable machine ratio and other reasons cause people and other machine phenomena. If there is a temporary machine failure, if there is no spare machine, it will need to wait for repairs before it can continue to work properly; some special machines are not commonly used, or high-priced special machines, many enterprises have insufficient ratios, when the style changes, there may be a phenomenon that special machines are not enough;
There are several reasons for the phenomenon of machines and other people, such as low proficiency of people, which does not match the efficiency of machines; long transfer time, large batches, more semi-finished products, slow flow; unstable personnel in garment enterprises, when the loss of personnel is serious, there will be many empty seats on the assembly line, too few personnel also bring about the balance of the assembly line. Difficulties;
Waiting phenomena of people and others are mainly caused by the unbalanced distribution of production lines, temporary absence of staff, leaving their posts, and unskilled new employees will also appear the phenomenon of people and others.
Stopping work and waiting for materials is common in some small foreign trade apparel enterprises. Fabric and accessories can not be in place at the same time, or the intermediate cutting needs to be processed by foreign partners (printing, embroidery, washing, etc.) can not be shipped back in time, which will result in the failure to follow the normal production plan. The waiting caused by stopping work and waiting for materials is a large number of personnel. It will also bring the confusion of production plan, which is strongly avoided by garment enterprises.
There are many reasons for unplanned outage, such as sudden blackout or temporary business. If unplanned outage is only temporary departure of individual, the team leader should do a good job of personnel allocation at this time to avoid more people waiting.
How to eliminate these wastes from the perspective of management?
Internal management, improve the field management and dispatching ability of grassroots managers, especially the balance and dispatching ability of front-line team leaders. To make a balanced distribution of the process, to timely find the production of non-smooth, make adjustments, so that the team can have work, and people do their best, make the best use of everything;
Material management, material management and production plan should be matched. The purchase or supply of fabric and accessories should establish a schedule. There should be time schedule regulation for the corresponding suppliers or external processing plants to eliminate the phenomenon of stopping work and waiting for materials. Material management on the production line, mainly by controlling the input of semi-finished products, forms a production section. Pat;
For external coordination, garment enterprises need to have a good relationship with the cooperative enterprises in the supply chain. We can have more initiative to cooperate with raw materials, logistics and foreign cooperative enterprises, instead of just waiting passively. In addition, communication and coordination with energy departments such as power supply and water supply can be done well in advance when power supply is allocated.
Clothing production is a kind of process production. In this process, there are many links. If one link goes wrong, the next link will be waiting. The balance of production will be broken. Managers should control these situations in time to keep production in an orderly and sustainable state. The managers at the grass-roots level should control the assembly line well, the middle managers should make good links between all sectors in production, and the top managers should make good external coordination and grasp the orderly coordination of the whole supply chain.
Four, eliminate action waste
Invalid action is not work. - Da Ye Yi (formerly vice president of TOYOTA automotive industry)
In the process of garment production, each process is composed of many actions. Observing the operation of sewing process, you will find that there are several kinds of actions of employees: taking cutting pieces, taking parts, finding parts, handling, alignment, judgment, sewing, placing, thinking, resting, holding, delaying, etc. These actions can produce additional value is the core action "sewing", and some actions are totally non-value-producing such as rest, delay, maintenance, and other actions are between the two, is the auxiliary action of the core action.
If we count a worker's working time in one day, we will find that the proportion of valuable actions in the core is very low, and most of the time is spent on actions and auxiliary actions that do not produce value at all. In this way, the waste of action will appear. We can divide actions into two categories: regular and irregular actions. The part that produces additional value in regular actions is called the main work, while the auxiliary action is called the additional work, and the irregular action is the part that is wasted. In motion research, we should not only eliminate the waste caused by irregular movements, but also shorten the time spent on auxiliary movements, as shown in the figure above.
The main manifestations of waste of action are:
(1) search for goods;
(2) excessive judgement and observation;
(3) thinking time is too long.
(4) excessive time and distance (such as cover illustration).
(5) a lot of stooping, raising arms and turning around;
(6) too frequent habitual little moves.
Causes of waste of action:
(1) unreasonable planning for offices, production sites and equipment;
(2) the workplace is not organized.
(3) unreasonable allocation of personnel and equipment;
(4) ergonomics is not considered.
(5) the working methods are not uniform.
(6) production volume is too large.
How to eliminate movement waste:
It is almost impossible to eliminate the waste of action completely, but the proportion of invalid action can be reduced by implementing standard action and standard operation method. At present, garment enterprises carry out action research by implementing GSD (general sewing data) system, and promote the standard working hours and methods of each process.
In addition, the waste can be eliminated by the following methods:
(1) Five S improvement activities on site, division of work area, rational planning of semi-finished product placement, reasonable placement of auxiliary tools (such as scissors, rules, templates);
(2) Promotion of standard operation methods and operation actions, competition activities in the same process, selection of the best operation methods and standard operation actions for promotion;
(3) adopt suitable semi-finished product transmission mode to reduce production volume and reduce the accumulation of semi-finished products on site.
(4) Man-machine ergonomics improvement activities are carried out on workbenches, benches and tools. Comfortable working height and convenient tools are also effective ways to reduce action waste.
Five. Eliminate transportation waste.
Handling is the activity of transporting materials from one place of work to another. Handling does not produce added value, so it is also a waste.
Clothing from garment factory to store sales must be transported. This kind of transportation is the necessary process to realize profits. Unlike this kind of transportation and transportation, the transportation of fragments and semi-finished products in factories, or the stacking and handling of finished products brought about by overproduction, and the handling of excessive fabrics and accessories in warehouses, these distances are not close. The same transportation is caused by itself. It is a waste of manpower, material resources, funds and venues.
Many apparel enterprises need to provide conditions and means of transportation for handling, such as increasing the space occupied by the assembly line, purchasing the loading basket or truck for storing semi-finished products, joining the conveyor belt and hanging line to solve the difficult problem of handling, and some enterprises specially build large semi-finished products warehouses and finished products warehouses, which have excessive stock accumulation. . But these are not reasonable expenditures and inputs, we should find ways to eliminate these unreasonable waste of handling.
There are two main types of transportation waste:
(1) Large handling, large handling generally requires means of transport, such as the packaging of ready-made clothes with forklift trucks to temporary storage places, a large number of fabric accessories into the warehouse shelves.
(2) Small handling, small handling in the garment processing line is particularly common, workers will cut or semi-finished products moved to the next place of work.
The waste brought by transportation is mainly reflected in the following aspects:
(1) additional human input is needed.
(2) additional storage space is required:
(3) additional handling tools are needed.
(4) a lot of inventory work is needed.
(5) damage of moving tools or articles during transportation.
The reasons for handling are as follows:
(1) the production plan is not balanced.
(2) production transfer time is long;
(3) the workplace lacks organization;
(4) site planning is unreasonable;
(5) material planning is unreasonable.
How can we gradually eliminate the handling in production?
If we want to gradually eliminate the removal, we must start with the root of the removal and remove the removal by means of management.
(1) Sewing line eliminating handling method: arranging equipment and personnel according to process flow, reducing processing batch;
(2) eliminate the raw material handling, make the procurement plan well, and plan the purchasing time and quantity reasonably.
(3) Eliminate the handling of finished products, make a good production plan, calculate the shipping time, and store the finished products in a reasonable location.
From the above methods, we can see that it is still necessary to improve the management ability of production planning, site management, organization and coordination in order to eliminate the waste brought by handling.
Six, eliminate excessive processing waste.
Excessive processing and high technological standards can also produce waste, which is often concealed by high quality requirements. Over-processing or over-processing waste refers to redundant processing, on the other hand refers to more than customer requirements of precision processing, resulting in waste of resources.
From above, we can see that over processing waste can be divided into two main categories:
(1) Processing waste caused by useless processes will lead to waste of manpower and raw materials. If the side seam has been sewn by four-or five-thread sewing machine, there is no need to use the flat sewing machine to re-seam in advance; if the counterpart cutting has been done in the cutting process, it is not necessary to draw this again on a piece of clothes. This waste is sometimes caused by the lack of analysis of the process or the lack of communication between the technicians and the production line.
(2) Excessive processing precision, when the accuracy of the product increases, the sewing speed decreases, and the qualified rate of the product decreases, and the repairing rate increases. Compared with mechanical and electronic products, clothing products need not have such high precision. Customer's standards will also allow a certain range of errors in size. Enterprises can implement customer standards in production, but they can not upgrade too much on the basis of customer standards. Otherwise, it will be futile and waste. If you fail to meet customer standards, it is not feasible.
The waste of over processing in production is mainly reflected in:
(1) Bottleneck process, excessive processing, first of all, will manifest as a laid-off, slow flow of semi-finished products, become the bottleneck of the pipeline, bring other processes or other people's waiting waste.
(2) There is no clear product/technical standard. When the customer supply standard is not clear enough, it will easily lead to high standard processing of processing enterprises. Clothing processing enterprises usually formulate corresponding product production and inspection standards according to customer requirements, but when there is no clear target on customer standards, processing enterprises will generally follow the past. Processing experience for production and inspection, if the products processed in the past are high standards of quality, then even in the production of mid-range clothing, employees are generally in accordance with the standard of quality clothing to develop fine processing. This is beyond the expectations of customers, but it is also a waste for processing enterprises. It is necessary to choose an order that is compatible with its production capacity to produce.
(3) Infinite excellence, garment enterprises are strict on quality, and it is not wrong to close the quality, but if the "perfectionism" of excessive excellence, it will bring unnecessary waste. There are a few slight defects in clothing, and there is a reasonable tolerance range in size.
(4) Redundant working time and auxiliary equipment are needed. There are reasonable processing time for garment processing. IE Department of some garment enterprises will set standard processing time for each process. Excessive processing will lead to long working time. Some processes do not need to be ironed immediately after sewing. If such redundant processes are added, the corresponding intermediate ironing equipment needs to be added. Clothing enterprises need to find such waste to save manpower, physics and equipment investment.
The causes of over processing are:
(1) there is no coordination between process changes and standard changes.
(2) introduce unnecessary advanced technology at will.
(3) lack of professional and technical personnel for process research and guidance;
(4) there is no requirement to balance various processes;
(5) do not have a correct understanding of customer requirements.
How to eliminate excessive processing?
(1) clear the general standard of processing products and understand the special needs of customers.
(2) formulate reasonable and clear process documents before production, and guide production;
(3) determination of standard processing time and promotion of optimized processing techniques and techniques;
(4) the stability of quality level and the selection of orders of suitable quality level;
(5) The equipment, technology and technology adopted are suitable for the current product type and the operation level of workers.
Over time, production can not be sloppy, but the processing technology should be in accordance with the product grade and quality level, to achieve moderate, appropriate and timely.
Seven, eliminate inventory waste
Inventory has always been the focus of garment business management. For the following reasons, enterprises feel that inventory is necessary:
Changes in meeting customer needs;
We should deal with various problems arising from production, such as the generation of unqualified products, the breakdown of machinery and equipment, etc.
Shorten lead time, such as raw material inventory, semi finished goods inventory, product inventory, etc.
Reduce costs through mass production, such as unified purchase, unified transportation, etc.
In recent years, with the intensification of market competition, enterprises are aware of the following two main problems of inventory to enterprises:
(1) Because inventory is a state in which money is converted into goods, it is necessary to increase the speed of turnover in order to generate profits in a short time.
(2) Once there is stock, there will inevitably be slack production, so waste becomes more hidden, and the speed of improvement will slow down.
Therefore, enterprises realize that the less inventory, the less waste they generate.
Although there is the ideal idea of "aiming at zero inventory", it is not easy to achieve zero inventory thoroughly, but to aim at zero inventory and reduce inventory to a reasonable level.
I. implementation premise of zero inventory
Do not often produce unqualified products.
Do not frequent machine failure.
The number of inventory books should be in line with the quantity of stock.
We should make full use of various inventory management methods, fully understand Kanban, economic order quantity, quantitative order mode, regular order mode, ABC management, safe inventory quantity and other scientific management methods.
Two, zero inventory can not be achieved.
Zero inventory strategy should start with eliminating the factors of overproduction. For example, the operators are very resistant to stop production in the middle of the pipeline processing, so they do not reduce the production speed, arbitrary production, resulting in the production of too many products.
The failure of unqualified products and equipment is a big problem for enterprises. If the equipment often breaks down or spends too much time on repairing unqualified products, it will cause production bottlenecks and affect the production speed.
If there is too much inventory, we will often have insufficient understanding of the existence of these problems, so that the various costs spent on inventory, needless to say, those problems that are not recognized will take root in the enterprise. If inventory is reduced, various problems will be exposed. Once problems occur, we can not evade the responsibility of inventory management as before.
If you want to reduce inventory, you need to solve many problems thoroughly. This needs to improve the production guarantee system of machine operation. In the production process, we need to reduce unqualified products, shorten the exchange of money, and ensure the normal operation time of machine and equipment. If a lot of problems found in the 7 kinds of waste are solved, the stock will naturally decrease.
Therefore, it is particularly important to establish a system that can produce the quantity of products needed when needed.
Three, zero inventory implementation
Zero inventory strategy should be implemented from improving inventory accuracy.
If the quantity in the inventory book does not match the spot quantity, you will be worried about whether you can deliver the quantity required by the customer at the delivery date. Therefore, we have developed many spare stocks to deal with the occasional shortage of stocking.
Such enterprises should aim at the real causes of errors in a certain stage for products with many errors. In Toyota, the so-called "automation" production contains the idea of stopping the machine at the scene of the problem and finding out the problem without time difference.
If Kanban mode is introduced, it is necessary to establish a balanced production system and a system that can shorten the time of money exchange operation, improve the machine's operational rate, establish a system that can adapt to small batch production, and reduce inventory can be achieved by planning and fine management that can achieve average production.
Eight, eliminate management waste.
Waste in management can cause the seven kinds of waste mentioned above, so management waste can also be said to be the biggest waste in production. Just as a hundred enterprises have a hundred different understandings of management, there are also different explanations for management waste. We can consider the following seven aspects:
1, the waste of waiting
Such as waiting for instructions from superiors, waiting for external replies, waiting for reports from subordinates and so on. In garment production, due to the non-timely arrival of raw and auxiliary materials, the production variety is temporarily changed. These can be summed up from the personal point of view to the lack of responsibility. From the organizational point of view, it can reflect the laxity of management and the lack of corporate culture. Lost.
2, coordination of adverse waste
Work process coordination is not good, work requirements are implemented, coordination is not good, information transmission coordination is not good, ERP business process coordination is not good, and so on. For the sake of information unimpeded, some garment enterprises make use of digital management methods such as ERP, RFID, hanging transmission system and so on, which really make the internal information communication of enterprises timely and accurate. There are many enterprises alone. Because of the inaccuracy of the data in the system, the industry has more impact on production, resulting in greater waste.
3, idle waste
The idleness of fixed assets, overlapping functions of jobs, complicated working procedures and personnel, such as the accumulation of a large number of equipment not commonly used in production, unreasonable ratios of auxiliary workers and lathe workers, will result in idle waste.
4, disorderly waste
It is manifested in the disorder of business process, the disorder caused by unclear responsibilities, the disorder caused by lack of rules and regulations, and the disorder caused by insufficient business ability. In the garment production enterprises, there is no rule of law and rule of man, and the process is not clear, which results in the disorder of repetitive things and the confusion of grass-roots production personnel. Things happen from time to time.
5, neglect of duty
Only lay out no inspection, cope with inspection, check and cope with, such as garment enterprises factory inspection links, was originally a good opportunity to improve enterprise management, standardize production and operation, many enterprises cope with the problem, resulting in negligence and waste.
6, inefficient waste
Performance in the work of inefficiency or inefficiency, work errors, etc., garment production of defective products is a typical negative efficiency, resulting in a large number of rework.
7, waste of management costs
It is shown that the plan is not scientific, the execution is not in place, and the proportion of input and output is unreasonable. If there are too many employees in the garment enterprises, the difference in the cost of labor per second is huge.
Compared with the previous seven wastes, management waste is not easy to quantify, more soft and recessive, and management improvement is the improvement of thinking and execution ability of relevant personnel, so it is more difficult. Only with one heart, one mind, no fear of hardship and constant persistence can we produce good results.
Every organization can run smoothly through effective management, but management is really a difficult technology, and waste in management is inevitable.
Peter Drucker believes that management is a kind of practice, its essence is not "knowledge" but "action", its verification is not "logic", but "achievement", its only authority is "achievement". In this sense, there is no unified standard for management, but it is a process of continuous pursuit of perfection.
Overproduction of waste;
Waste of unqualified products;
The waste of waiting;
The waste of action;
Waste of transportation;
Waste of processing itself;
Waste of inventory;
Waste of management.
There are many ways to improve the site, and the most important thing is to reduce waste. In the management thinking of garment factories, there is a saying that "all operations that do not produce added value are wasted" and waste can be divided into the following eight categories:
Overproduction of waste;
Waste of unqualified products;
The waste of waiting;
The waste of action;
Waste of transportation;
Waste of processing itself;
Waste of inventory;
Waste of management.
Although there will be other kinds of waste in the specific field situation of enterprises, but this intolerable waste is very dangerous if it is not stifled in the cradle! Therefore, the on-site improvement of enterprises should start with these wastes.
First, eliminate waste from overproduction.
"Waste of overproduction" is considered to be the root cause of all waste. If this waste is allowed, the remaining six kinds of waste will occur at the same time. If this waste is discovered and started to improve, the other six kinds of waste that were concealed before will show up.
Overproduction of waste is divided into excessive overproduction and excessive overproduction.
Excessive overproduction refers to the number of production exceeding the production plan (or delivery plan). Some people think that if the hands are over, continuous production can generate profits. But production is good. If it can't be sold out, then there will be a surplus, and this part will be completely lost. In addition, even products that can be sold sooner or later will be moved to warehouses for storage and management before the day they are sold, which will result in a lot of work that is totally unnecessary.
Too fast overproduction is due to the increase of manpower and the completion of production tasks ahead of schedule. Some people think that it is necessary to produce anyway. However, because in the time before delivery, the products can not be put in place and need to be temporarily transported to other places, so there will be all kinds of redundant work like this, and there will be quality risks.
Over production of waste can be caused by the following reasons:
Do not understand customers and market needs.
A production plan based on personal experience and way of thinking.
Overstaffing.
Overequipment.
Mass production.
Changes in production load.
Problems arise during the production process, such as substandard products, equipment failures, etc.
Production speed increased.
Solving the problem of over production waste can be considered from the following angles:
Use data to understand customers and market needs.
Standardization of production plan.
Balanced production.
A process.
Small batch production.
Flexible use of Kanban management technology to organize production.
Quick change of operation procedure.
Introduce production rhythm.
Two, eliminate the waste generated by unqualified products.
In the process of eliminating waste, waste caused by substandard products is the most far-reaching waste that should be paid attention to. This waste will affect the development of brands and the survival of enterprises.
Let's first take a look at what kinds of garments do not have.
Poor appearance, stains, breakage and ironing.
Poor sewing, many threads, slanting lines, small track density, low turnover and lack of fastness.
Bad size, size beyond tolerance range.
Physical and chemical properties are not qualified, harmful substances exceed standard, fiber content is not consistent, and color fastness is not enough.
The unqualified items shown above are mainly concentrated on the last physical and chemical properties.
What are the reasons for producing unqualified products?
Lack of necessary fabric accessories inspection, fabric accessories inspection not only includes the appearance of color defect inspection, but also should do the relevant physical and chemical properties of the spot test.
Lack of necessary quality control links, such as poor size, is mainly due to the lack of appropriate positioning, template size errors and other reasons.
Lack of awareness of the quality of employees, unclear understanding of the process quality requirements of operators, lax control, and lack of basic quality judgment ability for the semi-finished products delivered from the upper channel will lead to the continuing flow of defective products. For staff skills training and responsibility awareness, standard awareness should be appropriate. Training and assessment.
Lack of necessary quality inspection and supervision, the unqualified garment products should be detected in the production and intermediate inspection links or the final pre-packaging inspection links, and handled promptly. If the inspectors are careless, the inspection is not comprehensive and meticulous, or the lack of inspection of the corresponding items, it will result in the omission of inspection. Our current service Inspection capability of assembly and processing enterprises is generally weak, lacking of internal quality inspection links. If there is no internal quality control of facial accessories in the early stage, it is easy to appear the phenomenon of internal quality unqualified in the pictures above.
In order to eliminate the waste caused by unqualified products, we should strengthen management from the following aspects:
Establish a comprehensive quality management supervision and control system.
From the quality supervision and management of fabrics and accessories to a series of processes of cutting, sewing, finishing and inspection, there are relevant quality managers, relevant inspection and supervision systems, data records, specific implementers and execution methods. Some enterprises introduce ISO9000 quality management system, and quality control should be carried out in accordance with the requirements of this system. Don't just hang out.
Train staff's quality consciousness and standard consciousness.
For the training of employees, we also have a series of special topics before. Clothing production is completed by labor-intensive production, which requires the cooperation of human, machine, environment, facial materials and process methods. The final foothold is human, equipment depends on human maintenance, environment depends on human. Maintenance, technological methods are also carried out by people, and the selection of material inspection and judgment depends on people. How to respect the physiological and psychological characteristics of employees, give full play to their strengths, and stimulate employees'conscious awareness of maintaining product quality is the embodiment of enterprise human resources management level.
Pay attention to the details of clothing production, the quality of clothing is reflected in details.
Clothing is a product that can be easily copied and copied. The key to its quality lies in its details. High-quality clothing is more meticulous and stricter in the standard-setting of products. It has low tolerance or even zero tolerance for non-conforming products. Some low-quality products have loose standards for products. They can only meet the requirements of national standards, or even can not meet the requirements of national standards. Our national standards are low when they are formulated. If enterprises want to eliminate unqualified products, they can not achieve it by lowering standards and requirements. Instead, they should gradually improve standards in line with their own production conditions and strive for excellence. Only in this way can they produce products higher than national standards or even world-leading standards under strict requirements and inspection conditions and withstand external inspection.
The details of garment production begin with design, then with strict requirements of raw materials, followed by precise tailoring, fine sewing, fine ironing and final meticulous inspection and packaging. High-quality clothing can obtain higher brand praise, thereby gaining more brand added value. China's clothing production will inevitably develop towards a higher level in the future. Therefore, enterprises must strictly control and manage unqualified products, strictly require high standards in production, zero tolerance for unqualified products, and quality control. Preventive measures should be done well.
Three, eliminate waiting waste.
In clothing production line, it is often seen that some employees are in a state of inactive waiting, which not only wastes human resources, but also causes some temporary absence, chat, mobile phone playing and other phenomena that are not in harmony with the production rhythm, and even affects the working mood of employees who work normally. The main reason for waiting is caused by pipeline imbalance, but there are many kinds of performance.
To eliminate such disharmony, we should first look at the manifestations of waste waiting on the pipeline.
Human and other machines
Machines and others
People and others
Stop work to wait for material
Unplanned downtime
The reasons for these kinds of waiting are:
Machine failure, unreasonable machine ratio and other reasons cause people and other machine phenomena. If there is a temporary machine failure, if there is no spare machine, it will need to wait for repairs before it can continue to work properly; some special machines are not commonly used, or high-priced special machines, many enterprises have insufficient ratios, when the style changes, there may be a phenomenon that special machines are not enough;
There are several reasons for the phenomenon of machines and other people, such as low proficiency of people, which does not match the efficiency of machines; long transfer time, large batches, more semi-finished products, slow flow; unstable personnel in garment enterprises, when the loss of personnel is serious, there will be many empty seats on the assembly line, too few personnel also bring about the balance of the assembly line. Difficulties;
Waiting phenomena of people and others are mainly caused by the unbalanced distribution of production lines, temporary absence of staff, leaving their posts, and unskilled new employees will also appear the phenomenon of people and others.
Stopping work and waiting for materials is common in some small foreign trade apparel enterprises. Fabric and accessories can not be in place at the same time, or the intermediate cutting needs to be processed by foreign partners (printing, embroidery, washing, etc.) can not be shipped back in time, which will result in the failure to follow the normal production plan. The waiting caused by stopping work and waiting for materials is a large number of personnel. It will also bring the confusion of production plan, which is strongly avoided by garment enterprises.
There are many reasons for unplanned outage, such as sudden blackout or temporary business. If unplanned outage is only temporary departure of individual, the team leader should do a good job of personnel allocation at this time to avoid more people waiting.
How to eliminate these wastes from the perspective of management?
Internal management, improve the field management and dispatching ability of grassroots managers, especially the balance and dispatching ability of front-line team leaders. To make a balanced distribution of the process, to timely find the production of non-smooth, make adjustments, so that the team can have work, and people do their best, make the best use of everything;
Material management, material management and production plan should be matched. The purchase or supply of fabric and accessories should establish a schedule. There should be time schedule regulation for the corresponding suppliers or external processing plants to eliminate the phenomenon of stopping work and waiting for materials. Material management on the production line, mainly by controlling the input of semi-finished products, forms a production section. Pat;
For external coordination, garment enterprises need to have a good relationship with the cooperative enterprises in the supply chain. We can have more initiative to cooperate with raw materials, logistics and foreign cooperative enterprises, instead of just waiting passively. In addition, communication and coordination with energy departments such as power supply and water supply can be done well in advance when power supply is allocated.
Clothing production is a kind of process production. In this process, there are many links. If one link goes wrong, the next link will be waiting. The balance of production will be broken. Managers should control these situations in time to keep production in an orderly and sustainable state. The managers at the grass-roots level should control the assembly line well, the middle managers should make good links between all sectors in production, and the top managers should make good external coordination and grasp the orderly coordination of the whole supply chain.
Four, eliminate action waste
Invalid action is not work. - Da Ye Yi (formerly vice president of TOYOTA automotive industry)
In the process of garment production, each process is composed of many actions. Observing the operation of sewing process, you will find that there are several kinds of actions of employees: taking cutting pieces, taking parts, finding parts, handling, alignment, judgment, sewing, placing, thinking, resting, holding, delaying, etc. These actions can produce additional value is the core action "sewing", and some actions are totally non-value-producing such as rest, delay, maintenance, and other actions are between the two, is the auxiliary action of the core action.
If we count a worker's working time in one day, we will find that the proportion of valuable actions in the core is very low, and most of the time is spent on actions and auxiliary actions that do not produce value at all. In this way, the waste of action will appear. We can divide actions into two categories: regular and irregular actions. The part that produces additional value in regular actions is called the main work, while the auxiliary action is called the additional work, and the irregular action is the part that is wasted. In motion research, we should not only eliminate the waste caused by irregular movements, but also shorten the time spent on auxiliary movements, as shown in the figure above.
The main manifestations of waste of action are:
(1) search for goods;
(2) excessive judgement and observation;
(3) thinking time is too long.
(4) excessive time and distance (such as cover illustration).
(5) a lot of stooping, raising arms and turning around;
(6) too frequent habitual little moves.
Causes of waste of action:
(1) unreasonable planning for offices, production sites and equipment;
(2) the workplace is not organized.
(3) unreasonable allocation of personnel and equipment;
(4) ergonomics is not considered.
(5) the working methods are not uniform.
(6) production volume is too large.
How to eliminate movement waste:
It is almost impossible to eliminate the waste of action completely, but the proportion of invalid action can be reduced by implementing standard action and standard operation method. At present, garment enterprises carry out action research by implementing GSD (general sewing data) system, and promote the standard working hours and methods of each process.
In addition, the waste can be eliminated by the following methods:
(1) Five S improvement activities on site, division of work area, rational planning of semi-finished product placement, reasonable placement of auxiliary tools (such as scissors, rules, templates);
(2) Promotion of standard operation methods and operation actions, competition activities in the same process, selection of the best operation methods and standard operation actions for promotion;
(3) adopt suitable semi-finished product transmission mode to reduce production volume and reduce the accumulation of semi-finished products on site.
(4) Man-machine ergonomics improvement activities are carried out on workbenches, benches and tools. Comfortable working height and convenient tools are also effective ways to reduce action waste.
Five. Eliminate transportation waste.
Handling is the activity of transporting materials from one place of work to another. Handling does not produce added value, so it is also a waste.
Clothing from garment factory to store sales must be transported. This kind of transportation is the necessary process to realize profits. Unlike this kind of transportation and transportation, the transportation of fragments and semi-finished products in factories, or the stacking and handling of finished products brought about by overproduction, and the handling of excessive fabrics and accessories in warehouses, these distances are not close. The same transportation is caused by itself. It is a waste of manpower, material resources, funds and venues.
Many apparel enterprises need to provide conditions and means of transportation for handling, such as increasing the space occupied by the assembly line, purchasing the loading basket or truck for storing semi-finished products, joining the conveyor belt and hanging line to solve the difficult problem of handling, and some enterprises specially build large semi-finished products warehouses and finished products warehouses, which have excessive stock accumulation. . But these are not reasonable expenditures and inputs, we should find ways to eliminate these unreasonable waste of handling.
There are two main types of transportation waste:
(1) Large handling, large handling generally requires means of transport, such as the packaging of ready-made clothes with forklift trucks to temporary storage places, a large number of fabric accessories into the warehouse shelves.
(2) Small handling, small handling in the garment processing line is particularly common, workers will cut or semi-finished products moved to the next place of work.
The waste brought by transportation is mainly reflected in the following aspects:
(1) additional human input is needed.
(2) additional storage space is required:
(3) additional handling tools are needed.
(4) a lot of inventory work is needed.
(5) damage of moving tools or articles during transportation.
The reasons for handling are as follows:
(1) the production plan is not balanced.
(2) production transfer time is long;
(3) the workplace lacks organization;
(4) site planning is unreasonable;
(5) material planning is unreasonable.
How can we gradually eliminate the handling in production?
If we want to gradually eliminate the removal, we must start with the root of the removal and remove the removal by means of management.
(1) Sewing line eliminating handling method: arranging equipment and personnel according to process flow, reducing processing batch;
(2) eliminate the raw material handling, make the procurement plan well, and plan the purchasing time and quantity reasonably.
(3) Eliminate the handling of finished products, make a good production plan, calculate the shipping time, and store the finished products in a reasonable location.
From the above methods, we can see that it is still necessary to improve the management ability of production planning, site management, organization and coordination in order to eliminate the waste brought by handling.
Six, eliminate excessive processing waste.
Excessive processing and high technological standards can also produce waste, which is often concealed by high quality requirements. Over-processing or over-processing waste refers to redundant processing, on the other hand refers to more than customer requirements of precision processing, resulting in waste of resources.
From above, we can see that over processing waste can be divided into two main categories:
(1) Processing waste caused by useless processes will lead to waste of manpower and raw materials. If the side seam has been sewn by four-or five-thread sewing machine, there is no need to use the flat sewing machine to re-seam in advance; if the counterpart cutting has been done in the cutting process, it is not necessary to draw this again on a piece of clothes. This waste is sometimes caused by the lack of analysis of the process or the lack of communication between the technicians and the production line.
(2) Excessive processing precision, when the accuracy of the product increases, the sewing speed decreases, and the qualified rate of the product decreases, and the repairing rate increases. Compared with mechanical and electronic products, clothing products need not have such high precision. Customer's standards will also allow a certain range of errors in size. Enterprises can implement customer standards in production, but they can not upgrade too much on the basis of customer standards. Otherwise, it will be futile and waste. If you fail to meet customer standards, it is not feasible.
The waste of over processing in production is mainly reflected in:
(1) Bottleneck process, excessive processing, first of all, will manifest as a laid-off, slow flow of semi-finished products, become the bottleneck of the pipeline, bring other processes or other people's waiting waste.
(2) There is no clear product/technical standard. When the customer supply standard is not clear enough, it will easily lead to high standard processing of processing enterprises. Clothing processing enterprises usually formulate corresponding product production and inspection standards according to customer requirements, but when there is no clear target on customer standards, processing enterprises will generally follow the past. Processing experience for production and inspection, if the products processed in the past are high standards of quality, then even in the production of mid-range clothing, employees are generally in accordance with the standard of quality clothing to develop fine processing. This is beyond the expectations of customers, but it is also a waste for processing enterprises. It is necessary to choose an order that is compatible with its production capacity to produce.
(3) Infinite excellence, garment enterprises are strict on quality, and it is not wrong to close the quality, but if the "perfectionism" of excessive excellence, it will bring unnecessary waste. There are a few slight defects in clothing, and there is a reasonable tolerance range in size.
(4) Redundant working time and auxiliary equipment are needed. There are reasonable processing time for garment processing. IE Department of some garment enterprises will set standard processing time for each process. Excessive processing will lead to long working time. Some processes do not need to be ironed immediately after sewing. If such redundant processes are added, the corresponding intermediate ironing equipment needs to be added. Clothing enterprises need to find such waste to save manpower, physics and equipment investment.
The causes of over processing are:
(1) there is no coordination between process changes and standard changes.
(2) introduce unnecessary advanced technology at will.
(3) lack of professional and technical personnel for process research and guidance;
(4) there is no requirement to balance various processes;
(5) do not have a correct understanding of customer requirements.
How to eliminate excessive processing?
(1) clear the general standard of processing products and understand the special needs of customers.
(2) formulate reasonable and clear process documents before production, and guide production;
(3) determination of standard processing time and promotion of optimized processing techniques and techniques;
(4) the stability of quality level and the selection of orders of suitable quality level;
(5) The equipment, technology and technology adopted are suitable for the current product type and the operation level of workers.
Over time, production can not be sloppy, but the processing technology should be in accordance with the product grade and quality level, to achieve moderate, appropriate and timely.
Seven, eliminate inventory waste
Inventory has always been the focus of garment business management. For the following reasons, enterprises feel that inventory is necessary:
Changes in meeting customer needs;
We should deal with various problems arising from production, such as the generation of unqualified products, the breakdown of machinery and equipment, etc.
Shorten lead time, such as raw material inventory, semi finished goods inventory, product inventory, etc.
Reduce costs through mass production, such as unified purchase, unified transportation, etc.
In recent years, with the intensification of market competition, enterprises are aware of the following two main problems of inventory to enterprises:
(1) Because inventory is a state in which money is converted into goods, it is necessary to increase the speed of turnover in order to generate profits in a short time.
(2) Once there is stock, there will inevitably be slack production, so waste becomes more hidden, and the speed of improvement will slow down.
Therefore, enterprises realize that the less inventory, the less waste they generate.
Although there is the ideal idea of "aiming at zero inventory", it is not easy to achieve zero inventory thoroughly, but to aim at zero inventory and reduce inventory to a reasonable level.
I. implementation premise of zero inventory
Do not often produce unqualified products.
Do not frequent machine failure.
The number of inventory books should be in line with the quantity of stock.
We should make full use of various inventory management methods, fully understand Kanban, economic order quantity, quantitative order mode, regular order mode, ABC management, safe inventory quantity and other scientific management methods.
Two, zero inventory can not be achieved.
Zero inventory strategy should start with eliminating the factors of overproduction. For example, the operators are very resistant to stop production in the middle of the pipeline processing, so they do not reduce the production speed, arbitrary production, resulting in the production of too many products.
The failure of unqualified products and equipment is a big problem for enterprises. If the equipment often breaks down or spends too much time on repairing unqualified products, it will cause production bottlenecks and affect the production speed.
If there is too much inventory, we will often have insufficient understanding of the existence of these problems, so that the various costs spent on inventory, needless to say, those problems that are not recognized will take root in the enterprise. If inventory is reduced, various problems will be exposed. Once problems occur, we can not evade the responsibility of inventory management as before.
If you want to reduce inventory, you need to solve many problems thoroughly. This needs to improve the production guarantee system of machine operation. In the production process, we need to reduce unqualified products, shorten the exchange of money, and ensure the normal operation time of machine and equipment. If a lot of problems found in the 7 kinds of waste are solved, the stock will naturally decrease.
Therefore, it is particularly important to establish a system that can produce the quantity of products needed when needed.
Three, zero inventory implementation
Zero inventory strategy should be implemented from improving inventory accuracy.
If the quantity in the inventory book does not match the spot quantity, you will be worried about whether you can deliver the quantity required by the customer at the delivery date. Therefore, we have developed many spare stocks to deal with the occasional shortage of stocking.
Such enterprises should aim at the real causes of errors in a certain stage for products with many errors. In Toyota, the so-called "automation" production contains the idea of stopping the machine at the scene of the problem and finding out the problem without time difference.
If Kanban mode is introduced, it is necessary to establish a balanced production system and a system that can shorten the time of money exchange operation, improve the machine's operational rate, establish a system that can adapt to small batch production, and reduce inventory can be achieved by planning and fine management that can achieve average production.
Eight, eliminate management waste.
Waste in management can cause the seven kinds of waste mentioned above, so management waste can also be said to be the biggest waste in production. Just as a hundred enterprises have a hundred different understandings of management, there are also different explanations for management waste. We can consider the following seven aspects:
1, the waste of waiting
Such as waiting for instructions from superiors, waiting for external replies, waiting for reports from subordinates and so on. In garment production, due to the non-timely arrival of raw and auxiliary materials, the production variety is temporarily changed. These can be summed up from the personal point of view to the lack of responsibility. From the organizational point of view, it can reflect the laxity of management and the lack of corporate culture. Lost.
2, coordination of adverse waste
Work process coordination is not good, work requirements are implemented, coordination is not good, information transmission coordination is not good, ERP business process coordination is not good, and so on. For the sake of information unimpeded, some garment enterprises make use of digital management methods such as ERP, RFID, hanging transmission system and so on, which really make the internal information communication of enterprises timely and accurate. There are many enterprises alone. Because of the inaccuracy of the data in the system, the industry has more impact on production, resulting in greater waste.
3, idle waste
The idleness of fixed assets, overlapping functions of jobs, complicated working procedures and personnel, such as the accumulation of a large number of equipment not commonly used in production, unreasonable ratios of auxiliary workers and lathe workers, will result in idle waste.
4, disorderly waste
It is manifested in the disorder of business process, the disorder caused by unclear responsibilities, the disorder caused by lack of rules and regulations, and the disorder caused by insufficient business ability. In the garment production enterprises, there is no rule of law and rule of man, and the process is not clear, which results in the disorder of repetitive things and the confusion of grass-roots production personnel. Things happen from time to time.
5, neglect of duty
Only lay out no inspection, cope with inspection, check and cope with, such as garment enterprises factory inspection links, was originally a good opportunity to improve enterprise management, standardize production and operation, many enterprises cope with the problem, resulting in negligence and waste.
6, inefficient waste
Performance in the work of inefficiency or inefficiency, work errors, etc., garment production of defective products is a typical negative efficiency, resulting in a large number of rework.
7, waste of management costs
It is shown that the plan is not scientific, the execution is not in place, and the proportion of input and output is unreasonable. If there are too many employees in the garment enterprises, the difference in the cost of labor per second is huge.
Compared with the previous seven wastes, management waste is not easy to quantify, more soft and recessive, and management improvement is the improvement of thinking and execution ability of relevant personnel, so it is more difficult. Only with one heart, one mind, no fear of hardship and constant persistence can we produce good results.
Every organization can run smoothly through effective management, but management is really a difficult technology, and waste in management is inevitable.
Peter Drucker believes that management is a kind of practice, its essence is not "knowledge" but "action", its verification is not "logic", but "achievement", its only authority is "achievement". In this sense, there is no unified standard for management, but it is a process of continuous pursuit of perfection.
