1. The importance of on-site observation
But if we are a brand owner, we should go to the supplier’s site to understand its production status, production efficiency, and quality control. As a processing plant, you should also go to the customer’s demonstration plant to understand its standardized production process and better serve customers. As a colleague, if you have the opportunity to visit other factories, it is also a very good opportunity for learning, comparison and reference.
For clothing production enterprises, you can know the details through any details on the scene. The root cause of any major problem can be found on the spot. Even in a limited time, as long as you grasp the key points, you can fully grasp the key information about the operation of the factory.
2. Working atmosphere at the workshop site
At the scene, you can firstly see the most real employees’ mental outlook. The morale of employees will be in sharp contrast with the loose and indifferent employees. Talk to the workers on the spot, and you can get an important first impression from the workers’ facial expressions and body language, because these directly reflect the workers’ emotions and satisfaction with the factory. In a factory we visited, most of the workshops were playing cheerful music. At a glance, the lathes are chasing after me, and the enthusiasm for labor is very high. Working in such a relaxed and pleasant environment, the efficiency is relatively higher, and the products are more efficient. Quality will also make people more confident.
When walking around the workshop, you can pay attention to observe whether there is uneven busyness and stockpiling. For example, most of the lathe workers in the group are very busy, but a few lathe workers are doing nothing for a long time, or the workers in some stations are waiting for materials for a long time. The existence of this phenomenon shows that the factory lacks lean management, the utilization rate of personnel is low, and idle employees will also affect the working atmosphere of other people, and the overall work efficiency is low, and the cost is bound to be higher.
You should pay attention to whether the workshop’s light is sufficient, whether the air circulation is smooth, whether there is a peculiar smell, whether there is too much noise, and whether the workshop is tidy, because these will directly affect the mood of the workers, thereby affecting production efficiency and product quality. It is difficult to imagine a factory with a lazy, low-level atmosphere, grievances or inactivity at the site, which can make good products and create benefits.
3. Space utilization and layout
Some factory managers may think that the bigger the production workshop is, the better. As a result, the utilization rate is often low, and the equipment and process layout are scattered. In addition to wasting space, a lot of unnecessary transportation of noodles and auxiliary materials is also carried out in the factory. However, most factories in countries such as Japan do not look so spectacular, or even slightly cramped, but the space utilization rate is high, and the circulation efficiency is also high.
Transportation vehicles not only take up space and have high operating costs, but also encourage unnecessary material movement. We saw a lot of carts shuttle busily in a customer’s factory, but there was a lot of unnecessary transportation among them. For example, the same batch of fabrics are moved from area A to area B for processing, and then moved back to area A for subsequent processing, then moved to area C for processing, and finally moved back to area B. The waste of transportation is almost extreme.
In principle, the production fabrics used on the day should be stored along the production line instead of being stored separately in several storage areas. Tools and tooling should be placed as close to the machine as possible. The layout of the factory should ensure the smooth flow of products and try to avoid any partitions. If you see long fabric handling distances, repeated handling routes, or many handling times in a factory, it means that the layout is unreasonable, the space utilization is not ideal, and the production line has not been assembled as much as possible.
Post time: Apr-26-2021