How to transform Chinese garment processing enterprises?

At present, there are major problems in the production of small orders for garment processing companies: unbalanced tasks, various types of products, frequent reorders, urgent delivery dates, large rework rates, and difficult to control costs, etc., and they suffer from poor quality and poor incentive effectiveness. The impact of large staff turnover rate is poor. Seriously thinking that the above problems are mostly caused by man-made reasons, therefore, while processing and manufacturing enterprises actively adjust their ideas to adapt to small orders, they must also use innovative technologies and information technology to increase production efficiency and increase economic efficiency. In addition, the processing and manufacturing enterprises should have a long-term vision, no longer lock themselves tightly into manufacturers, but have independent innovation capabilities, can quickly respond to the supply platform, closely integrated with the booming e-commerce, exploring novel , Can develop the cooperation relationship of the network market demand, realize the real transformation and upgrading.

First, change the traditional model and create an e-commerce supplier platform

Faced with a small number of small garment processing orders that require rapid response, regardless of the size of the processing and production enterprises, we need to speed up the transformation of production mode, adjust the production line and workshop operation management. Mass production lines have the traditional advantages of low cost, high efficiency, and high quality, making it difficult to compete with ordinary medium-volume production. However, in the face of orders that are becoming more and more significant with “small-batch, diversified” features, small-volume production is more important. To meet the innovative and unique products.

The transition from a processing plant to a supply platform for e-commerce, the most important thing is to change the model, and change the production line without adding equipment. Some companies have already done this. Without adding a person or adding a piece of equipment, it will increase production efficiency. Whether it is for Amoy brand or offline brand service, we must take the route of many varieties, small batches, and rapid response.

Second, process reengineering, comply with market demand

The multi-variety, low-volume clothing production model is a production model that responds to market demand and has obvious features compared to the traditional single-mass production model. First of all, it is based on sales and production, instead of simply pursuing output and output value, it decides production according to the specific conditions of the market terminal. Second, it is a rapid response system for apparel production that can meet the needs of both markets, including rich styles and quick time-to-market.

For Taobao orders, Taobao sellers pay the most attention to the delivery date. Due to the unpredictable market, the constantly changing style places special emphasis on fashion. Whether it is the first order or replenishment, the production cycle must be shortened. So, how can we change the huge production line without increasing costs?

Once the factory accepts orders of multiple varieties and small batches, then in the long run, a large amount of data will be accumulated in the production process. These are very valuable data. Factories may wish to establish separate databases of products, components, production processes, and process hours based on different objects. Standard labor hours can be established through the search database, which can promote the unification and standardization of production data in enterprises.

Third, start small, with advanced technology

The production efficiency of the assembly line is high and has been widely adopted by garment companies. However, in fact, not all situations can use the assembly line to produce, and must meet certain conditions.

First, the batch size should be large enough to guarantee the normal load of the assembly line workstation. Secondly, the workload should be relatively stable to ensure that the machinery and equipment will function normally. Third, the product should be able to be split into individual parts for processing. Finally, the most important It is the hardware conditions of the shop floor that can satisfy the installation of assembly line equipment and tools.

For many factories, "change the production line is not easy" problem, in the original workshop hardware and workshop management, the factory can start with a small change. For example, for the requirements of the machine configuration, according to the specific types of clothing and equipment production capacity for a reasonable and scientific configuration, to ensure that the workshop layout has a certain degree of stability and flexibility.

In addition, in the current boom of e-commerce, it is necessary not only to fully consider the convenience of information communication during the assembly line, but also to maintain timely and comprehensive information communication between the factory and customers. At the same time, the layout of the machine should make the moving distance of pieces or semi-finished products as short as possible to avoid the occurrence of crossover, backflow, etc., and to follow the economic principle of action.

With the continuous advancement of technology in the Chinese garment industry, the application of computer-aided production management systems in the garment production process has also entered a new stage. The application of innovative technologies can also increase the production efficiency of the factory, and can adapt to multiple varieties and small batches more quickly. Production requirements.

For example, the process time database system enables the factory to accurately calculate its own production capacity, reasonably take orders, quote prices, and set salary standards, rather than relying on experience and intuition. At the same time, standardization and optimization of process scheduling can be realized, production preparation cycle can be shortened, the quality of process documents can be improved, dependence on operators' technical level and experience can be reduced, and the integration of internal information can be improved to adapt to multiple varieties, small batches, and short Cycle and high quality production requirements.

In addition to software such as database systems, there are innovative production equipment that can also achieve the effect of reducing the scale of the pipeline but ensuring efficiency. According to the industry's understanding, the shirt company in Dachen Town, Yiwu, and the CNC cutting system for large-size composite materials used by Eagle Machinery and other textile machinery companies have greatly improved accuracy and reduced energy consumption. The 3D rapid garment system introduced by these textile machinery companies can also enable manufacturers to achieve seamless connection of “human body-size--model-setting-to-cut-to-cut” and fully automate operations, especially for small-scale assembly line production.