2010 China'S Clothing Industry: Entering The Era Of Lean Production

Fu Dongliang, chief consultant of Nan Bo Wan Business Management Consulting Co., Ltd.

Master of business administration, master of psychology and senior economist, Waseda University, Japan.

It has unique views in strategic management of garment enterprises, garment enterprise process management, clothing brand management, garment enterprise financial management and so on. It has served as chairman of Hongkong L2 International Fashion Co., Ltd., chief research fellow of China Brand Strategy Research Institute, chief consultant of Nan Bo Wan Enterprise Management Consulting Co., and Senior Consultant of strategic planning for more than 30 well-known enterprises, and has been general manager of Japan's barren well company, Hongkong Rong Wei Fashion Co., Ltd. and Japan's Hsien Tak Garments Co., Ltd.

He published his paper on "Research on the clothing industry in Guangdong, Hong Kong and Macao", "government failure in clothing foreign trade economic analysis" and so on.

"In the era of meager profits, for garment enterprises, we must first enhance the added value of brands, and secondly, we should pay attention to process optimization and strengthen management so that enterprises can run more effectively."

Fu Dongliang said.

Single piece production system is effective.

The single piece flow is a production system that can effectively run the garment enterprises in the meager profit era.

According to the introduction, the objective of the single piece production system is to ensure the establishment of a vertical and flexible production line to ensure low cost, efficiency and waste reduction, and improve the quality and service quality.

Fu Dongliang believes that the purpose of the production system is to eliminate all kinds of waste hidden in the enterprise so as to gain more benefits.

Waste includes: waste of waiting, waste of inventory, waste of pportation, waste of action, waste of defective goods, waste of processing, excessive waste of production, and rapid and multifaceted improvement of results.

After checking the samples with the customers, the merchandiser distributes the order information to all relevant functional departments as the starting point, and the employee pays attention to the completion of sewing work and the delivery of the products to the packaging department.

Fu Dongliang introduced that the main contents of the system consist of mind, technology and body.

Among them, "heart" means that ideology must be established first.

The idea of single piece flow is very different from traditional production concept. Improvement must start with consciousness reform.

"Skill" means the meaning of technique.

It is about what methods to adopt to make ideas and ideas out.

It includes streamlined production, stable production, smooth production and supermarket production.

"Body" means the meaning of experience and practice.

This is the secret of improving the success of the whole piece flow.

Only by doing so can we find out the problems before we can improve them.

Streamlined production is the most important stage.

Streamlined production can be said to be the most important stage of the single piece flow. Its basic idea is to avoid making bad products and produce the finished products one by one through the production process.

There are the following conditions for establishing streamlined production: first, single piece flow, followed by arrangement of equipment in accordance with the sequence of process, production speed synchronization, multi process operation, multi worker operation, staff standing and walking operation, machine equipment miniaturization, parking arrangement U type and so on.

Streamlined production has the following specific requirements: first, the whole staff consciousness reform; the second is to set up an exemplary model group; the third is to select the demonstration production line; fourth, the current situation investigation and analysis, to make an understanding of the current production line; fifth, to set the production distance time according to the style; sixth, to decide the quantity of equipment and personnel; seventh to arrange the production line with "thin flow and fast" and counter clockwise flow; eighth to allocate the process, and ninth to single piece flow.

Finally, we should expand horizontally.

When the demonstration group members are accustomed to the new way of work, and the production line is gradually stabilized, the whole factory has a place to observe and learn. Other production line workers also have a certain understanding of streamlined production. At this time, each production line in the factory can be quoted in accordance with the establishment process of the demonstration group.

Stable production is a real improvement activity.

Streamlined production can only be regarded as an amendment activity. The real improvement activities should start with stabilizing production, including the stability of personnel and other factors.

The stability of personnel is to stabilize the production line by standard operation and to reduce the effect of the workers, while maintaining the stability of personnel and the flow of employees will not be too frequent. The stability of machines is often caused by machine failure and wastes much time in the process of production. Therefore, it is necessary to make the machine stable and operational with a mobility rate of 100%. The stability of quality is the single item pursuit of zero defects, and the implementation quality of "three no" policy (not making defective products, not pmitting defective products, not accepting defective products).

Finally, the stability of management.

The single piece flow should improve the traditional concept, and management is an important factor.

Managers should first understand the concept of consciousness, so as to have the ability to see and discover problems. Secondly, we should make use of auxiliary tools such as electronic billboards, warning lights, bottleneck process lights, etc. to make the production site easy to display problems and production activities to be pparent, so that an abnormal phenomenon on the scene can be detected and improved immediately.

Smooth production, first arrange the list.

How can we do well in smooth production? First of all, the scheduling should be arranged in a single row, so that the style of the production line has a continuity, that is, the changes between the styles will not be too large, and there are similarities, so that employees will not have too many technical problems when they open new models.

Secondly, the skill level of each employee in the production line can reach the level of multi capability and seamless pfer.

Again, the daily output arrangement should have a curve. The first day of the operation is 85%, and the second day is 117%, and it will keep 130% in the second week.

The highest level of smooth production is mixed flow production, that is, the style of cloth and sewing method is similar, even if the size is different, it is arranged on a production line to cross production at different intervals, so that equipment, space and manpower can be used without waste.

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Single piece flow is different from traditional production mode.

The main differences between the single piece flow and the traditional production mode include the arrangement of parking spaces, the different direction of production line, the different control modes of cutting pieces, and the related problems of production mode.

First of all, the arrangement of parking spaces is that the single flow requires parking spaces to be arranged in U and counterclockwise direction. During the production process, cross reflux and backflow are strictly prohibited, so that the streamline production of the production line is achieved. In traditional production mode production lines, sometimes the arrangement of parking spaces causes cross reflux between certain processes.

The different direction of production line is the requirement of single piece flow to establish an elastic production line.

According to the quantity of the order and the time of delivery, the styles, daily output and the number of operators are changed at any time. That is to say, the staffing needs to be changed as the demand changes. This requires higher skills for employees, and the need for training multi skilled workers.

The traditional production mode has no such requirements.

The method of controlling the distribution of chips is different from that of a single piece of flow. It is strictly controlled according to the rhythm time and is released by "water spiders", so that the flow is smooth. This is also a condition for streamline production.

In the traditional production mode, the time of the release is usually two hours, so the whole production line is very chaotic. The number of sewing joints between different departments is not consistent, so it is easy to pile up goods.

Single piece flow is standing production, traditional production mode is sitting production.

Many people do not understand why they should stand up and work hard. Why do they have to stand up?

"Standing production makes the upper and lower processes easier to pfer, and is also convenient for process deployment and balancing process.

For example, after you sew, you can go to the middle scalding, which will reduce the waste of time. If you sit and work, you should stand up and burn after sewing, which will be more troublesome.

Fu Dongliang said.

Relevant experts also believe that standing production can save space and facilitate visual management.

The single piece flow calls for U type parking spaces, so that there will be a channel in the middle, which is also convenient for visual management.

Before sitting in production, the parking lot was in disorder. Under the machine, there were many dead ends and chores. It was not easy to find and handle. After standing up, the space was large, and every problem could be found clearly everywhere.

Wage calculation to enhance system integrity

The traditional mode of production implements the individual piece wage system, the employees do much more and less, so they will only take care of their own working procedures, which will easily cause unbalance of the process, the flow of the process, the bad quality and so on, and the more fatal is the problem that once the rework is the whole batch.

The piecework wage system implemented in the single line production line is completely different. Each employee is part of a group, and the workload is equal. The money they earn is divided equally. This will strengthen their team spirit, and there will not be any dispute between employees or between employees and QC on the production line.

Naturally, after a long period of time, the production line is more stable and emotional, and this group is more united and productive.

Everyone will have a herd mentality. I will follow what others do. They all want to be valued in the collective.

At the same time, employees are independent individuals, lack of team spirit, will only care about their own sewing process, where they will supervise others; at the same time, they do not do well or are too slow to do their work. The most frequent rework is to return to work or to extend work hours to make up for them; and to implement group work, all employees are going to work at the same time and work at the same time, so that no one else can work overtime himself. Every employee in the production line is equivalent to a head waiter. They must supervise others, and be supervised by others too. In traditional production mode production line

Group counting requires that each employee has the same skill level, so that the process can be balanced, but in practice, the skill level of the employees is still different. The group pieces will make the skill poor people work harder and keep up with the pace. Therefore, the implementation of group pieces can bring the latter up and improve the skill level. On the traditional production mode, the skill level of the production line is uneven, there is no way to restrain them from improving their skills consciously, and the process is not easy to allocate, so there is often a phenomenon that the flow is not smooth and the goods are stacked up.

The single piece flow emphasizes the overall benefit. The production line must pursue the balance of overall benefits. That is to say, the benefits of each employee are equal, and the benefit imbalance between employees is not allowed. The traditional production mode does not have the requirements in this respect, so the actual calculation is personal benefit, so that the company and employees are not good.

In the aspect of non-standard action completion, the single stream production line is made by "water spider" on time, and the employee can not leave the post without any reason.

In traditional production mode production line, it is usually the batching staff who takes the target production of Kanban for every two hours to put the cutting piece on the cutting table at once. This wastes time and can not control the size of the cutting piece, and it is easy to form a packet flow, and the process is unbalanced and goods are stacked.

In the single piece production line, the "water spider" completes the arrangement, sorting and pruning of the cutting pieces, reducing the non-standard movements of the employees, reducing the workstation rhythm time and improving the efficiency.

The traditional production mode of the production line is usually done by the employees themselves, resulting in too many non standard movements of employees, increasing the workstation's rhythm time, and the efficiency will be reduced.

In the single piece flow, more emphasis is placed on team spirit of employees. Otherwise, it is impossible to implement single piece flow to streamline production.

First of all, let's imagine that the workload is not equal and the staff do not help each other. The whole production line will be in a mess.

Without team spirit, the team is not angry and lifeless.

The implementation of the group piecework system requires higher team spirit. Employees are only a small part of the group, and only when they are put together can they have greater strength.

Secondly, when employees have team consciousness, the deployment process is easier.

Because single piece flow requires single piece flow, it is necessary to deploy the process. If the team spirit of staff is not enough, the deployment process is very difficult, so that the production line will be stacked up, and the relationship between employees will not be harmonious.

Finally, the group piecework wage system is implemented, and the wages of employees are evenly divided. Therefore, team spirit is more important. Everyone should put their heart and soul into it. They should not be too fussy. Less work means less money. They should help others, help others and help themselves, and you need help from others too. Therefore, we should regard the production line as our home and everyone is a member of this family. We should unite and help each other and make progress together.