Do You Have High Profit In Small Season?

After entering May, some garment factories have entered the off-season production. The number of orders is generally smaller and smaller. Some styles are only a few hundred, and the delivery time is only 3 days ~5 days. In this way, small batch and high frequency will be a trend of clothing production in the future. So how can factories cope with the rapid production of small orders? Do not lose profits in the off-season?

I. concept of multiple varieties and small quantities

Multi variety and small batch production refers to a production mode which is more than the product type (specification, type, size, shape, color, etc.) as the production object during the specified production period, and the production quantity of each type of product is less.

Compared with mass production mode, small batch production has low efficiency, high cost, and is difficult to realize automation. Production plan and organization are more complicated. Under the fashionable and personalized market conditions such as clothing, consumers tend to diversify in pursuit of advanced, unique and popular goods that are different from others.

Two, multi varieties, small batch characteristics

One

Multi species parallelism

Because many enterprises' products are aimed at customer configuration and different products have different needs, the resources of enterprises are placed in multiple varieties.

Two

resource sharing

Every task in the production process needs resources, and the resources available in the actual process are very limited. For example, the problem of equipment conflict is often encountered in the production process, which is caused by the sharing of project resources. Therefore, we must allocate appropriate resources to meet the needs of the project.

Three

Uncertainty in order and production cycle

Due to the unstable demand of customers, the planned nodes are not consistent with the cycle of man, machine, material, law, ring and so on. The cycle of production is often uncertain. The projects with insufficient cycle need to occupy more resources and increase the difficulty of production control.

Four

Material demand changes frequently, resulting in serious delay in procurement.

Due to the order or change of orders, external processing and procurement are difficult to respond to the order delivery time. The risk of supply is enormous due to small quantities and single sources. (through the document management system of AI Ge Wen clothing, when the order changes, the system will automatically update the material demand, so that the purchaser can change the purchase according to the demand as soon as possible so as to avoid less mining and leakage. )

Three. Difficulties in multi variety and small batch production.

1. dynamic process path planning and deployment of virtual unit lines: emergency inserting, equipment failure, bottleneck drift.

2. identification and drift of bottlenecks: before and during production.

3. multilevel bottlenecks: bottleneck of assembly line, bottleneck of part's virtual line, and how to coordinate coupling.

4. buffer size: either backlog or poor anti-interference. Production volume, transfer batch, etc.

5. production scheduling: we must not only consider bottlenecks, but also consider the impact of non bottleneck resources.

Typical problems of multi product and small batch production mode:

(1) the production of multiple varieties and few batches is difficult.

Unable to deliver the goods on schedule, too many "fire fighting" overtime.

3. Orders need too much attention.

(4) production priorities change frequently, and the original plan can not be implemented.

(5) stocks are increasing but often lack critical materials. The system strictly controls the inventory level through strict material control. After listing the clear bill of materials, it can check the stock and reserve the required materials to the order, so as to avoid repeat purchase or leakage. )

Four, multi variety, small batch production and quality management.

One

The rework rate in the transfer stage is high.

As the product is constantly changing, it is necessary to constantly change the product and debug the product. In the process of changeover, it is necessary to modify the parameters of the equipment, the replacement of the tool and fixture, the compilation or the call of the NC program, and so on. Sometimes, workers have just finished a product and have not fully grasped the new product or remembered the relevant operational essentials. They are still immersed in the operation mode of the previous product, resulting in the production of unqualified products, resulting in the scrapping of the products.

In fact, in small batch production, most of the waste products are generated during the process of product change and commissioning. For multi variety and small batch production, it is particularly important to reduce the waste and rework during the transfer process.

Two

Quality control mode after inspection

The core issue of the quality management system is process control and total quality management.

In the company's scope, product quality is only regarded as a production workshop, while various departments are excluded. In terms of process control, although many enterprises have process regulations, equipment operation procedures, safety regulations and post responsibilities, due to poor operability and too complicated, and without monitoring means, the degree of implementation is not high. For operation records, many enterprises did not carry out statistics, and did not form the habit of checking operation records everyday. So many of the original records are just a pile of waste paper.

The garment production management system can monitor the production line in real time, grasp the progress and efficiency of each process at any time and place, real-time rework cause, statistical defect rate, and trace every defect procedure, worker number and time, so as to better assist the team leader in finding problems and correcting them as early as possible.

Three

Difficulties in implementing statistical process control

Statistical process control (SPC) is a quality management technology that applies statistical techniques to evaluate and monitor the various stages of the process, to establish and maintain the process at an acceptable and stable level, so as to ensure that products and services meet the specified requirements.

Statistical process control is an important method of quality control, and control chart is the key technology of statistical process control. However, because traditional control charts are produced in mass and rigid production environment, it is difficult to be applied to small batch production environment.

Because the number of processing parts is very small, the data collected can not meet the requirements of traditional statistical methods, that is, the control chart has not been done yet, and the production has ended. Control charts do not play a proper preventive role, and lose the significance of using statistical methods to control quality.

Five, quality control measures for multiple varieties and small batch production

Under the condition of multi variety and small batch production, the quality of products should be steadily enhanced. Detailed work instructions (SOP) and implementation of the principle of "prevention first" should be established, and advanced management concepts should be introduced to improve management level.

1. establish detailed operation instructions and standard operation procedures in commissioning phase.

The work instruction should include the required NC program, fixture number, testing means and all the parameters to be adjusted. The preparation of work instructions in advance can fully consider all kinds of factors, compile and proofread, and gather the wisdom and experience of many people, so as to improve accuracy and feasibility. It can also effectively reduce the online replacement time and improve the utilization rate of equipment.

The standard operating procedure (SOP) should determine every step of the commissioning process. Determine what each step should do and how to do it according to the order of time. For example, the replacement of the NC machine tool can be done according to the replacement claw claw procedure -- according to the cutter number used by the program - check - cutter - locate the workpiece - set the zero point - the sequence of step execution procedure will carry out a series of scattered work in a certain order in order to avoid omission.

At the same time, how to operate and inspect each step is also stipulated. For example, after changing the claw, how to detect whether the claw is eccentric or not. It can be seen that the debug standard operation procedure is the optimization of the control point operation of the debugging work, so that every employee can do things according to the relevant regulations of the program, and there will be no big mistakes. Even if there is a mistake, it can be quickly checked through SOP to identify problems and improve them.

2., implement the principle of "prevention first".

We should transform the theory of "prevention first, prevention and check" into "real" prevention. This is not to say that we no longer check. Instead, we will further examine the functions of the gatekeeper, that is, the contents of the inspection include two aspects: one is the check of product quality, and the other is the check of process quality. To achieve 100% qualified products, the first important thing is not to test the quality of the product, but to strictly control the production process in advance.

Six. Compiling method of production plan for multiple varieties and small quantities.

One

Comprehensive balance method

The comprehensive balance method is based on the requirements of objective laws. In order to achieve the planning objectives, the proportion of the relevant parties or related indicators in the planning period is appropriate, they should be linked to each other and coordinate with each other. The plan indicators can be determined through repeated balance analysis and calculation in the form of balance sheets. From the point of view of system theory, it is to keep the internal structure of the system orderly and reasonable. The characteristic of the comprehensive balance method is to comprehensively and repeatedly balance the targets and production conditions, and maintain the balance between tasks, resources and demands, between local and whole, between goals and long-term. It is suitable for the preparation of long-term production plan. It helps to tap the potential of enterprises, people and property.

Two

Proportional method

The proportional method, also known as the indirect method, is used to extrapolate the relevant indexes from the past two related economic indicators to determine the planning period. It is built on the basis of the ratio between the relevant quantities, and is therefore greatly influenced by the accuracy of the ratio. It is generally applicable to mature enterprises that accumulate long-term data.

Three

Quota method

The quota method is based on the relevant technical and economic quota to calculate the relevant indicators for determining the planning period. It is characterized by simple calculation and high accuracy. Disadvantages are affected by product technology and technological progress.

Four

Rolling planning method

Rolling planning method is a dynamic method of compiling plans. It is a planning method based on the implementation of the plan in a certain period, considering the changes in the environmental conditions inside and outside the organization, adjusting the plan in time, and postpone the plan accordingly.

Rolling planning method has the following characteristics:

(1) the plan is divided into several execution periods, of which the short-term plan is detailed and specific, whereas the forward plan is relatively rough.

(2) after the plan has been implemented for a certain period, the contents and relevant indicators of future plans should be revised, adjusted and supplemented according to the implementation and environmental changes.

3. Rolling plan method avoids the solidification of the plan, improves the adaptability of the plan and guides the actual work. It is a flexible and flexible production planning method.

(4) the principle of rolling plan is "near thin and far thick", and the mode of operation is "edge execution, side adjustment and side rolling".

Rolling production is constantly adjusted and revised along with the change of market demand, which coincides with the variety and small batch production methods that meet the changing market demand. Using rolling production method to guide multi variety and small batch production can not only improve the ability of enterprises to adapt to market demand changes, but also maintain the stability and balance of their own production, which is an optimal method.