Best Techniques to Minimize Style Changeover Time in Garment Manufacturing

One of the biggest challenges I’ve noticed in garment production over the past decade is that style changeover time often takes too long. But, with some smart techniques, this time can be shortened. In this article, we’ll explore this topic in detail, with easy-to-understand examples.

First, we’ll explain what style changeover time is and why it happens. Then, we’ll go through the best ways to solve this problem, with clear examples. So, let’s dive in and get started!

What is Style Changeover Time (COT)?

Style Changeover Time (SCT) is the time it takes to switch from making one product style to another in a factory. This involves tasks like adjusting machines, changing tools, and checking quality. 

Reducing SCT is important because it helps factories work faster, waste less time, and quickly meet customer needs. When SCT is managed well, it can save money and boost overall productivity in the manufacturing process.

Top 7 Reasons For Higher Style Changeover Time

Higher Style Changeover Time (SCT) can make production slower, costing more and lowering efficiency. Knowing the reasons helps to cut down on these delays.

• Complicated machine setups and adjustments.
• Staff not fully trained or experienced.
• Tools and materials not well organized.
• Long quality checks and testing steps.
• No standard process for changeover.
• Poor communication between teams.
• Waiting on materials to be ready or found.

 

By identifying and addressing these issues, manufacturers can reduce style changeover time. It also boosts efficiency and saves both time and money.

Best Techniques to Minimize Style Changeover Time in Garment Manufacturing

Minimizing Style Changeover Time in garment manufacturing is crucial for improving efficiency and reducing costs. Here are some of the best techniques:

1. Standardize Processes

Creating standard steps for changeovers helps everyone follow the same routine, making the process quicker and smoother. When everyone knows exactly what to do, there’s less chance of mistakes or confusion. This way, even newer employees can handle changeovers easily, helping the whole team work more efficiently.

2. Organize Tools and Materials

Having all tools and materials neatly organized and easy to find saves a lot of time during changeovers. When everything has its own place, workers can grab what they need right away without wasting time searching. This simple organization can make a big difference in speeding up the changeover process.

3. Train Employees

Regular training is key to making sure employees know how to do changeovers quickly and correctly. When workers are well-trained, they feel more confident and can get the job done faster. Hands-on practice during training helps them get familiar with the equipment, making the whole process much smoother.

4. Use Quick-Change Tooling

Quick-change tools are designed to be swapped out fast, which can really cut down on changeover time. These tools are easy to adjust, so workers can set them up quickly without mistakes. This investment can help the team work faster and avoid unnecessary delays.

5. Implement SMED (Single-Minute Exchange of Dies)

SMED is a method that aims to reduce changeover times to under 10 minutes by separating tasks into those done while the machine is running and those done while it’s stopped. By streamlining steps and cutting out unnecessary actions, SMED can significantly speed up the changeover process.

6. Pre-plan and Schedule

Planning changeovers ahead of time and scheduling them during slower production periods can help minimize disruptions. When you know in advance what’s needed, you can have everything ready to go, making the changeover faster and easier. This simple planning can make a big difference in keeping things running smoothly.

7. Continuous Improvement

Always look for ways to improve the changeover process. Regularly review how things are done, ask for feedback from workers, and look for any slow spots. Making small, continuous improvements based on these insights can add up to big time savings and a more efficient process overall.

 

By using these simple techniques, garment manufacturers can cut down on Style Changeover Time, making work smoother. Meanwhile, they can save money, and create a more efficient, productive workplace for everyone.

What Is The Ideal Style Changeover Time In Garment?

The ideal style changeover time in garment manufacturing is as short as possible to maximize productivity and minimize downtime. Generally, a good target is under 30 minutes, though the exact time can vary depending on the complexity of the change and the efficiency of the processes in place. 

 

The goal is to reduce changeover time without compromising quality, enabling faster and more flexible production.

 

For example–

If a factory usually takes 60 minutes to switch from making one style of shirt to another, aiming to cut that down to 30 minutes is ideal. This means they could produce more styles in the same amount of time, making the factory run faster and more efficiently.

 

So, by following these simple methods, you can increase your textile production. Plus, it will save you time, money, and effort.

 

Frequently Ask Question

How to reduce style changeover time?
To cut down on style changeover time, standardize procedures, organize tools, train staff well, use quick-change tools, plan ahead, and keep improving the process.

How to reduce changeover time?
Reduce changeover time by creating clear steps, keeping tools organized, training your team, using quick-change equipment, scheduling changes carefully, and continuously looking for ways to make improvements.

What is the use to reduce setup changeover time in lean?
In lean manufacturing, reducing setup changeover time helps boost efficiency, cut costs, and improve productivity. It allows you to switch tasks quickly and keep production running smoothly.

How to reduce QCO time?
To reduce QCO (Quick Changeover) time, focus on simplifying and speeding up the changeover process, use tools that are easy to swap, and keep everything organized and ready.

Why do clothing styles change over time?
Clothing styles change over time due to trends, cultural shifts, and new fashion ideas. Designers often create new styles to keep things fresh and to respond to what people want.

 

Explore More Related Reads At Garment Diary: Garment Pattern Making: Manual Techniques vs. Software Applications How to Find the Perfect Fabric for Your Garments Calculating CMT in the Garment Industry

 

Join Our Fashion Insider Daily!
Get the latest trends, industry insights, and exclusive tips delivered straight to your inbox. Don’t miss out on staying ahead in the world of fashion and garments. Sign up now!