Ways to reduce changeover time and increase efficiency in RMG production

The garment industry's “quick changeover time” is akin to a magic trick, swiftly transitioning production lines from one garment style to another.

In the readymade garments (RMG) sector, fast turnaround is key. Quick changeovers maximize efficiency, meet deadlines, and allow factories to adapt to trends, delivering high-quality products on time.

Faster changeovers in RMG significantly boost efficiency. Downtime shrinks, lead times drop, and output surges.

Figure: From a study of a ready-made garment (RMG) factory located in Bangladesh.

Achieving zero quick changeover time remains a challenge in Bangladesh's RMG sector, highlighting the need for systematic approaches. As per Mr. Mahamud Hassan, Executive, BPA Tropical Knitex Ltd., “There are some constraints in the implementation of Zero Quick changeover time, and it can be classified into two segments: before line feeding and after line feeding. The previous style of WIP management, in-time fabric and accessories in housing, critical process analysis for the new style, machine pre-setup, and providing the training facility for operators are the constraints for before line feed.

After line feeding, the constraints are: high absenteeism of workers, lower line balancing of running style, high bottleneck, mismatch between line target and achievement ratio, quality control, and proper follow-up from IE.”As per Dr. Engr. Azim Mohammad, CEO, Institute of Apparel Management (IAM), “The main steps of changeover operations start with separations of internal and external activities. The more internal activities can be converted to external ones, the more time will be saved, and the overall time for quick changeover will be lessened.”

In terms of working on QCO, the setup tasks are differentiated based on whether they can be performed internally or externally. External activities (E) can be conducted during the machine's regular operation while it is still running. Internal activities (I) are the ones that can only be performed when the machine is shut down.

There are some key Principles and techniques available for reducing the time in Changeover. Such as:

Implementing SMED (Single-Minute Exchange of Die), Standardizing Workflows and Simplifying Setup Procedures, Data Analysis and Optimization Tools for Improving Change Over Efficiency, Utilizing Automation and Robotics for Faster Changeovers, Implementing Lean Principles for Quick Changeovers, Creating Cross-Functional Changeover Teams including members from production, maintenance, quality control, and logistics to ensure a holistic approach to changeover optimization. Arranging training and Skill Development for Changeover Optimization.

Challenges in achieving efficient changeover in garment manufacturing

Managing resistance to change and workplace cultural adjustments is one of the main obstacles to implementing effective changeover in the apparel manufacturing industry. To overcome these challenges and create a more seamless transitional environment, it is necessary to cultivate a culture of continual development and openly convey the advantages of quick changeovers.

Overcoming Technical and Operational Hurdles can pose significant challenges to achieving seamless changeover processes in garment manufacturing. By investing in technology upgrades, implementing standardized operating procedures, and conducting thorough equipment maintenance, companies can overcome these hurdles and optimize their changeover processes.

Quick changeover in RMG is key to efficiency, cost reduction, and continuous improvement. By adopting these practices, garment factories can become more agile, responsive, and competitive in the fast-changing market. As the industry evolves, efficient changeover will be crucial for success.