For ZBT, opportunities exist to assist Garments companies in navigating these challenges and pursuing growth strategies. This can include market analysis, cost optimization, process improvement, organizational design, and growth strategy development etc.
The garment industry has a significant impact on the environment and is subject to increasing regulations and stakeholder pressure to adopt sustainable practices. ZBT is supporting garment companies in developing and implementing sustainability strategies, including reducing use of chemicals, improving resource efficiency, reducing waste and improving profitability.
Poor capacity utilization is a significant issue in the garment manufacturing industry. It occurs when a garment industry is producing at a lower rate than its maximum capacity, resulting in lower efficiency and reduced profitability. There are several factors that contribute to poor capacity utilization, including: Weak demand, Competition from import, Ineffecient production processes, High process and RM quality rejections, Outdated technology and poor management practices.
Garment manufacturers need to focus on improving production efficiency and adapting to changing market conditions. This may involve investments in new technologies, better management practices, better SOP in place, Optimised attrition rate etc.
THigh DHU is a common issue in the garment manufacturing industry, as it refers to a low rate of production relative to the theoretical maximum capacity. In garment production processes, quality checking stations are set for stopping defects at the source and stopping defective garment passing to the following processes. Normally, checking is done for raw materials, partially stitched garments, stitched garments and finished garments by quality checkers. High DHU can result in higher production costs, reduced profitability, and lower competitiveness. There are several factors that can contribute to high DHU in garment manufacturing, including: Inefficient production processes, Poor raw material quality, Equipment failure, Labor issues, poor SOP in place etc.Improving DHU in a garment manufacturing plant can be achieved through a combination of different methods, including: Raw material quality optimization, Process optimization, operator skill improvement, Waste management, Employee training, Maintenance and upkeep, Process innovation etc.
Improving profitability margins in the garment manufacturing industry involves a combination of cost-cutting measures, operational efficiencies, and revenue growth strategies. Here are some levers to improve profitability margins in garment manufacturing: Control production costs, Increase efficiency, Diversify product portfolio, Focus on high-margin products, Reduce overheads, supplier consolidations, RM price variations reduction etc.
SMED (Single-Minute Exchange of Dies) is a methodology used to reduce the time required to changeover from producing one product to another. Implementing SMED in a garment manufacturing plant can help to increase production efficiency and improve profitability margins. Here are some steps for implementing SMED in a garment manufacturing plant: Identify opportunities for improvement, Separate internal and external activities, Streamline the changeover process, Implement quick die change systems with the help of Gantt charts, Train people in dummy lines, define critical operations and give three times training, improving pre production activities etc.
We as a ZBT help in to improve your end to end performance improvement, also provide advice and support to organizations to help them improve their operations and reach their strategic goals with the help of down times reduction, product changeover times reduction, 3T SOPs implementation, debottlenecking of the stiching line etc. In the context of a garment manufacturer, a management consulting firm could help with a number of business transformation initiatives, including Process optimization, Cost reduction w.r.t MMR and avg SAM of garment, Market analysis, Organizational design, Technology integration etc
ZBT is helping out their client to improve thier overall performance improvement with the help of debottlenecking of the production line, reduction in the breakdown times of the key equipments', improving OEE, reducing their changeover time reduction with the help of SMED (giving more flexibility to make the nos. of types of the products), having dizital transformation in the textile industry first time (sales order real time tracking) etc.
Apart from that, we are helping our clients to reduce their direct spend as well with the help of supplier consolidation, price nagotiation, tail spend consolidation, yield improvement etc.