Garment Production Process Improvement to Increase Production Efficiency: A Case Study of ABC Co., Ltd.

DOI: 10.14416/j.ind.tech.2023.12.010

Abstract

ABC Co., Ltd., a garment manufacturer operating as an Original Design Manufacturing (ODM) company, is currently facing issues related to delayed delivery, resulting in a decline in on-time delivery performance, discounted rates due to late delivery, and increased air freight costs. The primary cause of these problems, identified through the analysis of last year's records, is factory production delays. Therefore, We chose the sample product that was recorded to have the highest amount and value of damage from delayed delivery as a sample for this study. The results of the study found that before the improvement, there were 30 stations in the production process for the sample product models. The average takt time was 106 seconds per unit, with a production capacity of 272 units per day in 1 working day of 8 hours, which is considered to be a production efficiency of 54%. After improving the production process and rebalancing production. Using the principle of Line balancing and ECRS techniques can help to reduce the steps and waste that occur in the production process. Rearranging work steps This includes distributing subtasks to nearby stations to balance waiting times at each station. The results were found that the production process was reduced to 28 stations, with the average takt time reduced to 77 seconds per piece which made the increase in production capacity to 374 pieces per day and a production efficiency of 80%.