Reduce Style Changeover Time. What is Zero feeding?

 

What is Zero feeding? How to reduce feeding time?

 

Planning dept. release monthly plan based on delivery priority. From monthly plan we know how many times style changeover are there in every line. So respective IE & supervisor can take preparation on that. Style change in a line is common subject. But if there responsible IE & supervisor not following the process properly, then factory will loss pcs.

 

  “Duration of last pcs output of running style time from the last process to first pcs output of new style time from the last process of the line is called style changeover time.

For Example: last pcs output of Style 553 from the last process on 3.15 PM & first pcs output of style 749 from the last process of the line on 6.45 PM. So duration of those style output is 3 hour 30 min is style changeover time/ feeding time. Sometime it takes more time than the example & sometimes less.

What is the reason behind it?

·   Unplanned style change

·   Panel not ready / check balance

·   Layout not ready

·   Machine setting delay at first machine

·   Special machine are not set earlier

·   Accessories unavailability

·   Yarn not approved

·   Sample not ready/approved

·   Delay of achieving quality standard

 

But what is IE responsibilities there to make it zero feeding time?

Zero feeding means there is no loss hour to get new style output. It means last pcs output of running style time from the last process to first pcs output of new style time from the last process will be relevant/same hour.

Before start new style feeding, follow below process accordingly…

·         Keep ready layout & handover to supervisor, machinist ,garments technician (if available)

·         Check machine requirement & availability, if need more arrange early.

·         Set special machine early by the mechanic

·         All kinds of accessories are ready like sewing thread/yarn, label, any attachment etc.

·         Approved sample arrange & discuss early to review critical operation & plan skilled operator accordingly.

Make a checklist & check prior to feeding. When everything is ok, then go for feeding. Whenever first machine work finish then at the same time start first process of new style on that machine based on layout. Fixed the first pcs output quality of first machine then go to next machine & like that one by one has to set. Must has to follow skill matrix while selecting operator especially on critical operation. If there any special machine required, prior to setting, mechanic should ready to stitch it early so that no need additional time to setting. Involve IE, production, mechanic, electrician both &Work as a team to maintain it for quick changeover.

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