In apparel factories, production delays can stem from a variety of factors that heavily impact resource utilization and disrupt product flow, ultimately leading to low productivity. These delays waste time, slow down manufacturing processes, and cause bottlenecks. Equipment failures or delayed maintenance can also halt production entirely, further exacerbating the issue.
A key challenge affecting productivity is the inefficiency of internal supply systems, the lack of value engineering input, and the limited effectiveness of machinery. These issues cause frequent disruptions for the frontline workforce, reducing overall output. To address this, the manufacturing sector must implement robust support systems and innovative concepts that ensure the timely supply of tools, materials, information, and reliable equipment at the point of use.
Maintenance teams are responsible for providing adequate machinery, while quality and stores teams ensure the timely delivery of accurate information and materials in the required quantities. Supervisors and line workers also need value engineering of key productivity drivers, including process setups, standardized practices, tolerances, and balancing points—tasks typically managed by the engineering team. This service evaluates the current functions of key support staff, identifies inefficiencies in work activities, and designs a point-of-use system to address these gaps. The assessment outlines necessary system simplifications and capacity adjustments for support roles. Based on the findings, training materials are developed, system changes implemented, and targeted training provided to enhance engineering capabilities. The service also strengthens the maintenance team’s ability to implement Total Productive Maintenance (TPM) and equips other support staff with role-specific skills.
