Composition on that quality of loom department in textile mill

It gave me a general understanding of the garment industry. As a member of the manufacturing industry, the garment industry condenses the general characteristics of the manufacturing industry: product-centered organization and operation, and it also has the production and operation mode of labor-intensive industries: the labor of workers is the source of value. Moreover, Shengjia's production is OEM production, foreign businessmen come to sample, and enterprises produce according to the sample version. Therefore, I have learned some knowledge of international trade here.

Shengjia's workshop gives people a comfortable feeling: spacious and bright, with a certain interval between each production area and each equipment, and equipped with "simple air conditioning" (a cooling device, even in midsummer, the room temperature is kept at more than 2 degrees). All this is to meet the requirements of foreign businessmen-to protect the basic rights and interests of workers.

As a garment enterprise, sewing machine is the most necessary and important equipment. After understanding, I know that sewing machines can be divided into three categories, including sewing machines, sewing machines and special machines, and each of these three categories includes 15 kinds of machines. Sewing machines are mainly configured according to different clothes styles and customer requirements. Now there are about 3 different kinds of sewing machines in the production workshop. In the auxiliary workshop on the other side, the auxiliary processes such as cloth inspection, cutting, thread cutting, ironing and packaging (branding and hanging trademark cards) are mainly carried out. The equipment used here includes pre-shrinking machine (shrinking the cloth in advance to prevent it from shrinking in future use, mainly used for high-grade clothes), cloth inspection machine, electric scissors, ironing equipment and needle inspection machine (detecting needles left on clothes to prevent pricking).

the production operation flow of this factory is in a ring shape (see the figure below), starting from the auxiliary workshop in the east of the factory, then transferring to the raw production workshop in the west for production, and finally returning to the auxiliary workshop in the east for the final process. Of course, this is only under normal circumstances, in general. Due to the particularity of fashion production, its variety, variety, unfitness and complex structure often lead to the intersection of processes in this ring. Moreover, sometimes it is necessary to cooperate with resources and processes outside the factory to complete the production. For example, if a customer requests that the clothes should be embroidered with patterns, the production must be stopped at a certain part, transported outside for processing, and then transported back for reproduction. It can be seen that the factory produces in a mixed organization mode.

specifically introduce the production process, first of all, take orders. Then, the designer of the garment factory will make a trial production of a garment according to the garment pattern brought by the customer by computer (considering how to make the garment pattern, with the least amount of materials), and make a technical drawing according to the method conclusion obtained in the trial production process, and then discuss and negotiate with the customer to modify it. When the customer is satisfied, the technical drawing will be finalized and will not be changed again, which will become the "sacred book" and "imperial decree" of the factory. Then, materials are purchased as required, ranging from cloth to small accessories (such as nail buttons). After the cloth arrives, it is necessary to inspect it, which is called "previous Q". Then the qualified cloth is sent to the cutting room and cut into different parts of the clothes with electric scissors according to the clothes sample, and then these "fine pieces" are "checked", that is, "pre-Q". The "fine pieces" qualified by the "film inspection" are sent to the production workshop to start the main production, during which it will go through several "Q's". After the production is completed, we will go to the post-whole department, that is, we will carry out the processes of thread cutting, ironing and packaging. During the process, we will pass the post-Q, and those who pass the inspection will enter the warehouse, waiting for the customer to send someone to the factory for the final inspection. Those who pass the inspection can sign the release slip, transport and deliver the goods.

according to the investigation, Shengjia's production operation belongs to small flow operation. The production workers are divided into eight groups, each group is supervised by a master, and the whole group completes the division of labor. The parts of clothes that need to be sewn flat should be finished by sewing workers, the parts that need to be sewn should be finished by sewing workers, and those that need to sew special lines should be finished by special workers. Because of the different requirements of each garment, you can do the flat sewing part first, or you can do other parts first. The arrangement of the three types of work is very flexible, and each batch of goods is different, so the placement of the three types of sewing machines can be changed as needed. Usually, after a sewing process is completed, there will be a QC, and after passing the inspection, it will directly enter the next process. The time required for each process mainly varies according to the style of the clothes. As far as the production steps are concerned, the simplest one minute and the most complicated one hour may not be completed. Usually, it takes half a year for a batch of goods to be completed from the time the customer places an order. The reason for adopting small flow production is mainly determined by the fashion style and the objective situation of the factory: the fashion process is short, the delivery date is short, there are many varieties, the structure is complex and unstable, and the factory is small, so it is impossible to complete it in large quantities and by large flow, so small flow production is more suitable.

the problems in this factory are: (1) manpower shortage. Shengjia's ideal state (to achieve maximum productivity) should be equipped with 5 sewing machines, but now it is less than 3 because of the shortage of workers. The output of this factory is 8, pieces per month, but it is understood that the total output of mature factories of the same scale should be at least 12, pieces, which shows how much the shortage of workers has affected this factory. In my opinion, besides continuing to recruit employees, we should also train sewing workers in the factory to improve their skills. Recruit a certain number of students with professional skills from professional technical schools, so that workers can learn from each other and make full use of their professional skills. (2) The scheduling problem is the MRP problem mentioned in the book. Sometimes there is an imbalance between leisure and busy in this factory: some jobs have to work overtime, while others have nothing to do. On the day of the visit, the ironing worker didn't go to work. It turned out that he had just rushed to deliver the goods last night, so he didn't work today. There is something wrong with the scheduling in this factory, and the connection between processes is not smooth, which wastes resources and causes idleness. (3)QC leads to higher appraisal cost. Solution: Cultivate employees' "quality-oriented" thinking, so that employees can consciously find and prevent quality problems in the production process, never let go of any found quality problems, prevent problematic clothes from entering the next production process, and remedy the problems in time. Quickly find the root of quality problems, effectively reduce the sunk cost caused by mistakes, and reduce the cost caused by repeated QC.