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Common Problems

Some Common Problems in Garment Production

 

All factories and manufacturing companies face various problems. We cannot find a single factory without a problem. Sometimes a problem will not end. Even if one problem is solved then another problem arises. Problem is not a bad thing, but knowing your problems can make you build the ability to face the problem with solutions accordingly. Understanding the problems, you can work for the better solution that keeps away from the frequent problems. Here are some problems that are normally faced by a lot of manufacturing companies.

Problem with Raw Materials:

Production floor doesn't get materials on time. Sometimes they receive materials in urgency with low quality and insufficient numbers. Sometimes the Sewing section receives input mistakes from the Cuttings section.

Delay in Production Start:

Planning department makes production schedules but in many cases the factory doesn't receive fabric before PCD (planned cut date). Line is ready with operators and machines but in-charge doesn't receive cuttings on the planned date. Sometimes the cutting department takes unexpectedly longer time which causes delay in sewing. May also happen due to delay of Size set making, pattern correction, delay in approvals from buyer.

Defect Generation in Sewing:

When garments are checked at the end of the sewing line, a number of defective garments are found. A defect may occur due to defective material or defective cutting or defect may be generated at the sewing stage. Or defects in garments may occur due to poor handling. Normally most of the defective garments are found after sewing. Even though some defects are found and repaired. Sometimes operators or line supervisors make mistakes due to poor communication.

Long Line feeding Time:

Line feeding time increases due to poor preparation. During the line feeding time In-charge / Supervisor / Quality should aware the workers about the client’s demand to do the good quality production.

High Lost Time:

Many productive hours are lost by operators due to various reasons. This may happen due poor interdepartmental coordination, delay in completion of previous process, layout imbalance, feeding shortage, machine adjustment problem and quality issues.

Operator Absenteeism:

With the operator shortage, operator absenteeism increases labour problems in the sewing floor. It causes defect percentage high and low productivity. Factories are paying an attendance bonus to attract operators to present maximum days in a month.

Frequent Change in Production Planning:

This often happens in factories where the production team loads a style to a line and certainly gets instruction to stop the style and load one urgent style. This breaks the production time, reduces line performance and increases the line cost.

Insufficient Information:

Factories conduct PP meeting and daily meeting. Even after meetings, details correct information is not passed to the production team. Due to delivery schedule pressure, bulk production is started without even getting the full requirements of the order.

Unskilled workers: 

Most of the illiterate workers employed in garments are unskilled and so their products often become lower in quality.

Lack of managerial knowledge:

There are some other problems which are associated with this sector. Those are lack of marketing tactics, absence of easily on-hand middle management, a small number of manufacturing methods, lack of training organizations for industrial workers, supervisors and managers, autocratic approach, negative attitude, incompetent ports, time-consuming custom clearance etc.

Lack of creativity:

Creativity is so important because every time the competitor tries to introduce new designs products in the market to use their creativity. So if we fail to show our creativity in our layout and uses of new technology we can’t touch the market.

Conclusion:

Industrial Engineers (IE) are working in garment production and facing new challenges every day. It would be a great discussion if we kindly add our points here. I mean what problems we find in our factory frequently.  I would like to improve it according to the current problems in the industry. We always want to solve a problem. But prior to looking for the solution you must study the problem and learn detailed knowledge of common problems occurring in garment production.


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This guide is part of our comprehensive Industrial Engineering Series. Access all 14 interconnected SOPs for Apparel Store Management in the master directory below to optimize your operations.

GARMENT STORE MANAGEMENT: MASTER SOP DIRECTORY


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