Case Study - Garment Manufacturer: New Efficiencies for Indonesian Garment Producer
Client
A garment manufacturer in Indonesia employs 4,000 workers producing knitted apparel products.
Challenge
The company was receiving pressure to change over from one style to the next more frequently with smaller production runs. During an operational assessment, TBM and the company discovered a major loss in efficiency due to excessive changeover times when switching to new styles. Changeover was taking an average of 35 hours. The annual sales growth objective was 15 percent, which needed to be supported by an equal or better increase in operating efficiency.
Solution
TBM and its client established a cross-functional changeover team to streamline the time required to changeover from last piece of one style to first piece output of second style. They needed to achieve a target speed or pace for every changeover in order to meet customer delivery requirements.
Results
- Changeover time reduced by 69 percent
- Productivity improved by 38 percent
- Quality improved by 31 percent
- Liberated capacity by 9 percent
- Sustained on time delivery close to 99 percent
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