9 Reasons of Delay to Setup a new Sewing Line

Industrial engineers and production managers are constantly on the lookout for ways to increase the efficiency of the sewing floor. But sometimes, it becomes challenging as sewing lines lose a significant amount of time in line settings. Increased line setting time is currently one of the most evident factors contributing to reducing overall factory productivity. When line setting time is increased, the operators cannot devote their full attention to the production of the garment, resulting in decreased operator productivity and increased labor costs.

Line supervisors and engineers have a dozen of reasons, when asked why they spend so much time setting up a sewing line. Line setup takes a long time for a few reasons. Some of them are mentioned below.

Reasons of Delay to Setup a new Sewing Line

Line setup takes a long time for a few reasons. Let’s discuss the main points that cause a longer time for line setting.  

✔ Once all operators have been released from the previous style, the factory begins loading a new style.

✔ Related persons are not concerned about the new style

✔ Not enough operators for all operations of style

✔ Line plan changed frequently

✔ In the initial operations as well as in the critical operations, no operators were present.

✔ Not all trims have been approved or sourced. No operation can begin unless essential trims are sourced.

✔ If layout started with unsourced garments parts. Sometimes printing and embroidered parts are not in-house once the line layout starts.

✔ The supervisor did not evaluate each operation sequence or skill required in style.

✔ Not allocation of the correct operator to the proper process.

✔ The maintenance technician cannot set up the machine on time. The replacement of the machine, setting guidelines, and attachment takes far longer than it should have taken.