The Application Research Of One Piece Flow In The Production Of Trousers Enterprises

At present the market economy leads to a more intense competition which requires thegarment enterprise to pursue the quick responsibility of market, higher quality, lower cost andshorter delivery time simultaneously. One-piece flow is one of the effective tools about leanproduction. This effective model allows garment enterprises to reduce wip inventory, saveresources, arouse the enthusiasm of staffs, reduce costs and enhance competitiveness. One-pieceflow implements the pull type production. The characteristics of this process are specification ofproducing targets, quantification of producing time, the faster output of product, responding qualityproblems quickly, achieving higher efficiency and quality of products. Meanwhile theimplementation of the one-piece flow requires adequate preparation and cooperation of productionconditions. About80%of China’s garment enterprises implement one-piece flow unsuccessfully.To solve this problem, on the basis of several enterprises’ successful experience and failure lessonwe further summarize the core premise of one-piece flow. During this study we adopt WITNESSsimulation method, field study method, case method, thorough production line.This paper analyzes the implementation requirements of hardware, software and staffs in-depth. The hardware includes arranging assembly line, equipment, transmit tools, machinery andequipment in place, material preparation reasonably, production template, production accessories,tempo controller, warning light and production card etc.. Software requires enterprise system,floating rate, process analysis, motion study, appropriate staffs and location, the number of dailyoutput, change the style smoothly,5S, eight types of production waste, quality control, logisticsefficiency, visual management and ergonomic etc.. Staffs require senior leadership, workshopdirector, team leader, QC, IE, machine repairman, seamer etc. Garment enterprises need to and follow an orderly way step by step, which can improve enterprise competitiveness. We take afamous pants processing enterprise which introduced one-piece flow production line as the researchobject. After nearly one year’s tracking and research, this paper summarizes the productionpreparation and productive maintenance. In addition, We demonstrate how to from hardware,software and Staffs aspects in detail in order to achieve the improvement in one-piece flow. Forenterprises which are suit for one-piece flow and which aren’t suit but are willing to promote, weprovide implementation steps and providing theory and practice basis for the upcoming one-pieceflow production enterprises.WITNSSS is a mature simulation system which is widely used in the manufacturing andservice sectors such as automobile, aerospace, chemical industry. To solve the difficult problembefore production, we apply the software to clothing dynamic simulation for the first time, whichcan greatly improve synchronization problem in One-piece flow implementation. We can providethe guidance of flexible simulation for the production status, data basis for decision makers, theoptimization of scheme by applying the WITNESS simulation software to knit operation pantsproduction line. It’s of great significance for gaining production efficiency and laying a solidfoundation for the related dynamic scheduling software development.