The production cost and speed are the deciding factors in textile manufacturing that determine whether a business will make a profit or suffer a loss. And hence top textile companies in India implement modern methods of production and inventory management models to reduce cost, work in process, as well as response times from fabric manufacturers in India to cotton buyers.
In this blog, we will explore modern production organization systems manufacturers can implement to minimize negative impacts on business productivity, risk management, and operational costs. They are Just-in-Time Manufacturing, Total Quality Management (TQM), and Toyota Production Systems (TPS).
If you want to know about the traditional production organization models for textile manufacturing, you can find them on TEXchange Global’s blog site.
Just-in-Time (JIT) Manufacturing
Just-in-Time (JIT) manufacturing is a widely adopted production model that focuses on efficiently meeting cotton buyers’ demand while reducing costs and speeding up fabric delivery. By eliminating waste associated with manufacturing, such as overproduction, wait times, and unnecessary inventory, cotton yarn manufacturers in India can implement an effective JIT strategy. In the textile industry, JIT plays a pivotal role in reducing the inventory of basic textile materials, such as linings, elastics, threads, buttons, and finished garments. This leads to flexible production for regular customers, streamlined workflows, and balanced capacities.
JIT for Fabric Manufacturers in India
By adopting this method, top textile companies in India optimize their production processes by aligning them with wholesalers’ and retailers’ demands. This results in a highly responsive and customer-centric operation. Moreover, synchronized workflows and balanced capacities further improve efficiency, leading to reduced lead times and increased productivity.
Benefits of Just-in-Time Manufacturing
- Reduces inventory space and cost
- Reduces labor costs
- Decreases Work in Process and the need for larger production space
- Boosts and streamlines production
- Improves production quality by lowering the rate of defects
- Cuts down throughput time and standard hours
- Quickens delivery and TAT
To implement a JIT production system, manufacturers must be disciplined, well-structured, and explicitly explain the strategies and processes.
A true JIT system goes beyond simply reducing inventory levels. It involves maintaining a tidy and organized workspace, addressing defects promptly, adopting flexible changeover approaches and setup reduction, using small lot sizes, achieving uniform plant load through leveling, actively managing flow with balanced batch sizes, promoting skill diversification among workers, enhancing communication with visual tools for better control through visibility, designing for efficient processes, streamlining material movement, adopting cellular manufacturing, and implementing a pull system with the help of Kanban.
In order to make JIT successful in garment manufacturing, businesses must meet the following requirements.
- Produce quality products
- Maintain zero to minimal inventory
- Create solid associations and collaboration with customers (suppliers and retailers)
- Ensure suppliers are located near the manufacturing unit
- Have reliable logistics and transportation
- Make sure production size aligns with consumer demand
- Develop an efficient team and unparalleled teamwork
Toyota Production System (TPS) or Lean manufacturing
The Toyota Production System (TPS) is a lean manufacturing approach streamlining a business’s manufacturing and logistical operations. Originally developed by Toyota, this methodology focuses on automobile production but has since been adapted for use in other industries, such as yarn and fabric manufacturing. By implementing TPS, yarn manufacturers in India can enhance their organizational efforts, reduce waste, and ultimately improve their profitability.
Principles of Toyota Production System in the Textile Industry
The Toyota Production System (TPS) is widely acknowledged as a significant driver behind the evolution of Lean manufacturing and various other related concepts that are prevalent today. Whether a yarn manufacturer in India or operating any other type of workplace, studying TPS can provide valuable insights that can foster innovation and lay the groundwork for implementing a range of workplace innovations.
- Focus on long-term financial goals
- Create a streamlined process for documenting and understanding production issues
- Use pull systems to avoid overproduction. It reduces inventory significantly
- Avoid employee burnout by distributing and leveling the workload
- Motivate teams to fix problems as soon as they arrive with positive work culture
- Standardize operations and workplace tasks to eliminate confusion
- Use technology, such as visual tools, to streamline operations and help employees identify crises faster
- Grow strong leaders who can pass on the TPS philosophy and methodology to their subordinates
- Create a stable manufacturing unit and business culture with training and development
- Have excellent rapport with suppliers, vendors, and trading partners
- Use tested techniques like Gemba to identify shortcomings in the process and recognize scopes for improvement
Lean manufacturing eliminates inefficiencies and streamlines operations to enhance productivity. It involves continuous improvement, value stream mapping, and standardized work and applies to all aspects of the business system.
Total Quality Management (TQM)
The Total Quality Management system in textile manufacturing is designed to improve production and create a customer-focused organization. It ensures that all workers and staff are in an environment of continuous improvement.
Total Quality Management (TQM) is a continuous and methodical process of identifying, minimizing, or eliminating errors in the manufacturing process. TQM focuses on optimizing supply chain management and improving the customer experience. Employee training and development are essential components of TQM, which aims to instill a sense of responsibility among everyone involved in the production process. The ultimate objective of Total Quality Management is to ensure a steadfast commitment to the highest quality of the final textile product, be it yarn, fabric, or thread.
Eight Guiding Principles to TQM
This process aims to enhance the quality of outputs, such as goods and services, produced by fabric manufacturers in India. This is achieved through ongoing improvement of their internal practices.
- The business should be customer-focused. No matter what the top textile companies in India do to improve quality, whether it is training, new technology implementation, or new designs – the customer, i.e., cotton buyers, will evaluate the company.
- All employees should be totally involved in achieving the business goal. This can be achieved through leadership, motivation, and training.
- The production organization planning must be process-centered.
- Implement integrated systems that streamline functions and improve collaborations.
- A strategic and systematic approach that integrates quality as a core component to achieve an organization’s vision, mission, and goals.
- Continually improving all aspects of manufacturing operations to drive manufacturers to be both analytical and creative to beat the competition.
- Make decisions based on facts by collecting and analyzing data in real-time. TEXbulletin can help fabric manufacturers in India obtain insights for accurate decision-making.
- Ensure effective communication between employees across all levels.
Efficient production organization systems can change how cotton yarn manufacturers in India improve production, reduce cost, and satisfy cotton buyers. Implementing modern methods like Just-in-time manufacturing and lean manufacturing and embracing technology and process automation, like our platform ‘TEXchange Global,’ can significantly improve efficiency and sales.
