The global apparel and textile industry has undergone massive changes in recent years. With rising labor costs, increased competition, and pressure for faster turnaround times, garment manufacturers need to adopt innovative strategies to stay ahead of the curve. Improving productivity is crucial for surviving in today’s dynamic fashion marketplace.
Productivity refers to the efficiency of production, measured by comparing inputs like labor and capital to output. For garment factories, key productivity metrics include items produced per operator hour, production lead time, quality rate, and material utilization. By optimizing these factors, manufacturers can enhance their profitability and responsiveness.
As we head toward 2024, the industry is primed for a new wave of technological and operational advancements that will reshape garment production. The factories of the future will leverage automation, real-time data, and connected supply chain networks to achieve maximum output. Investments in skills training and quality control will also be critical for productivity gains.
This article highlights ten important ways garment manufacturers can boost productivity levels by 2024. Implementing these strategies will require both technological and human capital investments. However, the long-term benefits for efficiency, speed, flexibility, and quality make the effort worthwhile. Companies that proactively adopt forward-thinking best practices will gain a competitive advantage.
The key opportunities for productivity improvement include optimizing production planning, increasing automation, empowering workers, utilizing data analytics, and creating collaboration across the value chain. By tapping into these areas, garment producers can save time and costs while satisfying customer demands for speed, personalization and excellence. Plants that upgrade their processes today will be best positioned for the digital, consumer-driven landscape of 2024 and beyond.
Invest in Automation and Digitalization
One of the biggest opportunities for improving productivity lies in adopting advanced automation technologies and digital platforms. By 2024, garment manufacturers can realize large productivity gains by investing in the following:
- Automated material handling – Automated guided vehicles, conveyor systems, robots, and automated storage and retrieval systems streamline material transport and inventory management. This saves labor and speeds up the flow of work-in-progress.
- Digital sewing systems – Digital features like automatic seam length adjustment, thread trimming and automatic lubrication improve sewing efficiency. IoT-enabled machines provide data for monitoring and optimizing performance.
- Automated spreading & cutting – Automated fabric inspection, fabric relaxation, pattern alignment, and cutting systems boost cutting productivity and accuracy. ERP integration optimizes cutting plans.
- Automated pressing & finishing – Automated machines for tasks like fabric inspection, pressing, embroidery, laser finishing and tunnel ovens improve quality and reduce labor.
- Warehouse automation – Automated sortation, picking and tracking systems help optimize warehouse inventory management and order fulfillment. This improves material flow to the shop floor.
- Manufacturing Execution Systems – These digital production management systems provide real-time visibility, analytics and tools for monitoring, controlling and improving manufacturing processes.
- Digital workflow tools – Mobile apps, digital work instructions, eKanban, and paperless workflow tools boost efficiency and flexibility on the shop floor.
With greater connectivity between equipment, machines, systems and people, manufacturers can transition to smart, data-driven production. By automating repetitive tasks, garment factories can refocus human effort on more value-adding activities. The result by 2024 can be dramatically improved productivity and responsiveness.
Optimize Production Planning and Scheduling
Efficient production planning and scheduling is vital for maximizing productivity in garment manufacturing. By taking a strategic approach to organizing workflows, factories can significantly increase output and reduce delays. There are several impactful ways garment manufacturers can enhance planning and scheduling by 2024:
- Implement advanced planning and scheduling software – Sophisticated digital tools will optimize capacity planning, production sequencing, inventory management, and other scheduling activities. AI-enabled systems can account for hundreds of constraints and provide real-time visibility for smarter decisions.
- Adopt modular production methods – Breaking down production into simplified segments with standardized operations improves flexibility and flow. Modules make it easier to balance workloads.
- Improve coordination between design and production – Aligning product development and manufacturing planning reduces errors and saves time. Cross-functional collaboration avoids schedule disruptions.
- Create optimized production lines – Grouping similar products and processes together on production lines improves efficiency. Smooth workflow between workstations eliminates bottlenecks.
- Build in schedule flexibility – Building in extra capacity, skilled multi-tasking workers, and production line agility accommodates rush orders and priorities changes.
- Leverage data for forecasting – Analyzing past production data enables more accurate demand forecasting. Machine learning can help predict output requirements and material needs.
- Refine planning parameters – Regularly updating standards and assumptions used for planning ensures schedules reflect real production capabilities and constraints.
With more strategic scheduling achieved through advanced analytics, modular manufacturing, and supply chain integration, garment producers can gain the speed, responsiveness, and efficiency needed to thrive in today’s market. Smarter planning directly translates into higher productivity.
Improve Inventory and Warehouse Management
To maximize productivity, garment manufacturers need to ensure optimal inventory levels and warehouse operations. Excess inventory ties up working capital while inadequate stock levels lead to production delays. Smooth warehouse activities are essential for supporting production workflows. By 2024, garment producers can upgrade inventory and warehouse management in the following ways:
- Implement inventory optimization software – Advanced analytical tools can help determine optimal inventory levels across raw materials, WIP and finished goods. This reduces carrying costs while preventing stock-outs.
- Introduce standardized processes – Documented, consistent procedures for activities like receiving, put-away, picking and counting streamline warehouse workflows.
- Leverage automation – Automated sortation, picking, tracking and inventory counting reduces labor requirements and boosts accuracy.
- Improve inventory accuracy – Cycle counting, barcoding, and RFID tracking enhances inventory record precision for better planning and control.
- Redesign warehouse layouts – Optimized layouts, storage locations and material flows using Lean principles improves efficiency and space utilization.
- Enhance coordination with suppliers – Collaborative planning, forecasting and replenishment with suppliers reduces variability in material availability.
- Provide employee training – Investing in skills upgrading for warehouse staff improves productivity through expert operations and material handling.
- Upgrade WMS and ERP systems – Modern IT tools synchronize inventory data across the supply chain, enabling smarter and faster decisions.
With real-time inventory visibility across the value chain, garment companies can avoid bottlenecks. Smooth material flows allow factories to operate at peak efficiency. Enhanced inventory and warehouse management is integral for higher productivity.
Focus on Lean Manufacturing Principles
Adopting lean manufacturing principles will be an impactful way for garment producers to improve productivity leading into 2024. Lean methods eliminate waste, reduce costs, and promote continuous improvement across production processes. Key strategies include:
- Improving workflow – Analyze and optimize production flow using value stream mapping. Smooth workflows prevent delays at choke points.
- Reducing changeover times – Use SMED techniques to streamline changeovers between product variants for more uptime.
- Building in quality – Employ poka-yoke methods to prevent defects from occurring rather than inspecting after.
- Creating production cells – Group similar processes together for better flow and fewer disruptions between steps.
- Enabling continuous improvement – Engage staff in kaizen events and process improvements through tools like 5S and standard work.
- Monitoring performance – Use kanban, productivity boards and key metrics to identify issues and improvement opportunities.
- Developing a pull system – Move to just-in-time production that is demand-driven rather than supply-push.
- Eliminating non-value-add steps – Critically evaluate processes to remove any activities that do not contribute value for the customer.
With lean principles permeating all facets of production, garment factories can build a smooth, efficient system that wastes no time, effort or material. By preventing losses, enhancing flow, and engaging staff, lean manufacturing builds the foundation for world-class productivity.
Implement Advanced Quality Control Systems
Stringent quality control is essential for driving productivity in garment manufacturing. Defects disrupt production workflows and waste time and materials. By 2024, manufacturers can leverage advanced technologies and analytical tools to prevent errors and achieve right-first-time quality:
- Automated inspection systems – Machine vision systems rapidly and reliably detect fabric flaws, correctly placed patterns, and finished garment defects. This prevents rework.
- Data-driven analytics – Collecting and analyzing real-time defect data identifies root causes. Data visualizations highlight quality issues.
- Predictive analytics – AI and machine learning models forecast potential quality failures from historical data, enabling proactive corrections.
- Digital worker instructions – Digitized work manuals, photos, videos and markings ensure proper training and consistent quality application.
- Product lifecycle management – Centralized data allows tracking of all processes and parameters from design to production to pinpoint risks.
- Closed-loop corrective actions – Mandatory failure analysis and corrective actions ensure problems are systematically eliminated at source.
- Real-time monitoring – IoT sensors on machines enable tracking of live data to remotely diagnose and resolve issues as they occur.
- Model factories – Test out process changes on a small scale first to validate enhancements before full implementation.
By integrating and correlating multiple data sources, garment producers can exert much tighter control over manufacturing variation, leading to uniformly high quality and productivity.
Provide Training and Skill Development for Workers
Garment workers are the backbone of manufacturing productivity. Investing in continuous training and skill development will maximize the potential of human talent. Some impactful initiatives by 2024 include:
- Technical skills upgrading – Provide on-site vocational training in areas like operating automated equipment, digital systems, and specialized machinery.
- Multi-skilling programs – Train workers in multiple functions to improve workforce flexibility and line balancing.
- Management training – Educate supervisors and managers in leadership strategies, communication, and problem-solving tools.
- Continuous learning ethos – Foster a culture of ongoing education and growth through classroom and on-the-job learning.
- Cross-training – Rotate staff through different departments and roles to broaden experience and perspectives.
- Skills certification – Benchmark worker capabilities and provide credentials to align skills with production needs.
- Ergonomic training – Educate workers on proper techniques for lifting, sitting, stretching to prevent injuries.
- Performance management – Provide coaching and mentoring for workers to reach productivity goals and maximize strengths.
- New hire onboarding – Use robust onboarding programs to integrate new workers seamlessly into production.
Factories that invest heavily in their people will reap dividends in optimized performance and productivity. A highly skilled, expanding workforce will drive the flexible, high-quality manufacturing needed for the future.
Foster Collaboration Through Vertical Integration
By 2024, apparel brands and manufacturers can no longer operate in silos. Vertical collaboration across the value chain is key for improving productivity. Strategies include:
- Strategic partnerships – Brands and manufacturers work jointly on product development, forecasting and supply planning for faster time-to-market.
- Vendor managed inventory – Suppliers access brand inventory data to proactively replenish stocks, reducing stock-outs.
- Contract manufacturing – Brands work closely with trusted contract manufacturing partners for greater flexibility and capabilities.
- fabric platform – Connect raw material suppliers, mills, manufacturers and brands on a shared platform for collective planning and development.
- Data integration – Share sales, inventory and production data across the value chain for visibility and coordinated decision-making.
- Co-location – Locating upstream and downstream partners in the same facility improves communication and responsiveness.
- Joint capability building – Brands fund skills training and process improvements at manufacturer facilities to upgrade capabilities.
- Collaborative forecasting – Leverage input from all stakeholders to produce more accurate demand projections and capacity plans.
- Risk and reward sharing – Enter into agreements that share costs, risks and benefits to align incentives.
With greater interconnectedness and transparency between players, the apparel industry can unlock synergies that maximize productivity at every link in the chain.
Utilize Real-Time Data Analytics and Forecasting
Valuable data is generated at every step of garment production. By 2024, manufacturers can tap into analytics and machine learning to translate this data into productivity gains. Key approaches include:
- Data collection sensors – IoT sensors on machines and throughout facilities collect granular real-time data on production, quality, equipment performance and more.
- Central data platform – A digital platform consolidates and structures data from all sources into an integrated, unified view.
- Dashboards and visualization – Data analytics transform numbers into actionable business insights via digital dashboards, scorecards and data visualizations.
- Predictive capabilities – Machine learning algorithms analyze data to predict demand, maintenance requirements, quality issues and other variables to optimize planning.
- Simulation and digital twin – Digital twins and simulation enable modeling of scenarios to assess productivity impact before actual change implementation.
- Automated notifications – Real-time automated alerts notify managers of potential bottlenecks, low material stocks, machinery failures etc to enable quick response.
- Data-driven decisions – Insights derived from analytics inform planning decisions at a granular level regarding capacity, staffing, maintenance, inventory etc.
- Continuous improvement – Identify data-driven improvement opportunities related to layout, processes, supplier performance, logistics and more.
By fully utilizing advanced data analytics, garment factories gain unparalleled visibility into all factors impacting productivity. Proactive optimization driven by real-time data will be a key competitive advantage.
Adopt New Product Development Processes
Streamlining the path from design concept to production is crucial for responsive, efficient garment manufacturing. By 2024, digital tools and collaborative approaches can enhance product development:
- Digital design – CAD software, 3D visualization, and other digital tools enable faster design iterations and modifications.
- Virtual sampling – Digital samples reduce waste and compress development timelines compared to physical sampling.
- Automated grading – Software automatically generates required size sets from base patterns, avoiding manual grading.
- Tech packs – Digitized tech packs allow instant communication of detailed product specifications to material suppliers and manufacturers.
- Costing analytics – Data-based algorithms help predict costs and identify savings opportunities early in product development.
- Collaborative workflow – Cross-functional teams involving design, engineering, manufacturing, and sourcing collaborate for concurrent workflows.
- Design for manufacturing – Design choices consider production requirements, capabilities, and constraints.
- Knowledge management – Centralized records of fittings, alterations, and corrections capture learning to improve future products.
- Supply integration – Early supplier involvement for material selection, manufacturability feedback, and lead time estimation.
With seamless information flows and early alignment between design and production, garment companies can maximize quality and productivity right from product inception.
Create an Ergonomic and Employee-Friendly Workspace
The production floor environment has a major impact on garment worker productivity, safety, health, and satisfaction. Manufacturers that invest in optimizing workspace ergonomics and amenities will gain benefits including:
- Ergonomic equipment design – Customize machines, chairs, tables, and other tools to fit worker anthropometrics and reduce strain.
- Sit-stand workstations – Height-adjustable workstations prevent fatigue and stress from prolonged sitting or standing.
- Proper lighting – Ensure adequate light for tasks without glare or eye strain through natural light and task lighting.
- Air quality – Monitor and control temperature, humidity, and air circulation for worker comfort and respiratory health.
- Noise control – Engineer facilities to minimize hazardous noise through sound-dampening materials.
- Safety design – Incorporate safety guards, sensors, markings, and protective gear needed for hazard-free operations.
- Stretch zones – Provide open areas for guided movement breaks to alleviate repetitive-motion strains.
- On-site amenities – Offer health facilities, canteens with nutritious meals, and recreation to support wellbeing.
- Communal spaces – Designate open comfortable areas for social interactions and relaxation during breaks.
An optimal working environment boosts engagement, focus, satisfaction, and health – all critical ingredients for human productivity. Worker-centric facilities will be a source of strategic advantage.
Conclusion
Achieving a step change in productivity will be imperative for garment manufacturers to remain competitive in the coming years. While automation and digitization are important pieces of the puzzle, optimizing human and operational elements are equally crucial. By taking a holistic approach across technology, processes, people and collaboration, manufacturers can build purposeful, data-driven factories that maximize output, cost-efficiency and flexibility.
Companies that delay investing in productivity risk obsolescence. However, those putting in place robust solutions for planning, quality, skills development, workflow, and more will gain a distinct advantage. Tapping into the opportunities outlined in this article can help garment producers become responsive, high-quality, low-cost suppliers to global brands.
Ultimately, a sound productivity enhancement strategy must align with a company’s unique capabilities and constraints. While learnings can be derived from industry best practices, each manufacturer will need to chart its own path. Lasting gains require building a culture of continuous improvement across both processes and people. The garment factories that will thrive into 2024 and beyond are those harnessing technology while developing their human capital. With the right vision and execution, substantial productivity gains are certainly within reach.
