Pre-production activities in the garments industry refer to all the essential tasks completed before bulk production begins. These activities ensure that production runs smoothly, efficiently, and with minimal defects. The key pre-production activities include:
1. Sample Development – Creating proto samples, fit samples, size set samples, and pre-production samples for buyer approval.
2. Fabric & Trim Approval – Sourcing, testing, and approving fabrics, trims, and accessories to meet buyer requirements.
3. Pattern Making & Grading – Developing accurate patterns and grading them into different sizes.
4. Consumption & Costing – Calculating fabric and material consumption, costing per garment, and setting price margins.
5. Production Planning & Line Layout – Organizing production schedules, defining the workflow, and preparing the line layout for efficient manufacturing.
6. Risk Analysis & Pilot Run – Identifying potential risks in production and conducting pilot runs to resolve issues before bulk production.
Quick Changeover (QCO) is a lean manufacturing concept aimed at reducing the time required to switch from one style to another in garment production. The goal of QCO is to minimize downtime, maximize efficiency, and increase production flexibility.
Key Steps in Reducing QCO Time:
1. Preparation in Advance – Ensuring all necessary materials, trims, and tools are available before the style change.
2. Standardized Work Methods – Using standardized machine settings, attachments, and templates to streamline the changeover process.
3. Operator Training – Training operators and technicians to quickly adjust machines and workstations.
4. Parallel Processing – Performing some changeover tasks while production is still running to save time.
5. Use of SMED (Single-Minute Exchange of Die) – Implementing techniques to complete changeovers in the shortest possible time.
By implementing QCO strategies, garment factories can reduce style changeover times, improve production efficiency, and enhance overall productivity.
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