LEAN MODEL – GARMENT FACTORY DIGITALIZATION TOOL

Digitization in garment factories demonstrates the development of garment businesses in the 4.0 era. As we know, the Lean Model is one of the important support tools for factory digitalization . Lean is currently being applied by many Vietnamese businesses operating in the Garment sector with the purpose of increasing profits and minimizing costs and production waste.

However, some enterprises are not successful when applying Lean due to many different reasons such as only focusing on material changes, copying some tools, saving costs by using wrong solutions, etc. These problems happen because enterprises do not really understand and seriously invest in Lean.

In this article, ATSCADA will help customers, especially Garment businesses, understand the benefits of applying Lean to the production process. Besides, a number of leading units in the industry will be presented with typical achievements when “Implementing the Lean model”.

Why Digitalization in Garment Factories is important for every business?

Lean brings many practical financial efficiencies to businesses, such as reducing defective products and saving space for investing in new production lines without having to build factories or increase labor’s salary.

One of the successful businesses applying Lean is Nha Be Garment Corporation (NBC). Productivity of the whole system raises by more than 20%, especially, this leads to the emulation effort in production of each unit. Since implementing Lean, NBC’s employees have seen a one-hour daily reduction in work hours, as well as a Saturday afternoon absence from overtime.

After implementing Lean, Garment Corporation 10’s productivity has increased by 52%, the rate of defective goods has decreased by 8%, working time has reduced by 1 hour per day, income has improved by over 10%, and production expenses have reduced by 5 – 10% annually.

Viet Tien Garment Corporation has confirmed that Lean helped grow 14% in 2013 compared to 2012. Workers have a stronger spirit because they have more time to take care of themselves and their families.

Hoa Tho Textile and Garment Corporation lowered the number of goods in stock on the line from thirty to three. The percentage of defective items decreased from 20% to 8%; no overtime is required, yet the income is still the same.

SigA garment company, after implementing Lean, had a 20-30% improvement in productivity, reaching 650 USD per person/month. There are already lines that can produce one product in as little as 36–40 seconds, with a daily productivity of 800-900 goods.

In addition, Hung Yen Garment Corporation saw a 21% boost in productivity after implementing Lean on a single line in just three weeks. This demonstrates the necessity for garment enterprises of Lean.

Above are some businesses operating in the garment sector that have had outstanding achievements in production. As can be observed, digitization in garment factories is being done carefully and according to demands, which will undoubtedly result in remarkable production efficiency.

Businesses must seek out a credible and skilled business that specializes in Lean model implementation, identify issues that require improvement by getting down to work together.

Digitizing software pioneer for garment factories-ATSCADA

With over a decade of expertise in the industrial automation sector, ATSCADA is a leading brand when it comes to Lean system implementation. We have a range of customers operating in the garment industry: Vinatex, Quoi Chi, Moon Chang Vina, Phong Phu,…

ATSCADA is a provider of software solutions as well as entire systems including hardware. With a team of experienced human resources and a contemporary equipment factory, we guarantee to offer the highest quality products and equipment to market.

Production monitoring project for Vietnam Textile and Garment Group (Vinatex)

• The software is displayed and monitored directly via LCD screen and computer. At the same time through smart devices with internet connection (smartphone, tablet, laptop,…).
• The software interface displays intuitively, full information and production parameters as required:
• Time information: Day – Month – Year, Hour – Minute – Second
• Production parameters: Input products, Product codes, Total products, Rate of standard products, Implementation, Standard products, Production rate,… All of them are updated and calculated automatically in real time.

Production monitoring project for MoonChang Vina company

The monitoring software has full parameters: Production plan, Current output, Difference Rate, Performance, etc., which are displayed directly on the on-site monitoring dashboard & remote software monitoring.

Production monitoring project for Quoi Chi company

At the same time production information is displayed on led panels at production and monitoring software.

• Target: entered directly on the leaderboard or remotely via monitoring software.
• Actual (actual): input from the box button at the QC position (or automatically count the sensor depending on whether the product is suitable or not).
• Balance: (difference): auto feature on the software was set up.

Our projects are implemented and are operating stably over time. With quality hardware and monitoring software designed and manufactured to meet standards. Respond to requests from customers. Besides, the work of adding/removing features on the system is always answered quickly by ATSCADA.

Manufactured software of ATSCADA

Designed by ATSCADA Lab, this is a software lab that unites experienced engineers. With in-depth knowledge of production management and Lean model, the software is designed to be very intuitive and easy to use. Here are some benefits when using the software:

• Monitor and synthesize data in real time
• The software displays intuitively and vividly with diverse screens: Number (Excel), Chart (Chart)
• Easily retrieve data at any time
• The software has built-in automatic calculations of production parameters such as: Availability, Performance, Quality, OEE,…
• Remote monitoring solution anytime, anywhere only requires a network connection to the device: Smartphone, Tablet, Laptop,…
• Tool to set up complete information data, easy to understand,…

The system has monitoring capabilities and can centrally manage all scattered factories easily. This is the top strength when using ATSCADA’s system production. Especially for business operations in the industry, it can be default. There are many factories in many places and need centralized monitoring.

The leading brand in digitalization in garment factory – ATSCADA

We are always proud to be one of the leading brands. Providing production management solutions for the garment industry in particular and industrial manufacturers in general.

Our system prioritizes points and utilities that live up to customers’ expectations for selection. The system supports remote monitoring everywhere and anytime. This is an effective support job for the Managers and Board of Director to grasp the production situation ” ANYTIME – EVERYWHERE – EVERYTHING”

In addition, the system also supplies extremely helpful production status reporting tools. The report file interface is detailed, intuitive, easy to understand, full of output products for status evaluation.

Besides, the system also helps save energy and reduce costs for factory supervision and inspection managers.

Some images of production management software come from ATSCADA

Production management software is always updated by ATSCADA not only in terms of graphics (vivid, user-friendly). Besides, we always integrate convenient and smart features to serve our customers.

The software automatically calculates supporting LEAN parameters such as:

• Availability
• Performance
• Quality
• …

Benefits of choosing ATSCADA

ATSCADA, a long-standing and reputatable brand, will definitely have the best servers mode. Besides, quality and project implementation time are always our strengths to attract customers.

• Free support for enterprises and factories inspection everywhere
• System maintenance and upgrades assistance at any time
• Project implementation speed and acceptance always satisfy customers’ expectations and requirements.
• 100% work master, work security, system upgrades are always supported easily and quickly.
• Optimal supports of value, installation costs, etc.
• Skilled team for supporting the device monthly, anually, etc.

> See more:  factory digitalization solutions.

Through this article, ATSCADA hopes that customers will be given priority when using the Lean model. For any detailed information, advice or detailed support on: Lean models, production management systems, digitalization in factories in the machinery industry, etc. Please contact us via hotline.

ATSCADA - Providing ATSCADA software - The monitoring and data acquisition control system is the appropriate choice for integrated system projects, IoT, smart city projects, agriculture 4.0... Is trusted by many customers.