Improving Change Over Process using Operational Excellence in the Textile Industry

Abstract

In today’s fast-paced fashion industry, staying competitive means creating quality products efficiently and agilely. Industrias Valores is a textile company that has been producing quality formal apparel for men since the 1990s. At Industrias Valore, the Polo Shirt production line faces a critical challenge: prolonged model changeover times that can reach 368 minutes, especially with less common designs. This bottleneck not only drives up costs but also limits our ability to meet dynamic market demands and customer expectations.  This project aims to transform this process, slashing changeover time from 368 to 60 minutes within 18 weeks. By standardizing processes, empowering the team with rapid adaptation skills, and fostering seamless communication across departments, we are setting the foundation for a leaner and faster production line. The approach includes rigorous training, efficiency testing, and targeted analysis with Lean Manufacturing tools, such as SMED, standardized processes, and 5S's.  All these tools are shown using the A3 methodology.  Early results are promising, with noticeable reductions in changeover times hinting at a new era of productivity for Industrias Valore. By aligning these enhancements with customer-facing metrics, this project optimizes the back end and fortifies our reputation to be more competitive in the market. In conclusion, this initiative is more than just operational efficiency—it’s about delivering on our promise of quality, speed, and innovation to keep Industrias Valore at the forefront of the textile industry.