Clothing: how process innovation can reduce costs

Here at Delta, we always reinforce the need for textile industries to modernize production and invest in innovation in manufacturing processes. There is no longer room for backward companies, with outdated and inefficient procedures and equipment. This scenario intensifies even more in times of recession, like the one we are experiencing due to the coronavirus pandemic.

With this in mind, we prepared this article with the main strategies and measures that need to be adopted and reviewed to innovate in your production and not lose competitiveness. Understand and see how to survive the economically turbulent scenario.


Carry out a process analysis to achieve innovation in manufacturing

The economic scenario changes, demands change and several other aspects that impact your production are volatile. Therefore, it is necessary to carry out an analysis to review and make appropriate adjustments to industry processes.

Process innovation in manufacturing-information-graphics

The objective of this “scan” is to find production bottlenecks, production imbalances, sectors in which employees need training and other problems in manufacturing that could harm productivity and quality control.


Work on productive gain

Among the most important objectives of process innovation in manufacturing, we highlight production gains. The increase in capacity and production efficiency is linked to gains in competitiveness, revenue and quality.

The most efficient and important way to achieve this is process optimization. You need to invest in machinery that meets your production needs and allows you to speed up the production phases.

For example, think of a knit and fabric relaxer. While a traditional rest procedure takes 24 to 48 hours, this equipment does the same job in a matter of minutes. As a result, in addition to production and time gains, several flaws and waste are eliminated, making the product more quality.


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Reduce the percentage of second quality

Another necessary measure for process innovation in manufacturing is the reduction of the level of second-quality products and raw materials. This term is used to define fabrics with holes, stains, variations in dimensions, colors and other non-standardization problems.

In the textile industry, the second quality is synonymous with waste, as it even affects your image among your customers. After all, even if they are not thrown away, these materials cannot be used in other stages, as most of these defects are irreversible. In other words, this second quality control results in more products suitable for commercialization.

To overcome this problem, it is necessary to implement rigorous quality control processes for any and all raw materials and inputs that enter the company. In addition, of course, to having supplier management with strict criteria regarding the quality of what is negotiated.


Process innovation in manufacturing-E-book-How to ensure quality control in the textile industry?


Optimize testing steps

Testing represents an essential step for the quality of your products and their manufacturing. However, if they are not modernized and automated, in addition to failures going unnoticed, they require time and other valuable resources for their production.

To optimize this activity, gain productivity and reduce costs, one of the machines that makes a big difference is a sample washer. This equipment evaluates the percentage of mesh shrinkage and performs fading tests in just three minutes. This means your production can test a greater quantity of fabrics in less time.


Process innovation in manufacturing - infographic


Classify suppliers to innovate in manufacturing processes

The first step in supplier management is classification. This is done so that you can know who and what to count on when you need to replace some equipment, inputs and raw materials.

This categorization must be done according to criteria such as product quality and delivery. After all, these are factors that will affect your production. To do this, ask questions such as:

  • Does the supplier deliver on time?
  • Is the raw material of quality and within our parameters?
  • Does the partner meet ISO 9001 certification?
  • Is service and support fast?

The quality of its suppliers and, consequently, of the inputs used in its production, reduce the amount of mesh and other fabrics that are wasted.


Modernize your production

The modernization and innovation of manufacturing processes is the bridge to cost reduction, competitiveness and efficiency gains. Old and inefficient machinery takes time to complete the steps, has many faults, needs to undergo a lot of maintenance and can also consume a lot of electricity.

In addition to putting the safety of operators at risk, as many old machinery are not adapted to NR12. In industry, time is money and therefore reducing time also eliminates costs.

Automation with modern equipment also guarantees quality gains and the minimization of failures and elimination of many errors. In modernization, there is also a reduction in waste, as modern and efficient machinery avoids the use of more mesh than is necessary, as they are calibrated to the millimeter.. In other words, they do not use more fabric or packaging than is really necessary.

Investing in process innovation in manufacturing is a strategic way to get through economically troubled times, as it is possible to achieve productive gains and eliminate costs. Furthermore, this factor, which also encompasses modernization, is a primary factor in gaining competitiveness and market space.

Speaking of controlling the inputs that enter and the products that leave your production, check out what quality control is and how it works in the textile industry.

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Delta Equipamentos was born out of the need for textile industries to optimize their production, aiming for greater competitiveness and constant updating in the globalized market. We offer innovative products and customized solutions, meeting the expectations and needs of our customers.