Layout planning with the style changeovers in development centers: A case study in apparel industry

Purpose: We conducted this study in a selected garment manufacturing firm, where the sample room used a fixed layout system. As a result of this, inefficiencies can be noticed with the frequent style changeovers. Resultantly, the firm had to confront several non-value added activities, which in turn, incurred additional costs. We attempted to identify the importance of the sample room layout planning with style changeovers to improve this firm’s operational efficiencies. Methodology: We collected data referred to one garment cluster representing both fixed and pre-planned layouts. We intended to provide a head start in finding out the factors that contribute to less productivity and less efficiency experienced by the apparel development centers due to poor layout methods. We used graphical representation to understand positives and negatives of layout methods and make conclusions. Findings: The results identified a positive impact of operator motion reduction, and improved the sample room efficienc. Further, we also noted that enhanced layout assists in reducing sample sewing delays, which in turn, facilitate fewer fit cancellations. Moreover, we facilitated the pre-planned layout in order to reduce sample completion time. Implications: Effectively, we identified the importance of layout planning according to the style changeovers, especially with regard to the study factors selected for the development centers in the apparel manufacturing sector. An effective layout management technique always enables to shorthand the production process, which ultimately reduces operational costs. Originality: Elimination of non-value adding activities when updating the layout is always profitable, and improves the overall performance of a firm’s operations.