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What are the "3 points" to improve productivity at the factory?
2 major issues : Machine operation ratio which directly affects sales and,
product quality which influences factory reputation.
We would like to introduce 3 points which help to solve these issues.SCROLL
The enemy of operation ratio
is needle breakage!One occurrence of needle breakage Around15minutes of work stoppage Around30minutes for mechanic
to adjust the machine A total of45
minutes lostThere are various factors which negatively impact to operation ratio in a sewing factory, but the biggest one is needle breakage. Of course we have to replace needles,and another cause of dropping operation ratio is the need to check for broken needles in products.
Reduce the amount of needle breakage to improve operating ratio!
One reason for inferior products :
insufficient worker skill!When it comes to making various types of items, sewing machines must be adjusted frequently and the operator has to have high levels of sewing skills. Without this, the lines keeps producing defective product. This leads to a loss of relationship with customer.
The operator should not be a factor in improved quality.
Reduce unproductive operations!
70% 30% Sewing machine operation ratio Non-sewing-related work
It is said that the actual time spent at sewing machine is 30% of the total working hours. The rest of the time is spent on processes which do not need sewing machine such as handling and setting material, making adjustments, and removing puckering. These operations are a barrier to improved productivity.
Minimize the machines' stop time to improve productivity!
Don't worry - Brother's innovative new technology
"DigiFlex Feed" can solve these problems.Preventing needle breakage leads to better operating ratio.
DigiFlex Feed technology feeds the cloth at the appropriate time to prevent needles bending or breaking. Even with thick materials which would normally break the needles, the cloth is not fed through at the moment the needle is inserted, thus there is less stress placed on the needle. The result is less needle breakage and an improvement in operation ratio.
Needle breakage per month for one machine
Conventional
model DigiFlex FeedEvery operator can achieve high quality with the suitable feed motion.
DigiFlex Feed has 4 different "feed motions" to choose from, which each provides different thread tightening, depending on the material. This will allow every operator to produce stable quality even with processes which once relied on a highly experienced operator.
Quality
upImproving productivity by reducing unnecessary setup steps.
Procedures which until now were done by hand are now handled digitally by DigiFlex Feed machines. The simple button operations can be carried out by even a new employee. This helps us to minimize machine stop times and leads to an improvement in line productivity.
Production numbers
Conventional
model DigiFlex FeedComments from owners
Quality has certainly improved. And feedback from buyers has improved too.
The burden on the operators has been reduced, and the retention rate has improved.
Using this DigiFlex machine, we get a positive response from buyers.
Success stories from users
*This movie is posted on YouTube.
*All the figures on this page come from Brother's data.
LINE UP
S-7300A
- Equipped DigiFlex Feed, which is digital feeding system
- We have achieved high quality sewing
- Needle breakage is down, and productivity is up
- Thread processing work has been reduced
- We can offer new value through design stitch
- Clogging at cross-over seam reduction
- Smooth operation through the color LCD touch panel
- Improved efficiency through remote switches
S-7250A
- Equipped DigiFlex Feed, which is digital feeding system
- We have achieved high quality sewing
- Needle breakage is down, and productivity is up
- We can offer new value through design stitch
- Handy control panels designed simple
- Improved efficiency through remote switches
For catalogue requests or consultation on improved productivity,
Inquiry
installation of sewing machines, etc,
please do not hesitate to contact usIs a workplace problem or issue causing you trouble?
IoT - from even a single machine.
Nexio series equipped with DigiFlex Feed feature network support as standard.
The network support function offers new value to customers through facility management by IoT.
