Prevention is always better than cure, especially when machines and equipment worth thousands of dollars are involved. 

According to a study, apparel manufacturers may face an average downtime of 800 hours a year, the cost of which can be as high as $30,000 to $50,000. The breakdown of machinery not only causes losses occurring from the loss of business that results from inactivity, but could also lead to hefty repair costs.

Garment manufacturers can avoid these losses by adopting a preventive maintenance strategy. Such an approach involves continuous monitoring, scheduled inspections, and timely servicing of their machines and equipment. Preventive maintenance, especially when coupled with software solutions that streamline task monitoring, schedule maintenance activity, and issue timely alerts during breakdowns and disrepair, can help manufacturers save money.

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Understanding Preventive Maintenance

Preventive maintenance can be thought of as a regular, scheduled practice that occurs routinely in a garment manufacturing unit before a piece of equipment breaks down. Whereas, reactive or corrective maintenance occurs after there has been an issue or disrepair with the machinery.  

Manufacturers must develop and maintain a maintenance schedule laying down the frequency and determining the timing of the inspections. They must consider several factors while conducting the maintenance of equipment and machinery like:

• Scheduling inspections during non-peak hours to minimize disruptions during production.
• Developing checklists for each type of machinery to ensure all critical components are covered and failure points addressed.
• Creating standardized inspection forms to ensure consistency across all inspections.
• Training personnel like machine operators in inspections and assigning them to perform inspections.
• Conducting preliminary external examination by looking for visible signs of wear and tear and ensuring cleanliness to avoid debris from affecting operations.
• Testing of controls, switches and safety features by performing operational testing.
• Classifying various areas of machine maintenance like lubrication and fluid levels, electrical components, and mechanical components.  
• Documenting inspections to create inspection records and report to seniors management and supervisors.
• Following up after inspections to conduct immediate minor repairs, to prevent them from escalating.
• Maintaining an inventory of critical spare parts to enable quick replacements.

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Insights from Other Manufacturing Sectors

Apparel manufacturing may take cues from a range of other manufacturing sectors that practice proactive and preventive maintenance of machinery. The automotive and general manufacturing sectors are excellent examples of this. Let’s look at what the apparel industry can learn from them:

1. Regular scheduled maintenance

Manufacturers of automotives conduct scheduled maintenance activities regularly that include brake inspections, tire rotations, and oil changes. The apparel industry can similarly ensure scheduled maintenance of sewing machines and cutting equipment. 

2. Use of diagnostic tools

Automobiles manufacturing, and the vehicles themselves, are often equipped with diagnostic tools that help monitor a number of parameters. Apparel manufacturers could consider deploying diagnostic tools and IoT sensors to monitor the performance of machinery in real time. This real time data collection and analysis can help detect early signs of wear and tear, allowing for timely maintenance interventions.

3. Predictive maintenance

The automotive industry increasingly uses predictive maintenance, leveraging data analytics and AI to predict when parts are likely to fail. This approach minimizes unplanned downtime and maximizes the efficiency of maintenance activities. Apparel manufacturers can adopt similar predictive maintenance strategies to anticipate and address machinery issues before they disrupt production.

4. Ensure cleanliness systematically

The Hazard Analysis Critical Control Points (HACCP) approach, in addition to automated cleaning systems, is used in food and beverage manufacturing to ensure food safety by maintaining the equipment in a way that it prevents contamination. Apparel manufacturers may implement such systematic maintenance protocols and automations to ensure the machines are clean and in good working condition, thus maintaining product quality.

5. Digital twins

Pharmaceutical companies use the digital twin technology to create a digital replica of physical goods to simulate and analyze the performance of machines. Apparel manufacturers may consider digital twin technology to model critical machinery, predict maintenance needs, and optimize performance. 

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The Need for Preventive Maintenance in Apparel Manufacturing

Apparel manufacturing faces several specific challenges that can hinder efficiency and profitability. 

1. Machine breakdowns

Frequent machine breakdowns are a major issue, disrupting the production process and causing significant downtime. This not only delays the manufacturing schedule but also increases operational costs due to emergency repairs and potential overtime pay for workers to meet deadlines.

2. Productions delays

Production delays, often resulting from machine malfunctions or supply chain issues, are another significant challenge. These delays can lead to missed deadlines, lost orders, and damaged relationships with retailers and customers. Maintaining a consistent production schedule is crucial in the fast-paced apparel industry.

3. High cost of maintenance

High maintenance costs further compound these challenges. The expense of regular maintenance, coupled with the cost of spare parts and skilled technicians, can strain the budget of manufacturing operations. Older machinery might require more frequent repairs, further driving up costs.

These challenges are common, frequent, and highly avoidable – if manufacturers transition from reactive to preventive maintenance of machinery and equipment. By adopting a preventive maintenance strategy, manufacturers may not just avoid challenges in apparel manufacturing, but exploit several benefits: 

1. Increased productivity: Preventive maintenance ensures that machinery and equipment are regularly inspected, serviced, and kept in optimal working condition. This proactive approach minimises unexpected breakdowns and reduces downtime, leading to a more consistent and efficient production flow. By avoiding unplanned halts, manufacturers can maintain steady production schedules, meeting delivery deadlines more reliably and increasing throughput.

2. Enhanced quality control: Well-maintained equipment operates more accurately and consistently, which is crucial for maintaining high-quality standards in garment production. Inconsistent machine performance can lead to defects such as uneven stitching, incorrect cuts, or poor fabric handling, which compromise product quality. Regular maintenance ensures that machines perform at their best, producing garments that meet precise specifications and quality benchmarks. This, in turn, reduces the rate of returns and rework, saving time and resources.

3. Competitive advantage: In the highly competitive apparel industry, the ability to deliver high-quality products on time is a significant competitive edge. Preventive maintenance helps manufacturers achieve this by ensuring their production lines are reliable and efficient. It allows for better planning and resource allocation, as maintenance activities can be scheduled during times of low productivity, minimising disruptions. This strategic advantage enables manufacturers to respond more swiftly to market demands and customer needs.

4. Save costs: While preventive maintenance requires an upfront investment, it leads to substantial long-term savings. By addressing potential issues before they become major problems, manufacturers can avoid the high costs associated with emergency repairs, extensive downtime, and lost productivity. Extending the lifespan of machinery through regular upkeep reduces the need for frequent replacements, further lowering capital expenditures.

5. Workplace Safety: Regular maintenance ensures that all equipment operates safely, reducing the risk of accidents and injuries in the workplace. A safe working environment is not only a legal and ethical requirement but also boosts employee morale and productivity.

6. Use of IoT and AI: The integration of Internet of Things (IoT) and artificial intelligence can help with preventive maintenance of apparel manufacturing machinery. These tools can help with bringing efficiency into preventive maintenance practices.

• IoT devices that are equipped with sensors can be attached to machines to collect data on variables that affect their performance like speed, operating hours, and temperature in real time. These devices can detect deviations from normal conditions and immediately alert maintenance teams. Moreover, IoT devices collect historical data and detect patterns to anticipate machine failures to a certain extent. Real-time and historical data and analyses can be viewed on centralised dashboards that aid decision making and maintenance scheduling. 

• AI uses machine learning algorithms to analyze the data collected by IoT sensors. These algorithms can detect subtle patterns that might be missed by human analysis. AI can also automatically schedule maintenance activities based on predictive analytics. 

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The Role of Software Solutions like Maintain8

Maintaini8 by Solvei8 is a machine and task management tool built for Industry 4.0. Our solution goes native with manufacturing units equipped with advanced machinery to help manufacturers get the most out of it.

Maintaini8 streamlines preventive maintenance activities by:

1. Easily assigning tasks to mechanics and tracking their performance
2. Generating reports in real time with alerts on WhatsApp and email for quick resolution
3. Generating root cause analysis reports that help track the time and effort spent while also planning future maintenance

Our maintenance tool comes with the following features:

• Real-time monitoring of machine health and activity
• Easy task and people management 
• Location tracking using QR codes
• Automated ticket creation for scheduled maintenance
• Web, tablet and mobile view of dashboards

Implementation Strategy

Apparel manufacturers can assess current maintenance practices and identify areas for improvement through the following steps:

1. Conduct a maintenance audit including inventory assessment for all machinery, tools, and spare parts. The relevant team must take note of the maintenance history and current condition of the machines.
2. Review records of maintenance activities in the past to analyze frequency of issues, causes of downtime, etc. 
3. Measure performance based on key performance indicators like total downtime, mean time between failures, mean time to repair, and maintenance costs.
4. Get feedback from maintenance and operations staff members on current practices. Identify the skill level of staff members and provide training.
5. Deploy technology solutions like computerized maintenance management systems like Maintaini8 to streamline maintenance tasks and manage inventory of parts.
6. Use predictive analytics to anticipate failures and schedule maintenance in advance.

However, implementing a preventive maintenance plan is easier said than done. This is why developing a well-thought out plan is important. A comprehensive preventive maintenance plan must include a proper assessment of existing maintenance practices, setting clear objectives, developing maintenance schedules, integrating new technologies, staff training, implementation, and continuous monitoring. 

Conclusion

Preventive maintenance not only helps save on costly repairs, but also ensures that your manufacturing unit is up and running at all operating hours. This strategy involves developing and following a carefully crafted plan involving monitoring, inspections, staff training, and timely repairs. These processes must be enhanced and made more efficient by predictive analytics, use of IoT devices and artificial intelligence, and the use of maintenance tools like Maintaini8. Industry 4.0 is being propelled by machinery and tech, and their maintenance, likewise, requires sophisticated tools for tracking and early warning signals.

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