In this video we explain how a just-in-time production island is set up inside a garment factory, and why the big brands work this way to run small batches without stopping the main line.
Where just in time comes from
The idea comes from Toyota. Kiichiro Toyoda summed it up like this: make only what is needed, when it is needed and in the right quantity. The other pillar of the system, jidoka, was born in the automatic looms of his father, Sakichi Toyoda, so the most copied method in industry has textile roots. To make sure material arrives on time, kanban is used, a card that signals what needs to be replenished.
What a production island is
It is a small group of machines inside the factory itself, set up to make one particular garment. For example, a women’s jacket made separately while the main line carries on with its own work. For the island you choose the specialised machines that garment calls for, each one set up to sew at the highest quality.
Ideally they are set up for standing work, usually in a U shape. The operator moves from one machine to the next in a couple of steps, parts do not pile up waiting and the island takes up much less room than a section of line. Toyota brought this way of working to sewing in the late 1970s, and in the West it became known as the Toyota Sewing System.
An island that changes with the order
If the model or the volume changes, the machines are regrouped in a short time. The order is changed, one is added or another taken out, and the island is producing again. The best operators on the line are chosen to work in it, people who can handle several machines and several operations.
Since we are not all the same height, we recommend stands with electric height adjustment: at the push of a button, each person sets the machine to suit them. You can see the Kessler and Carcano Egidio stands we work with.
Before you set up your island
It helps to be clear about which garment you will make in it, with what material and how many pieces you need a day. If you want to see which machine does each operation, look at our guides on how each garment is made or the video on how a jacket is made on an industrial production line. You can also see how we handle workshop projects.
Write to us or call us on 659 730 968 and we will help you choose the machines and stands you really need for your island.