Quick Changeover Process & its implementation on apparel manufacturing

1. Quick Changeover (QCO)
Epyllion Knitwears Limited – Madanpur

2. Changeover
Time
Changeover
• Last good part from last style to first good part from new style.
Available Run Time
Changeover
Time
Available Run Time
Changeover
Time
Increased Available Run Time = More Capacity For Throughput
Before:
After:
Decreased Changeover Time = Increased Available Run Time

3. Changeover Activities
• Internal Activities – Performed when machine is not running.
- Activities that can not be performed without
stopping the machine.eg: machine plugin/plug out.
• External Activities – Performed when machine is running.
- Activities that doesn’t necessarily require the
machine to stop. eg: Machine preparation in QCO
line, Layout Making.

4. Types Of Machines For QCO
• Internal Machines – Machines that doesn’t change their position
from the previous style. They may require some internal changes.
E.g.: thread change, bobbin change, feet change etc.
• QCO Machines – Type 1: Completely prepared in the QCO line.
– Type 2 : Prepared in the QCO line but taken from
the existing layout.
• Size Set Machines – Machines that are taken from the new style’s
sizeset. Generally, the machines that are critical to setup are taken
from sizeset. These machines are kept in the idle zone after the
sizeset is done. E.g.: Flatlock machines with special attachments.

5. QCO Flow Chart
Flow Chart of QCO

6. Formats Used For QCO
Comparison Format
QCO Monitor Card

7. Guidelines For QCO
• Once the paper layout is finalized, machine layout can not be changed
after the production starts.
• No deviation is allowed in machine layout from paper layout.
• QCO machines should be 100% prepared from the QCO line. Including
trial run.

8. Thank You…