What is New Style Planning
New style planning is the process of preparing the line for a new style before production starts. It covers everything from sample approval to line balancing, training, and the first week of production. Good new style planning reduces changeover time and ramp-up losses.
Key Steps
Confirm the SMV and BOM. Review the operation breakdown. Check machine requirements. Plan line layout. Assign operators using the skill matrix. Arrange training. Set targets. Plan the first week ramp-up.
Practical Example 1 — Basic Style
New T-shirt style with SMV 15 minutes. Line has 30 machines. 8 operations are new to the line. Plan: 2 days of training on new operations, 1 day of trial run, ramp-up target 70 percent in week 1, 85 percent in week 2.
Practical Example 2 — Complex Style
New jacket with SMV 25 minutes and 45 operations. Requires 3 new machines. Plan: bring machines 1 week in advance, train 5 operators, arrange pre-production meeting, pilot run on 100 pieces.
Practical Example 3 — Similar Style
New style similar to current with only 2 new operations. Plan: quick training of 2 hours, use skill matrix to assign, start at 80 percent target.
Practical Example 4 — Ramp-Up Curve
Week 1: 60 percent target. Week 2: 75 percent. Week 3: 85 percent. Week 4: 95 percent. This is the standard learning curve.
Pre-Production Meeting
Before every new style, hold a pre-production meeting with IE, quality, production, maintenance, and merchandising. Discuss SMV, critical operations, machine requirements, training needs, and risk points.
Common Mistakes
Starting production without training. Not arranging machines in advance. Ignoring the skill matrix. Setting full targets from day 1. Not holding the pre-production meeting.
When to Use It
New style planning is done for every new style, whether similar or different from the current one.