A Research Paper by Ishika Shandilya
Title: StitchGrid: Digitally Optimizing Changeover Times in Garment Manufacturing Using SMED Principles
The paper presents the design, development, and implementation of StitchGrid — an intelligent digital platform that addresses one of the major bottlenecks in garment manufacturing: high changeover times in sewing lines. By adapting the Single-Minute Exchange of Dies (SMED) methodology to the complexities of garment production, StitchGrid integrates real-time task allocation, predictive alerts, inter-departmental synchronization, and live dashboards to streamline changeover operations, ultimately improving productivity, delivery timelines, and cost efficiency.
Abstract:
Garment manufacturing often suffers significant productivity losses due to prolonged changeover times in sewing lines, directly impacting line efficiency, delivery schedules, and cost competitiveness. This paper introduces StitchGrid, an intelligent digital platform that applies Single-Minute Exchange of Dies (SMED) principles to the complexities of garment production.
StitchGrid integrates real-time task allocation, pre-changeover readiness validation, predictive notifications, resource synchronization, and live visual dashboards to streamline the style changeover process. By digitizing multi-departmental coordination across cutting, trimming, planning, and sewing, the system ensures seamless preparation and execution.
The platform’s flexible and scalable architecture supports Industry 4.0 adoption, enabling IoT integration and data-driven decision-making. Experimental implementation demonstrates significant reductions in changeover time, improved operational agility, and overall productivity enhancements for garment manufacturers.
Summary of Key Results
Changeover Time Reduction: Across multiple style transitions in Lines 7 and 8, the average changeover time decreased by around 40–50% after implementing Stitch Grid.
Targeted Delay Minimization: Delays due to machine setup, material readiness, and operator availability—identified through Pareto and root-cause analysis—were significantly reduced, demonstrating the effectiveness of focused interventions.
Statistical Validation: A one-sample t-test confirmed that the observed mean changeover loss (~70 minutes) was statistically greater than the 10-minute SMED target at a 95% confidence level, thereby validating the need for systemic optimization.
Positive User Feedback: Supervisors and operators reported improved task visibility, better coordination across departments, and increased confidence in changeover planning—all of which align with the quantitative improvements.
Altogether, the results demonstrate that StitchGrid not only delivers measurable reduction in changeover time and delays, but also enhances workforce coordination and process accountability—key steps toward leaner, Industry 4.0–aligned garment manufacturing.
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