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LEAN MANUFACTURING IN APPAREL INDUSTRY
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LEAN MANUFACTURING IN APPAREL INDUSTRY


INTRODUCTION :


A systematic approach to identifying and eliminating waste through continuous improvement by flowing the product at the demand of the customer”. Lean is about doing more with less: Time, inventory, space, people, and money. Apparel manufacturers- pressed to deliver high quality garments at low costs.


HISTORY OF LEAN MANUFACTURING:

It was originated from the Toyota Motor Company. It is a management philosophy of production that emphasizes the minimization of the amount of all the resources (including time) used in the various activities to produce a goods or service. It involves identifying and eliminating non-value (waste) added activities which increase product cost.


THE BASIC LEAN MANUFACTURING PRINCIPLES:

 Value
 Value stream mapping
 Flow
 Pull
 Perfection


THE TRADITIONAL PRODUCTION VS LEAN MANUFACTURING.

• Job definition
• Quality control
• Production process
• Inventory
• Competing on
• Cost reduction
• Product flow
• Product development
• Leadership
• Design
• Outcome


STEPS TO IMPLEMENT THE LEAN MANUFACTURING:

There are four steps in implementing lean manufacturing. They are;
 Identifying the fact that there are wastes to be removed.
 Analysing the wastes and finding the root causes for these wastes.
 Finding the solution for these root causes.
 Application of these solutions and achieving the objective.


THE LEAN PRODUCTION GOALS:

Deliver the product, while…
"maximizing value (give the customer what they exactly need)”
“Minimizing waste (eliminate anything not needed for delivering value)”
“Pursuing perfection”



LEAN MANUFACTURING TOOLS & TECHNIQUES:

 Seven QC tools
 JIT (Just In Time)
 5s
 Kanban tooling
 Total productive maintenance
 QFD (Quality Function Deployment)



SEVEN QC TOOLS:

 Check sheet or tally sheet
 Histogram
 Pareto chart
 Cause and effect diagram
 Process flow chart
 Control chart
 Scatter diagram



JIT (JUST IN TIME):

• JIT much interconnected with lean manufacturing; and it is the backbone of the lean manufacturing.
• JIT concepts are based on the pull demand model. JIT has three main areas.
 JIT purchasing
 JIT Production
 JIT distribution
5s :
5s is a series of five simple lean manufacturing tools to improve the work environment.
1. Seiri (sort)
2. Seiton (straighten)
3. Seiso (shine)
4. Seiketsu (standardize)
5. Shitsuke (sustain)



KANBAN TOOLING:

Kanban is one of most popular tools in lean manufacturing. This is a simple concept, but very effective. Kanban mainly focus on the reduction of overproduction. There are mainly two types of kanbans. They are
 Withdrawal kanban
 Production kanban


ADVANTAGES OF LEAN MANUFACTURING:

 Lean manufacturing is normally known to reduce the; Lead time by 50% at least (some reports says stories where lead time is being reduced up to 90%)
 Reduced WIP up to 80%
 Floor space savings around 30 %( sometimes more than 50%)
 Increased productivity at least by 30%. (even more than 100% in some cases)
 Overall cost reduction



BARRIERS FOR LEAN IMPLEMENTATION:

 Lack of interest.
 Lack of awareness.
 Shortage of basic infrastructure.
 Wasteful movements due to larger distance.
 No regular and proper training to workmen and officers.
 Initial Stage- Applying- Production disturbed.
 Wrong concept about lean among employees.
Thus by following the lean manufacturing we can achieve less waste and eliminate unwanted wastes. We can achieve high quality garment at low cost.
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