LEAN MANUFACTURING IN APPAREL INDUSTRY

CONTENTS

• INTRODUCTION• TYPES OF WASTE •  LEAN MANUFACTURING PRINCIPLES• TOOLS & TECHNIQUES• IMPLENTATION• BENEFITS OF LEAN• CONCLUSION• REFERENCES

INTRODUCTION

• Lean manufacturing is a philosophy pioneered by Toyota Motors (and codified by James P. Womak’s The Machine that Changed the World: The Story of Lean Production)

• Lean Manufacturing is a systematic approach for achieving the shortest possible cycle time by eliminating the process waste through continuous improvement

TYPES OF WASTE

• Overproduction • Inventory • Transportation • Defects • Motion • Extra Processing • Waiting

PRINCIPLES

TOOLS AND TECHNIQUES

• Quality control Tools • 5S • Just in time • Kanban • Kaizen

IMPLEMENTATION

BENEFITS OF LEAN

KEY PARAMETERS RESULTS FROM LEAN IMPLEMENTATION

Reduction in production cost 3.44% & 14.28%

Productivity improvement 10% to 50%

Reduction in production lead time 8% to 25%

Garment quality improvement 10% to 35%

Reduction in production cycle time 12.5% to 33%

Annual saving Up to 44%

Factor Mass production Lean production

Skill level of work force

Narrow skilled professional

Multi skilled professional

Machine Layout Single purpose Multi purpose

Production method High volume standardized product

Customer focused production process.

Inventory Large Buffer Stock Minimum in process inventory

Product Flow Single product Mixed flow

Lead time Very high Less

CONCLUSION

• Lean Production system reduces all forms of non-value added activity

• Indian garment manufactures are hesitating to implement Lean Manufacturing tool

• So as a Technologists and future ENTREPRENEURS we must encourage to implement these kind of systems in each and every industry to make quality and economical production.

REFERENCES

• Latin D (2001): Lean Manufacturing, American Society for Quality Journal, December, pp 2-9

• Hines, P., and D. Taylor, Going Lean, Lean Enterprise research center, Cardiff Business School, 2000.

• Ohno, 1., Toyota Production System: Beyond large‐scale production 1997.