TOPIC:LEAN MANUFACTURING IN APPAREL INDUSTRY

PRESENTER:

Ehsan Hameed BET-FA07-033

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:

After the Second World War, Japanese industry underwent complete rebuilding

Manufacturers did not have the volume to justify Detroit-type mass production assembly lines, and needed a better way

Lean production principles were developed by Japanese engineers based on practical considerations, and are largely a matter of common sense

TOOLS & TECHNIQUES:

1 JIT (Just In Time).

2 5s.

3 Total productive maintenance.

4 QFD (Quality Function Deployment) 5 Kanban tooling

Just-In Time Manufacturing

Uses a systems approach to develop and operate a manufacturing system

Organizes the production process so that parts are available when they are needed.

A method for optimizing processes that involves continual reduction of waste

Principles Of JIT Manufacturing

Total Quality Management

Production Management

Supplier Management

Inventory Management

Human Resource Management

Advantages of JIT Manufacturing

Materials Cost Savings

Manufacturing Cost Savings

Sales Cost Savings

5-S

Creates a clean, ordered and disciplined work environment.

The first S focuses on eliminating unnecessary items from the workplace.

Sort – (Seiri)Sort – (Seiri)

Set in Order – (Seiton)Set in Order – (Seiton)

Painting floors Outlining work areas and

locations Shadow boards Modular shelving and cabinets

“A PLACE FOR EVERYTHING AND EVERTHING IN ITS

PLACE”

“A PLACE FOR EVERYTHING AND EVERTHING IN ITS

PLACE”

Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement.

Shine – (Seiso)Shine – (Seiso)

Standardize – (Seiketsu)Standardize – (Seiketsu)

Workplace Layout and Design

Materials Handling Analysis

Clear and Concise Work Instructions

Well Defined Work Methods

Safe (Ergonomic) Working Practices

Cycle Time Reduction

Training

Documentation

Standardize means establishing “Best Manufacturing,

This is by far the most difficult S to implement and achieve.

Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S.

Sustain – (Seiketsu)Sustain – (Seiketsu)

Why 5-S

It is a foundation for Lean Reduces waste

Less searching

Decreased walking and motion

Reduced downtime

Fewer accidents

Fewer mistakes

Improved flow

Better use of space

Total Productive Maintenance (TPM)

” Ineffective equipment is a form of waste

TPM seeks to find the root causes of equipment problems, and fix them

Done using continuous improvement methods

Elements of TPM

Preventive maintenance done by operators

Restore and redesign equipment to make it better than new, and to extend its life

Eliminate human error in maintenance and operation Education and training

Improved maintenance procedures

Quality Function Deployment

Quality Function Deployment is a design planning process driven by customer requirements.

Quality: Meeting the specifications

Function: Function that forms quality

Deployment: Step-by-step deployment of that function

Benefits Of QFD

Customer Driven

Reduces Implementation Time

Promotes Teamwork

Provides Documentation

The Overall Goal

Increase customer satisfaction

= Increase business success

Kanban Systems

A Kan-ban is a card containing all the information required to be done on a product at each stage along its path to completion and which parts are needed at subsequent processes.

These cards are used to control work-in-progress production, and inventory flow. A Kan-ban System allows a company to use Just-In-Time Production and Ordering Systems that allow them to minimize their inventories while still satisfying customer demands.

Types of Kan-bans

1. Withdrawal Kan-ban 2. Production Kan-ban 3. Express kan-ban - used when shortages of

parts occur 4. Emergency kan-ban - used to replace

defective parts and other uncertainties such as machine failures or changes in production volumes

5. Through kan-ban - used when adjacent work centers are located close to each other. It combines production and withdrawal kan-bans for both stages onto one, through, kan-ban

REFRENCES:-

www.eng.usf.edu/~besterfi/class/capDOCS/qfd

www.sixsigmazone.com/assets/QFD_WCBFv4

www.freequality.org/documents/.../Quality%20Function%20Deployment

http://www.beyondlean.com/kanban.html