Presentation of the development and implementation of a Lean model used to reduce the fluctuations in WIP within a Textile company in Sri Lanka, Asia.

1. Paper by James Marsh Vijitha Ratnayake Gamini Lanarolle

6. Changes in Garment Style Company Garment type Number of style changes per month per line 2005 2006 A Blouses, pants, shirts 3 4 B Night wear, lingerie 2.5 3 C Jackets, pants, T-shirts 4 12 D Ladies wear, children wear 2.5-3 4-5 E Ladies wear, children wear 2 3 F Trousers 2 2 G Bras, under wear 1 3 H Bras, under wear 3 5 I T shirts, blouses 2 4 J Lingerie 1 1 K Pants, Jackets, Coats 1.2 1.2 L Caps 2 3

8. Measure & Analyse

9. Statistical Analysis Average WIP and its variation of 42 garment manufacturing lines Factory Line 1 Line 2 Line 3 Ave. WIP CV % Ave. WIP CV % Ave. WIP CV % Selected factory 32 164 66 146 18 134 A 22.3 127.4 28.6 134.0 48 90.4 B 23 143.2 38.2 111.4 40 112.5 C 55 79.2 20 133.5 25.2 125.2 D 32.2 150.4 41.69 96.6 34.52 118.4 E 45 122.3 30.67 105.5 29 98.7 F 44 93.2 30.58 142.7 27.07 132.4 G 31.6 99.8 29 121.2 39 135.5 H 49 117.4 20.04 131.6 27 110.3 I 39 144.5 34.2 122.7 34.05 112.5 J 32.5 92.2 26.3 123.4 27 142.3 K 28 98.4 40 105.3 39 112.4 L 29 135.2 45 103.4 33.2 108.9 M 41 155.6 37 87.7 31 132.6 N 49 99.3 20.04 112.2 22.04 165.6

10. Root Cause Analysis of WIP Fluctuation

11. Root Cause Analysis of WIP Fluctuation

15. Current Layouts in Garment Manufacturing

16. Designing Cells

17. Setting the pitch

18. Pilot to Full Implementation

19. Quantified Financial Benefits (Assuming 22 working days/ month)

20. Results and Discussion

21. Example reduction in WIP Fluctuation

22. Results and Discussion

23. Conclusion & Next Steps

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