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Study on Lean Manufacturing Process in Garments Production

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Study on Lean Manufacturing Process in Garments Production

  1. 1. Welcome To The Presentation Study on Lean Manufacturing Process in Garments Production
  2. 2. Abstract Manufacturers are now a days facing intensive global competition. The key to competing in the international market place is to simultaneously improve both quality and productivity on continual basis. The major purposes of the use of lean production are to increase productivity, improve product quality and manufacturing cycle time, reduce inventory, reduce lead time and eliminate manufacturing waste. To achieve these, the lean production philosophy uses several concepts like Kaizen, Kanban, 5’s, OEE, Just in Time (JIT) etc. This paper clearly explains the lean concepts, its principle, importance and benefits. This paper also addresses the approaches to implement lean practices in apparel industry
  3. 3. Lean manufacturing Lean Manufacturing is a systematic approach for achieving the shortest possible cycle time by eliminating the process waste through continuous improvement. Thus making the operation very efficient and only consisting of value adding steps from start to finish. In simple lean is manufacturing without waste. Lean manufacturing=half the human effort in the company +half the manufacturing space + half the investment in tools +half the engineering hours =to develop a new product in half
  4. 4. Lean theories Objective of lean manufacturing: Lean Manufacturing, also called Lean Production, is a set of tools and methodologies that aims for the continuous elimination of all waste in the production process. The main benefits of this are lower production costs, increased output and shorter production lead times. More specifically, some of the goals include:  Defects and wastage - Reduce defects and unnecessary physical wastage, including excess use of raw material inputs, preventable defects, costs associated with reprocessing defective items, and unnecessary product characteristics which are not required by customer  Cycle Times - Reduce manufacturing lead times and production cycle times by reducing waiting times between processing stages, as well as process preparation times and product/model conversion times.  Inventory levels - Minimize inventory levels at all stages of production, particularly works-in-progress between production stages. Lower inventories also mean lower working capital requirements
  5. 5. Lean theories  Labor productivity - Improve labor productivity, both by reducing the idle time of workers and ensuring that when workers are working, they are using their effort as productively as possible (including not doing unnecessary tasks or unnecessary motions);  Flexibility - Have the ability to produce a more flexible range of products with minimum changeover costs and changeover time.  Output – Insofar Utilization of equipment and space - Use equipment and manufacturing space more efficiently by eliminating bottlenecks and maximizing the rate of production though existing equipment, while minimizing machine downtime; -as reduced cycle times, increased labor productivity and elimination of bottlenecks and machine downtime can be achieved, companies can generally significantly increased output from their existing facilities. -Another way of looking at Lean Manufacturing is that it aims to achieve the same output with less inputs – less time, less space, less human effort, less machinery, less materials, less costs
  6. 6. What kinds of companies benefit most from lean  Lean is most widely used in industries that are assembly-oriented or have a high amount of repetitive human processes. These are typically industries for which productivity is highly influenced by the efficiency and attention to detail of the people who are working manually with tools or operating equipment. For these kinds of companies, improved systems can eliminate significant levels of waste or inefficiency. Examples of this include wood-processing, garment manufacturing, automobile assembly, electronics assembly and equipment manufacturing.  Since Lean Manufacturing eliminates many of the problems associated with poor production scheduling and line balancing, Lean Manufacturing is particularly appropriate for companies that don’t have ERP systems in place or don’t have strong material requirements planning (MRP), production scheduling or production allocation systems in place. Lean Manufacturing is also appropriate in industries for which it is a strategic priority to shorten the production cycle time to the absolute minimum as a source of competitive advantage for the company
  7. 7. Traditional Garment Manufacturing Process  Effective utilization of capacities which results more products were produced by lesser number of worker & infrastructures. (progressive system)  Work in process is very high around 3000 pcs /line  Workers & Machines need not wait for the product  Product spends more time in manufacturing just waiting  Garment defects are very high.  This system is not suitable in today’s scenario
  8. 8. Lean manufacturing concepts Value Creation and Waste:  In Lean Manufacturing, the value of a product is defined solely based on what the customer actually requires and is willing to pay for. Production operations can be grouped into following three types of activities:  Value-added activities are activities which transform the materials into the exact product that the customer requires.  Non value-added activities are activities which aren’t required for transforming the materials into the product that the customer wants. Anything which is non-value-added may be defined as waste. Anything that adds unnecessary time, effort or cost is considered non value-added. Another way of looking at waste is that it is any material or activity for which the customer is not willing to pay. Testing or inspecting materials is also considered waste since this can be eliminated insofar as the production process can be improved to eliminate defects from occurring.
  9. 9. Traditional Manufacturing Vs Lean Manufacturing: Activity Traditional Lean Inventory level High level Low level Suitability For high order quantity For low order quantity Higher product design Not suitable Highly suitable Cost of production High Low Bundle size Low High Process waste High Low Product inspection Sample based inspection 100% inspection Work in progress High Low Production type Stock production Custom production Layout Functional layout Product layout
  10. 10. Advantages lean system in apparel industry  Waste Elimination  Work place Standardization  Effective plant layout  Quality will be enhanced at source level.  Increase the Productivity by 30% from the existing level.  Reduction of Production cost & other Overheads  Reduce the Risk of non compliance and Late Delivery.
  11. 11. Principles of lean manufacturing  Principle 1: Production of value  Principle 2: Optimizing the Value Stream  Principle 3: Converting the Process to Flow  Principle 4: Activating the Demand Pull  Principle 5: Perfection of All Products, Processes and Services
  12. 12. Tools and Techniques Involved in Lean Manufacturing  Quality control Tools  5S  Just in time  Kanban  Kaizen
  13. 13. Continue….. 1. Quality control Tools involved in lean manufacturing process:  Pareto Chart  Fish Born Diagram  Histogram  Control charts  Scatter Diagram 2. 5 S System: These 5 Tools are utilized for Workplace Standardization  Seri (Sort)  Seiton (Straighten)  Seiso (Shine)  Seiketsu (standardize)  Shitsuke (Sustain)
  14. 14. Tools and Techniques Involved in Lean Manufacturing 3. Just in time (JIT):  This tool is one of the important tool for LEAN manufacturing .It defines the PULL Demand model instead of PUSH Demand model in earlier system which is mostly control the following activities  Purchase  Production  Distribution. 4. KANBAN:  This is also another important LEAN Manufacturing Tool. Which will mainly focusing on over production. There are mainly two types of Kanbans. 5. Kaizen:  Kaizen is the Japanese term for continuous improvement within a business, operations or productive process. Some of the areas where kaizen activities and programs can be of great benefit include:  Individual plant and machinery  Entire production lines  Raw material procurement and utilization  Labor utilization  Production processes and tasks
  15. 15. Approaches to Implement the Lean Production system in apparel industry The Following approaches will convert the apparel industry in to Lean based Production factory. These approaches will be met through Effective Utilization of above said LEAN TOOLS. 1. Minimizing the required inventory level 2. Zero down the defects 3. Reduce the process lead time (WIP) 4. Minimizing the production cost 5. Continues process improvement
  16. 16. Application of kaizen  Continuous Improvement can be applied in all the garment manufacturing operations .From cutting to finishing various places are available for improvement .  Improve the fabric handling practice while sewing.  Reduce the Sewing pucker.  Stitch & Seam failure can be controlled through continuous improvement  Minimizing the Standard Minute value for a given garment  Once the new standard has been created, the factory floor must follow it in addition to this KAIZEN activity should be done continuously
  17. 17. Five Things Sales & Marketing Can Learn from Lean Benefits Challenges Produce increases in profitability and market share Require cultural / educational change Provide enormous competitive advantage Generally last several years Possess clear best practices (we’ll list some below) Are often not understood at first Have aspects that are easy to accomplish Require leadership commitment from top Management Have elements that are not at all easy
  18. 18. Conclusion The concept of lean manufacturing is new in Bangladesh, and proactive organizations have already been observed to implement this tool in their functional departments. This is primarily due to the multitude of cost advantages which arise from having lean manufacturing processes.
  19. 19. THANK YOU