An Overview of Lean Manufacturing Using in Garment Industry

AN OVER VIEW OF LEAN MANUFACTURING USING IN GARMENT INDUSTRY
R.Vignesh,
B.Tech, MBA.,
Planning/Financial Analysis
Sree Santhosh Exports, Tirupur.
Email: vigtex@gmail.com



What is Lean?
Lean Manufacturing is a systematic approach for eliminating the process waste through continuous improvement. The Lean approach is based on finding efficiencies and removing wasteful steps that don't add value to the end product. Lean production is not about eliminating people.

Waste
From the customers’ point of view process waste is anything which does not contribute the product transformation that is all the non value added activities in the process line is known as waste

Value
A capability provided to a customer at the right time at an appropriate price, as defined in each case by the customer. Features of the product or service, availability, cost and performance are dimensions of value.

Value-Added Activities
  • Transforms materials / information into products & services that…
Result in change in terms of FORM, FIT OR FUNCTION
  1. The customer is willing to pay for, and..
  2. Is done right the 1st time.
Non-Value Added Activities
  1. Does not transform
  2. The customer “could care less…”, and
  3. Creates waste
LEAD TIME MANAGEMENT
Lead time management
Lead time management
VARIOUS NAMES, BUT THE SAME CONCEPT
  • Toyota Production System
  • Pull Manufacturing
  • Just-In-Time
  • World Class Manufacturing
  • Lean Manufacturing
  • Short Cycle Manufacturing
  • One-Piece-Flow
  • Cellular Manufacturing
  • Demand Flow Manufacturing
  • Stockless Production
  • Focused Flow Manufacturing
  • Agility
  • Value Adding Manufacturing
  • Group Technology
  • Time Based Management
  • Synchronous Flow Manufacturing
  • End-Lining Operations
  • Continuous Flow Manufacturing
APPLICATION
The Lean concept is just as applicable to offices and other work environments as it is to manufacturing plants. It's helpful to relate words like "inventory," "customers," and "production" to whatever you're processing – data, documents, knowledge, services, and so on. 

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 in 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
ADVANTAGES LEAN SYSTEM
  • 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.
LEAN PRODUCTION VS MASS PRODUCTION

Activity
Mass production system
Lean production system
Production type
Stock production
Custom production
Layout
Functional Layout
Product Layout
Inventory level
High level
Low level
Suitability
Suitable for High order quantity
Suitable for low order quantity
Higher Product design
Not Suitable
Highly suitable
Cost of  Production
Higher level
Low level
Bundle Size
Lower
Higher
Process waste
Higher
Lower
Product Inspection
Sample Based inspection is possible
100% Inspection possible
Work In progress
High
Low

EFFECT OF EXCESS INVENTORY
More Inventory means:
  • More Over Time
  • Delayed shipments
  • Air Freight
  • Poor quality
  • High Absenteeism
  • High Attrition
  • Poor Responsiveness
  • Poor profits
  • High Cost per unit
In reality, no one knows about inventory that much. Factory managers / Supervisors say problems are caused by poor planning, absenteeism, etc.

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