Implementation of Lean Manufacturing Tools in Garment Manufacturing Process Focusing Sewing Section of Men’s Shirt
Paneru, Naresh (2011)
Oulun seudun ammattikorkeakoulu
2011
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-2011110514259
https://urn.fi/URN:NBN:fi:amk-2011110514259
Tiivistelmä
Traditionally operated garment industries are facing problems like low productivity, longer production lead time, high rework and rejection, poor line balancing, low flexibility of style changeover etc. These problems were addressed in this study by the implementation of lean tools like cellular manufacturing, single piece flow, work standardization, just in time production etc.
After implementation of lean tools, results observed were highly encouraging. Some of the key benefits entail production cycle time decreased by 8%, number of operators required to produce equal amount of garment is decreased by 14%, rework level reduced by 80%, production lead time comes down to one hour from two days, work in progress inventory stays at a maximum of 100 pieces from around 500 to 1500 pieces. Apart from these tangible benefits operator multi-skilling as well as the flexibility of style changeover has been improved.
This study is conducted in the stitching section of a shirt manufacturing company. Study includes time studies, the conversion of traditional batch production into single piece flow and long assembly line into small work cells.
After implementation of lean tools, results observed were highly encouraging. Some of the key benefits entail production cycle time decreased by 8%, number of operators required to produce equal amount of garment is decreased by 14%, rework level reduced by 80%, production lead time comes down to one hour from two days, work in progress inventory stays at a maximum of 100 pieces from around 500 to 1500 pieces. Apart from these tangible benefits operator multi-skilling as well as the flexibility of style changeover has been improved.
This study is conducted in the stitching section of a shirt manufacturing company. Study includes time studies, the conversion of traditional batch production into single piece flow and long assembly line into small work cells.