Yaa Concept Of Iso 9000, Half Dozen Sigma & Thin Production For Wearing Clothing Industry

Concept of ISO 9000, Six Sigma & Lean Production for Apparel Industry

Shabuz Biplob,
Apparel Professional,
Cell Phone: +8801511779988
Email: shabuz.biplob@outlook.com

Introduction:
So many methodologies receive got been created to dominion the manufacturing well. Amongst them, ISO 9000, Six Sigma in addition to Lean Production System are really pop inwards clothes trade. Almost clothes companies are next them anyhow. Some are next one, three, to a greater extent than than iii or other methodologies.

ISO 9000
ISO, International Organization for Standardization, develops & publishes international standards. It is founded on 23 Feb 1947, headquartered inwards Geneva, Switzerland. The iii official languages of the ISO are English, French, in addition to Russian. According to the ISO, its yell inwards dissimilar languages has dissimilar abbreviations (IOS inwards English, OIN inwards French for Organisation internationale de normalisation), the organisation adopted ‘ISO’ equally its abbreviated yell inwards reference to the Greek give-and-take isos which way equal. Now they receive got members inwards 163 countries worldwide. They receive got published over 21000 International Standards roofing well-nigh all aspects of applied scientific discipline in addition to manufacturing. ISO 9000 refers to establish, document, implement in addition to hold a lineament management scheme in addition to continually improve its effectiveness inwards accordance amongst the requirements of this International Standard.

The methodology is known equally ‘Plan-Do-Check-Act’ (PDCA) tin hand the axe hold upwards applied to all processes. PDCA tin hand the axe hold upwards briefly described equally follows.

Plan: Establish the objectives in addition to processes necessary inwards accordance amongst client requirements in addition to the organization's policies.

Do: Implement the processes.

Check: Monitor in addition to mensurate processes in addition to production against policies, objectives in addition to requirements in addition to study the results.

Act: Take actions for continuous improvement.

PDCA Cycle is presented below which is also called PDSA (Plan, Do, Study, Act) Cycle, Deming Cycle, Shewhart Cycle & Control Cycle.

So many methodologies receive got been created to dominion the Yaa Concept of ISO 9000, Six Sigma & Lean Production for Apparel Industry

PDCA Cycle

Six Sigma:
Six Sigma is a laid of techniques in addition to tools for physical care for improvement. It was introduced past times engineer Bill Smith spell working at Motorola inwards 1986. Jack Welch made it famous to his concern strategy at General Electric inwards 1995. To attain Six Sigma, a physical care for must non attain to a greater extent than than 3.4 defects per meg opportunities. That means, nosotros acquit a business 1 meg times, nosotros brand mistakes 3.4 times only. It consists of 2 methodologies named DMAIC in addition to DMADV. The Six Sigma DMAIC physical care for (defines, measure, analyze, improve, control) is an improvement scheme for existing process. The Six Sigma DMADV physical care for (define, measure, analyze, design, verify) is an improvement scheme used to prepare novel physical care for or production at Six Sigma lineament levels. This is also called DFSS (design for Six Sigma).

We tin hand the axe briefly explicate the methodology DMAIC equally follows:

Define the goals of the improvement activity.
Measure the existing system.
Analyze the source effort of the problem.
Improve the system.
Control the novel system.

Seven basic lineament management tools for physical care for improvement / Six Sigma are given below:

1. Cause in addition to Effect Diagram (also called Ishikawa Diagram or Fishbone Diagram): It helps to position many possible causes for a occupation in addition to form out ideas into useful categories. Causes are derived from brainstorming. Causes are designs equally follows:

Cause in addition to Effect Diagram

2. Check Sheet: A prepared canvas for collecting in addition to analyzing data.

Check Sheet

3. Control Chart: Graphs used to study how a physical care for changes overtime.

Control Chart

4. Histogram: Graphs used for showing frequency distribution, or how oft each dissimilar value inwards a laid of engagement occurs.

Histogram

5. Pareto Chart: A Pareto nautical chart combines both bars in addition to a trace graph. The Pareto regulation provides a theory maintaining that 80% of the effects come upwards from 20% of the causes. The purpose of the Pareto nautical chart is to highlight the most of import amidst a laid of problems.

Pareto Chart

6. Scatter Diagram: This is also called Scatter plot, Scatter Graph, Scatter Chart, X-Y graph. H5N1 Scatter Diagram shows the human relationship betwixt 2 sets of data. In next Example, each point shows Defects vs Months.

Scatter Diagram

7. Flow Chart / Run Chart or Stratification: These tools correspond a process, workflow or algorithm. The steps are represented past times a serial of boxes in addition to and so connected amongst arrows. Flow Chart is ideal for communicating a pace past times pace physical care for to others.

Flow Chart

Six Sigma Calculations:
Six Sigma tin hand the axe easily hold upwards calculated using a Six Sigma calculator. To figure out Six Sigma, nosotros demand define amount opportunities, amount defects & DPMO (Defects per Million Opportunities).

Sigma calculator

Six Sigma Table / Scale:

LEAN PRODUCTION:
Lean Production or Lean Manufacturing is a management philosophy derived to a greater extent than oft than non from the Toyota Production System (TPS). The essence thought is to maximize client value spell minimizing waste. This is a systematic method for the elimination of waste matter (Muda) inside a manufacturing system. The term was commencement introduced past times John Krafcik, a Quality Engineer inwards his 1988 article ‘Triumph of the Lean Production System’. Lean Production is thence focused on getting the correct things to the correct house at the correct fourth dimension inwards the correct quantity to attain perfect operate flow. Lean Manufacturing tools mainly operate to eliminate iii types of waste: Muda (valueless work), Mura (unevenness) in addition to Muri (overburden).

Muda is categorized into seven. These are:

Transport : The displace of production betwixt operations in addition to locations.
Inventory: The operate inwards progress (WIP) in addition to stocks of finished goods in addition to raw materials that a companionship holds.
Motion: The physical displace of a soul or machine spell conducting an operation.
Waiting: The human activeness of waiting of a machine or a soul for something.
Over production: Over producing production beyond customers order.
Over processing: Conducting operations beyond client requirements.
Defects: Product rejection in addition to rework.

Taking the commencement alphabetic character of each waste, the acronym ‘TIMWOOD’ is formed to retrieve the 7 Muda well.

Many tools or techniques are used at Lean Manufacturing. Amongst them I would refer 10 useful tools for clothes probationers below.

1. Quality at the Source: In this process, each operator checks his / her ain operate earlier the usage or production is sent to the adjacent pace inwards the process.

2. Bottle Neck Analysis: Bottleneck literally refers to the altitude narrow usage of a bottle. Bottleneck is a physical care for inwards the production trace which reduces the performance of entire production.

3. Root Cause Analysis (RCA): Root effort analysis (RCA) is a method of occupation solving used for identifying the source causes of problems. Cause & Effect Diagram in addition to v whys techniques are to a greater extent than oft than non used for Root Cause Analysis. v Whys is the technique to decide the source effort of a occupation past times repeating the query ‘Why’? Each answer asks to the footing of the adjacent question. To tape the countermeasure, nosotros tin hand the axe usage a concern strip to ensure that the countermeasure is fully implemented; that the occupation is followed up; that the countermeasure works; that the occupation doesn’t occur 1 time to a greater extent than in addition to that the countermeasure is locked into standard.

4. Standardized Work: This is a documented description of every physical care for (with responsibility, how to do in addition to estimated time). This physical care for of manufacturing captures best practices.

5. PDCA (Plan, Do, Check, Act): An iterative methodology for implementing improvements.

Plan: Establish programme in addition to expected results.
Do: Implement plan.
Check: Verify expected results achieved.
Act: Review in addition to assess in addition to do it again.

6. Kaizen (Continuous Improvement): The Japanese give-and-take ‘Kaizen’ only way ‘change for better’. Kaizen aims to eliminate wastes & continuous improvement.

7. 5s: It eliminates waste matter that results from a poorly organized operate area. See 5s below:

Sort: Remove unnecessary items.
Set inwards Order: Organize remaining items.
Shine: Clean in addition to inspect operate area.
Standardize: Write standards for above.
Sustain: Regularly apply the standards.

8. Andon: Andon way ‘Signal’. Andon Process starts when a occupation happens inwards production. Andon is faster to solve a problem. This is a visual assist which alerts where activeness is required. For example, a flashing calorie-free inwards a production trace that indicates 1 of the operators has stopped working due to whatsoever problem.

9. Overall Equipment Effectiveness (OEE): Overall Equipment Effectiveness is a metric for measure productivity & lineament level. There are 3 OEE factors, each of which makes a dissimilar type of loss. They are Availability, Performance in addition to Quality. The next calculations are to a greater extent than oft than non applied to indentify OEE factors percentage.

Availability percentage = run fourth dimension / planned production fourth dimension X 100
(Planned production fourth dimension – destination fourth dimension = run time).
(Shift fourth dimension – interruption fourth dimension = planned production time)

Performance percentage = (ideal cycle fourth dimension X amount count) / run fourth dimension X 100
Or, Performance percent = (total count / ideal run rate) / run fourth dimension X 100
(Ideal Cycle Time is the fastest cycle fourth dimension for a physical care for inwards optimal environment)
(Ideal Run Rate way highest output inwards per minute)

Quality percentage = adept count / amount count X 100
(Total count – turn down count = adept count)

OEE percentage = (good count X ideal cycle time) / planned production fourth dimension X 100
Or, OEE = availability X performance X quality.

10. Six Big Losses: Six categories of productivity loss are well-nigh experienced inwards manufacturing process. This is a really effective way to categorize equipment-based losses. These are Breakdowns (unplanned stops), Setup (Changeovers), Small Stops, Reduced Speed (slow cycles), Startup Rejects, Production Rejects. They are aligned amongst OEE (Overall Equipment Effectiveness) & render an fantabulous target for improvement actions.