Yaa An Overview Of Thin Manufacturing Using Inwards Garment Manufacture

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 procedure waste matter through continuous improvement. The Lean approach is based on finding efficiencies in addition to removing wasteful steps that don't add together value to the terminate product. Lean production is non well-nigh eliminating people.

Waste
From the customers’ indicate of sentiment procedure waste matter is anything which does non contribute the production transformation that is all the non value added activities inwards the procedure draw of piece of employment is known every bit waste matter

Value
A capability provided to a client at the correct fourth dimension at an appropriate price, every bit defined inwards each instance yesteryear the customer. Features of the production or service, availability, cost in addition to functioning are dimensions of value.

Value-Added Activities

Transforms materials / information into products & services that…

Result inwards alter inwards terms of FORM, FIT OR FUNCTION

The client is willing to pay for, and..
Is done correct the 1st time.

Non-Value Added Activities

Does non transform
The client “could aid less…”, and
Creates waste matter

LEAD TIME MANAGEMENT

AN OVER VIEW OF LEAN MANUFACTURING USING IN GARMENT INDUSTRY Yaa An Overview of Lean Manufacturing Using inwards Garment Industry

Lead fourth dimension 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 but every bit applicable to offices in addition to other operate environments every bit it is to manufacturing plants. It's helpful to relate words similar "inventory," "customers," in addition to "production" to whatever you're processing – data, documents, knowledge, services, in addition to and thence on.

TRADITIONAL GARMENT MANUFACTURING PROCESS

Effective utilization of capacities which results to a greater extent than products were produced yesteryear lesser pose out of
worker & infrastructures.(progressive system)
Work inwards procedure inwards really high approximately 3000 pcs /line
Workers & Machines quest non hold off for the production
Product spends to a greater extent than fourth dimension inwards manufacturing but waiting
Garment defects are really high.
This organisation is non suitable inwards today’s scenario

ADVANTAGES LEAN SYSTEM

Waste Elimination
Work house Standardization
Effective found layout
Quality volition live enhanced at origin level.
Increase the Productivity yesteryear 30% from the existing level.
Reduction of Production cost & other Overheads
Reduce the Risk of non compliance in addition to 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 social club quantity	Suitable for depression social club 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 character
High Absenteeism
High Attrition
Poor Responsiveness
Poor profits
High Cost per unit of measurement

In reality, no ane knows well-nigh inventory that much. Factory managers / Supervisors state problems are caused yesteryear piteous planning, absenteeism, etc.