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

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

Non-Value Added Activities

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

LEAD TIME MANAGEMENT

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.

Share this post