Yaa Thin Manufacturing Inwards Wearing Clothing Industry
Wednesday 19 December 2018
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Lean Manufacturing inward Apparel Industry
R.S. Balakumar
M.A.(SOCIOLOGY ), M.L.M.(Labour Management), Pursuing MBA (EXECUTIVE) inward (FASHION-TECH), MISTE.,
Chennai, Republic of Republic of India
Cell: +91-9283182955
Email: rsbalakumar1953@gmail.com
Lean Manufacturing
The Lean Manufacturing concept inward the Apparel Industry tin bring down the operational toll inward manufacturing yesteryear eliminating the procedure waste, empowering people alongside greater communication, increasing the higher productivity inward the execution procedure together with turning the organisation into a learning organization.
However, for lean to deliver meaningful alter to an organization, the implementers should showtime empathize the organisation together with hence innovate lean where it makes feel rather than the other agency around.
There are several fundamental lean manufacturing principles that demand to hold upwards understood inward society to implement lean. Failure to empathize together with apply these principles volition almost probable final result inward failure or a lack of commitment from everyone inward your organization. Without commitment the procedure becomes ineffective.
Elimination of Waste
One of the almost critical principles of lean manufacturing is the elimination of waste materials (known equally MUDA inward the Toyota Production System). Many of the other principles revolve roughly this concept.
There are vii basic types of waste materials inward manufacturing:
Continuous Improvement
(Commonly referred to yesteryear the Japanese give-and-take kaizen) is the almost critical regulation of lean manufacturing. It should genuinely shape the solid soil of the lean implementation. Without continuous improvement your progress volition cease. As the hollo implies, Continuous Improvement promotes constant, necessary alter toward achievement of a desired state. The changes tin hold upwards large or modest but must lend itself toward improvement (often many modest changes are required to laissez passer the target). The procedure genuinely is continual equally in that location is ever room for improvement.
Continuous Improvement should hold upwards a mind-set throughout your whole organization. Do non acquire caught upwards inward only trying to break the large ideas. Small ideas volition ofttimes fourth dimension Pb to large improvements.
Lean Manufacturing is a systematic approach for achieving the shortest possible bicycle fourth dimension yesteryear eliminating the procedure waste materials through continuous improvement. Thus making the functioning rattling efficient together with only consisting of value adding steps from start to finish. In uncomplicated words lean is manufacturing without waste.
To laissez passer these, the lean production philosophy uses several concepts like,
Lean Manufacturing is a systematic approach for achieving the shortest possible bicycle fourth dimension yesteryear eliminating the procedure waste materials through continuous improvement. Thus making the functioning rattling efficient together with only consisting of value adding steps from start to finish. In uncomplicated lean is manufacturing without waste.
Lean manufacturing = one-half the human endeavour inward the fellowship + one-half the manufacturing infinite + one-half the investment inward tools + one-half the applied scientific discipline hours =to educate a novel production inward one-half
Lean Manufacturing, also called Lean Production, is a laid of tools together with methodologies that aims for the continuous elimination of all waste materials inward the production process.
The master copy benefits of this are lower production costs; increased output together with shorter production Pb times.
More specifically, some of the goals include: Defects together with wastage - Reduce defects together with unnecessary physical wastage, including excess job of raw stuff inputs, preventable defects, costs associated alongside reprocessing defective items, together with unnecessary production characteristics which are non required yesteryear customer. Cycle Times - Reduce manufacturing Pb times together with production bicycle times yesteryear reducing waiting times betwixt processing stages, equally good equally procedure training times together with product/model conversion times.
Inventory levels - Minimize inventory levels at all stages of production, especially works-in-progress betwixt production stages. Lower inventories also hateful lower working uppercase requirements.
Improve labor productivity, both yesteryear reducing the idle fourth dimension of workers together with ensuring that when workers are working, they are using their endeavour equally productively equally possible (including non doing unnecessary tasks or unnecessary motions); Flexibility - Have the mightiness to make a to a greater extent than flexible make of products alongside minimum changeover costs together with changeover time.
Output – Insofar Utilization of equipment together with infinite - Use equipment together with manufacturing infinite to a greater extent than efficiently yesteryear eliminating bottlenecks together with maximizing the charge per unit of measurement of production though existing equipment, spell minimizing machine downtime; -as reduced bicycle times, increased labor productivity together with elimination of bottlenecks together with machine downtime tin hold upwards achieved, companies tin by together with large significantly increased output from their existing facilities. -Another agency of looking at Lean Manufacturing is that it aims to laissez passer the same output alongside less input – less time, less space, less human effort, less machinery, less material, less cost.
Lean is almost widely used inward Apparel industries that are assembly-oriented or convey a high sum of repetitive human processes. These are typically industries for which productivity is highly influenced yesteryear the efficiency together with attending to especial of the people who are working manually alongside tools or operating equipment. For these kinds of companies, improved systems tin eliminate important levels of waste materials or inefficiency.
Examples of this include wood-processing, garment manufacturing, car assembly, electronics assembly together with equipment manufacturing. Since Lean Manufacturing eliminates many of the problems associated alongside misfortunate production scheduling together with draw balancing, Lean Manufacturing is especially appropriate for companies that don’t convey ERP systems inward house or don’t convey potent stuff requirements planning (MRP), production scheduling or production resources allotment systems inward place. Lean Manufacturing is also appropriate inward industries for which it is a strategic priority to shorten the production bicycle fourth dimension to the absolute minimum equally a source of competitive payoff for the company.
Traditional Garment Manufacturing Process, Effective utilization of capacities which results to a greater extent than products were produced yesteryear lesser release of worker & infrastructures. (Progressive system) .Work inward procedure is rattling high roughly 3000 pcs /line. Workers & Machines demand non hold off for the product. Product spends to a greater extent than fourth dimension inward manufacturing but waiting. Garment defects are rattling high. This scheme is non suitable inward today’s competitive draw concern trend.
Lean manufacturing concepts Value Creation together with Waste: In Lean Manufacturing, the value of a production is defined alone based on what the client really requires together with is willing to pay for. Production operations tin hold upwards grouped into next 3 types of activities:
Value-added activities are activities which transform the materials into the exact production that the client requires. Non value-added activities are activities which aren’t required for transforming the materials into the production that the client wants. Anything which is non-value-added may hold upwards defined equally waste. Anything that adds unnecessary time, endeavour or toll is considered non value-added. Another agency of looking at waste materials is that it is whatsoever stuff or action for which the client is non willing to pay. Testing or inspecting materials is also considered waste materials since this tin hold upwards eliminated insofar equally the production procedure tin hold upwards improved to eliminate defects from occurring.
Advantages of the lean scheme inward clothes manufacture
 |
| Lean Manufacturing |
There are several fundamental lean manufacturing principles that demand to hold upwards understood inward society to implement lean. Failure to empathize together with apply these principles volition almost probable final result inward failure or a lack of commitment from everyone inward your organization. Without commitment the procedure becomes ineffective.
Elimination of Waste
One of the almost critical principles of lean manufacturing is the elimination of waste materials (known equally MUDA inward the Toyota Production System). Many of the other principles revolve roughly this concept.
There are vii basic types of waste materials inward manufacturing:
- Over Production
- Waste of Unnecessary Motion
- Waste of Inventory
- Production of Defects
- Waste of Waiting
- Waste of Transportation
- Waste of Over processing
Continuous Improvement
(Commonly referred to yesteryear the Japanese give-and-take kaizen) is the almost critical regulation of lean manufacturing. It should genuinely shape the solid soil of the lean implementation. Without continuous improvement your progress volition cease. As the hollo implies, Continuous Improvement promotes constant, necessary alter toward achievement of a desired state. The changes tin hold upwards large or modest but must lend itself toward improvement (often many modest changes are required to laissez passer the target). The procedure genuinely is continual equally in that location is ever room for improvement.
Continuous Improvement should hold upwards a mind-set throughout your whole organization. Do non acquire caught upwards inward only trying to break the large ideas. Small ideas volition ofttimes fourth dimension Pb to large improvements.
Lean Manufacturing is a systematic approach for achieving the shortest possible bicycle fourth dimension yesteryear eliminating the procedure waste materials through continuous improvement. Thus making the functioning rattling efficient together with only consisting of value adding steps from start to finish. In uncomplicated words lean is manufacturing without waste.
Below are the few steps which are required to implement the Lean manufacturing :
- Identifying the fact that in that location are wastes to hold upwards removed.
- Analyzing the wastes together with finding the root causes for these wastes.
- Finding the solution for these root causes.
- Application of these solutions together with achieving the objective.
To laissez passer these, the lean production philosophy uses several concepts like,
- Kaizen,
- Kanban,
- 5’s, OEE,
- Just inward Time (JIT) etc.
Lean Manufacturing is a systematic approach for achieving the shortest possible bicycle fourth dimension yesteryear eliminating the procedure waste materials through continuous improvement. Thus making the functioning rattling efficient together with only consisting of value adding steps from start to finish. In uncomplicated lean is manufacturing without waste.
Lean manufacturing = one-half the human endeavour inward the fellowship + one-half the manufacturing infinite + one-half the investment inward tools + one-half the applied scientific discipline hours =to educate a novel production inward one-half
Lean Manufacturing, also called Lean Production, is a laid of tools together with methodologies that aims for the continuous elimination of all waste materials inward the production process.
The master copy benefits of this are lower production costs; increased output together with shorter production Pb times.
More specifically, some of the goals include: Defects together with wastage - Reduce defects together with unnecessary physical wastage, including excess job of raw stuff inputs, preventable defects, costs associated alongside reprocessing defective items, together with unnecessary production characteristics which are non required yesteryear customer. Cycle Times - Reduce manufacturing Pb times together with production bicycle times yesteryear reducing waiting times betwixt processing stages, equally good equally procedure training times together with product/model conversion times.
Inventory levels - Minimize inventory levels at all stages of production, especially works-in-progress betwixt production stages. Lower inventories also hateful lower working uppercase requirements.
Improve labor productivity, both yesteryear reducing the idle fourth dimension of workers together with ensuring that when workers are working, they are using their endeavour equally productively equally possible (including non doing unnecessary tasks or unnecessary motions); Flexibility - Have the mightiness to make a to a greater extent than flexible make of products alongside minimum changeover costs together with changeover time.
Output – Insofar Utilization of equipment together with infinite - Use equipment together with manufacturing infinite to a greater extent than efficiently yesteryear eliminating bottlenecks together with maximizing the charge per unit of measurement of production though existing equipment, spell minimizing machine downtime; -as reduced bicycle times, increased labor productivity together with elimination of bottlenecks together with machine downtime tin hold upwards achieved, companies tin by together with large significantly increased output from their existing facilities. -Another agency of looking at Lean Manufacturing is that it aims to laissez passer the same output alongside less input – less time, less space, less human effort, less machinery, less material, less cost.
Lean is almost widely used inward Apparel industries that are assembly-oriented or convey a high sum of repetitive human processes. These are typically industries for which productivity is highly influenced yesteryear the efficiency together with attending to especial of the people who are working manually alongside tools or operating equipment. For these kinds of companies, improved systems tin eliminate important levels of waste materials or inefficiency.
Examples of this include wood-processing, garment manufacturing, car assembly, electronics assembly together with equipment manufacturing. Since Lean Manufacturing eliminates many of the problems associated alongside misfortunate production scheduling together with draw balancing, Lean Manufacturing is especially appropriate for companies that don’t convey ERP systems inward house or don’t convey potent stuff requirements planning (MRP), production scheduling or production resources allotment systems inward place. Lean Manufacturing is also appropriate inward industries for which it is a strategic priority to shorten the production bicycle fourth dimension to the absolute minimum equally a source of competitive payoff for the company.
Traditional Garment Manufacturing Process, Effective utilization of capacities which results to a greater extent than products were produced yesteryear lesser release of worker & infrastructures. (Progressive system) .Work inward procedure is rattling high roughly 3000 pcs /line. Workers & Machines demand non hold off for the product. Product spends to a greater extent than fourth dimension inward manufacturing but waiting. Garment defects are rattling high. This scheme is non suitable inward today’s competitive draw concern trend.
Lean manufacturing concepts Value Creation together with Waste: In Lean Manufacturing, the value of a production is defined alone based on what the client really requires together with is willing to pay for. Production operations tin hold upwards grouped into next 3 types of activities:
Value-added activities are activities which transform the materials into the exact production that the client requires. Non value-added activities are activities which aren’t required for transforming the materials into the production that the client wants. Anything which is non-value-added may hold upwards defined equally waste. Anything that adds unnecessary time, endeavour or toll is considered non value-added. Another agency of looking at waste materials is that it is whatsoever stuff or action for which the client is non willing to pay. Testing or inspecting materials is also considered waste materials since this tin hold upwards eliminated insofar equally the production procedure tin hold upwards improved to eliminate defects from occurring.
Advantages of the lean scheme inward clothes manufacture
- Waste Elimination
- Work house Standardization
- Effective found layout.
- Quality volition hold upwards enhanced at source level.
- Increase the Productivity yesteryear 30% from the existing level.
- Reduction of Production toll & other Overheads.
- Reduce the Risk of non-compliance together with
- Late Delivery.
- Production of value
- Optimizing the Value Stream
- Converting the Process to Flow
- Activating the Demand Pull
- Perfection of All Products, Processes together with Services
- Quality command Tools
- 5S
- Just inward fourth dimension
- Kanban
- Kaizen
- Pareto Chart
- Fish Born Diagram
- Histogram
- Control charts
- Scatter Diagram
These five Tools are utilized for Workplace Standardization
Conclusion:
The concept of lean manufacturing is novel inward some of the United Nations developed countries, together with proactive organizations convey already been observed to implement this tool inward their functional departments. This is primarily due to the multitude of toll advantages which arise from having lean manufacturing processes.
Sources:
- Seri (Sort)
- Seiton (Straighten)
- Seiso (Shine)
- Seiketsu (standardize)
- Shitsuke (Sustain)
Conclusion:
The concept of lean manufacturing is novel inward some of the United Nations developed countries, together with proactive organizations convey already been observed to implement this tool inward their functional departments. This is primarily due to the multitude of toll advantages which arise from having lean manufacturing processes.
Sources:
- Production together with functioning administration (text together with cases) Author-upendra kachru.
- Clothing Production management-A.J.CHUTTER.