Yaa Thin Manufacturing Procedure Inwards Garments Production

Lean Manufacturing Process inward Garments Production

(The New Era inward People's Republic of Bangladesh Garments Production)

Imran Khan Emon
Lecturer & Coordinator
Department of Textile Engineering
Atish Dipankar University of Science & Technology
E-mail: emonlam9@gmail.com

Abstract: 

The manufacturer wants alone production. Now a day’s manufacturers are facing intensive global competition. For competing manufacturer pick out to occupation novel strategy such equally Lean manufacturing tools for improving both productivity & quality. To accomplish this, the lean manufacturing strategy occupation diverse tools such equally 5’s, Kanban, Kaizen, JIT etc. This article clearly explains the lean concepts, its benefits in addition to to a greater extent than beneficial strategy than the traditional procedure for the manufacturer.

Keywords: lean, tool, manufacturer, traditional, manufacturing, production.

Introduction: 

Lean Manufacturing tin live defined equally "A systematic approach to identifying in addition to eliminating waste matter through continuous improvement of the production at the demand of the customer." Taiichi Ohno in 1 lawsuit said that “Lean Manufacturing is all near looking at the fourth dimension draw of piece of work from the 2nd the client gives us an gild to the indicate when nosotros collect the cash. And nosotros are reducing that fourth dimension draw of piece of work past times removing the non – value added wastes”. Lean ever focuses on identifying in addition to eliminating waste matter in addition to fully utilizing the activities that add together value to the concluding product. From the client indicate of view, value is equivalent to anything he is willing to pay for the production or service he receives. Formally value adding activities tin live defined as: activities that transform materials in addition to information into products in addition to services the client wants. On the other mitt non-value adding activities tin live defined as: activities that eat resources, but attain non straight contribute to production or service. This non-value adding activities are the waste matter inward Lean Manufacturing. Waste tin live generated due to hapless layout (distance), long setup times, incapable processes, hapless maintenance practices, hapless piece of work methods, lack of training, large batches, ineffective production planning/scheduling, lack of workplace organisation etc. By eliminating wastes inward the overall process, through continuous improvements the product’s atomic number 82 fourth dimension tin live reduced remarkably. By reducing atomic number 82 fourth dimension organisation tin obtain operational benefits (enhancement of productivity, reduction inward work-in-process inventory, improvement inward quality, reduction of infinite utilization in addition to ameliorate piece of work house organization) equally good equally administrative benefits (reduction inward gild processing errors, streamlining of client service functions in addition to so that customers are no longer placed on hold, reduction of paperwork inward business office areas, reduction of undertaking turnover.)

Fig: Basics of lean manufacturing

Main Objectives of Lean manufacturing:
Quality: Increasing the lineament degree of the working procedure way reducing the expose of errors, repairs in addition to rejects. The resultant is less demand for fellowship resources in addition to thus lower total operating costs.

Reducing through time: Through fourth dimension is the fourth dimension that elapses betwixt the fellowship receiving its raw materials in addition to receiving payment for the products produced using those raw materials. Reducing this interval way beingness able to attain to a greater extent than products inward the same time, ameliorate rotation of resources in addition to the might to react faster in addition to to a greater extent than flexibly to satisfy client needs.

Reducing inventory: Inventories eat upwards space, add together considerably to logistics costs in addition to eat pregnant amounts of fiscal assets; assets that could live ameliorate employed elsewhere.

Reducing space: Most companies occupation far besides much infinite in addition to to a greater extent than personnel than they remove to: Lean Manufacturing using the LeanTek scheme does away amongst unproductive conveyors, reduces production draw of piece of work length, incorporates previously split upwards workstations into the principal line, in addition to reduces stocks in addition to cuts logistics costs. All these improvements assist cut the remove for infinite in addition to offering the selection of earmarking the regained infinite for futurity expansion.

Reduce Defects & Wastages: Waste is anything that happens to a production that does non add together value from the customer’s perspective. Products beingness stored, inspected or delayed, products waiting inward queues, in addition to defective products attain non add together value.

The seven wastes are at the root of all unprofitable action within your organization.

The seven wastes consist of:

1. Defects
2. Overproduction
3. Transportation
4. Waiting
5. Inventory
6. Motion
7. Processing

Traditional Garments Manufacturing Process:

In Traditional garments manufacturing process Work inward procedure (WIP) is rattling high. Product spends to a greater extent than fourth dimension inward manufacturing, only waiting. In this procedure garments defects are rattling high. This scheme is non suitable inward today’s scenario.

A comparing betwixt Traditional & Lean manufacturing procedure is given below, which is the evidence of benefits of lean manufacturing inward garments.

Traditional Manufacturing vs Lean Manufacturing

Activity	Traditional	Lean
Inventory level	High	Low
Suitability	For depression gild quantity	For high gild quantity
Higher production design	Not suitable	suitable
Cost of production	High	Low
Bundle size	Low	High
Work inward Process	High	Low
Process waste	High	Low
Production type	Stock Production	Custom Production
Layout	Functional	Product

 

Advantages of Lean Manufacturing:

1. Increased overall productivity.
2. Reduced amount of flooring infinite required for production.
3. Reduced manufacturing atomic number 82 time.
4. Improved flexibility to react to changes inward production flow.
5. Improved lineament of the product.

Conclusion: 

The concept of lean manufacturing is novel inward Bangladesh. Now most of the factories are trying to implementing these tools & they are getting benefits past times improving lineament & production rate.

Reference:

1. www.lean.org
2. en.wikipedia.org
3. www.toyota-global.com
4. leanmanufacturingtools.org 

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