Now You Know An Overview of Lean Manufacturing Using in Garment Industry

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 process waste through continuous improvement. The Lean approach is based on finding efficiencies and removing wasteful steps that don't add value to the end product. Lean production is not about eliminating people.

Waste
From the customers’ point of view process waste is anything which does not contribute the product transformation that is all the non value added activities in the process line is known as waste

Value
A capability provided to a customer at the right time at an appropriate price, as defined in each case by the customer. Features of the product or service, availability, cost and performance are dimensions of value.

Value-Added Activities

Transforms materials / information into products & services that…

Result in change in terms of FORM, FIT OR FUNCTION

The customer is willing to pay for, and..
Is done right the 1st time.

Non-Value Added Activities

Does not transform
The customer “could care less…”, and
Creates waste

LEAD TIME MANAGEMENT

AN OVER VIEW OF LEAN MANUFACTURING USING IN GARMENT INDUSTRY Now You Know An Overview of Lean Manufacturing Using in Garment Industry

Lead time 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 just as applicable to offices and other work environments as it is to manufacturing plants. It's helpful to relate words like "inventory," "customers," and "production" to whatever you're processing – data, documents, knowledge, services, and so on.

TRADITIONAL GARMENT MANUFACTURING PROCESS

Effective utilization of capacities which results more products were produced by lesser number of
worker & infrastructures.(progressive system)
Work in process in very high around 3000 pcs /line
Workers & Machines need not wait for the product
Product spends more time in manufacturing just waiting
Garment defects are very high.
This system is not suitable in today’s scenario

ADVANTAGES LEAN SYSTEM

Waste Elimination
Work place Standardization
Effective plant layout
Quality will be enhanced at source level.
Increase the Productivity by 30% from the existing level.
Reduction of Production cost & other Overheads
Reduce the Risk of non compliance and 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 order quantity	Suitable for low order 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