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Performance and Development of Garment Factory in Lean Principles

Author(s):

P. Sakthivel , Maharaja Engineering College; Dr. R. Murali Manohar, Maharaja Engineering College, Coimbatore,641654,India.sakthivel.samy0383@gmail.com

Keywords:

VSM, WIP, TPS

Abstract

In this era of globalization, it is necessary for all the companies to stay competitive, Globalizations of markets made the companies to prove themselves among others. Increased productivity is a main driver of competitiveness in the sensitive garment market. There are number of ways to improve productivity, sales and profit but it is basic to supply a quality product at right time. Traditional garment manufacturing companies in Tiruppur are facing problems like low productivity, high rework and rejection, high cycle etc. Lean Manufacturing is a management philosophy derived mostly from the Toyota Production System (TPS).Apparel manufacturing industries are trying to improve their production system continuously looking for new production tools and techniques to keep swiftness with the rapid changes of trend in consumers of apparel products. To deal with the challenges, industries must improve production efficiency labor productivity reduce lead time and ensure delivery schedule requirements. Applying lean tools in micro sized companies are very challenging because of poor planning and execution. The organization’s attitude and less awareness about lean techniques are one of the major bottle necks for implementing lean manufacturing concept. This research addresses the implementation of lean tools in a garment manufacturing company in Tiruppur. The main issue in their export is meeting the deadline and many times delayed delivery occurs which leads to either Air Shipment (which is 10 times more expensive than sea shipment) or even cancellation of order. Good will and reputation of company is dropped. Time study, process analyses and Quality tools were used as tools to measure and analyse the process. Preliminary survey showed that there were some processes that lead to overall increase in production lead time and Work in Progress (WIP). A brainstorming session was conducted which included production manager, shop floor managers and operators to discuss upon this issue and derived a cause and effect diagram out of it. Value stream mapping (VSM) was used to understand the production process in the organization which shows that existing production process was inefficient and leads to bottleneck in sewing department. The objective of this research is to evolve and test various strategies to reduce idle time of workstations and improve the productivity for meeting the delivery schedule. This paper briefly describes the application of cause and effect analysis, pareto charts and time study techniques, value stream mapping and line balancing to improve productivity of the garment company. Flexible line balancing software version 3.0 has been used to simulate and estimate line efficiency. It is observed that by the implementation of lean tools meeting production dead line and the results were highly encouraging. From the proposed method production time of the style selected has been reduced from 4.4 minutes to 3.76 minutes. Number of operators have been reduced from 12 to 8. Rework level has been reduced by 1%, the main reduction is due to balanced work cells. Assembly line efficiency has been increased from 60% to 86.4%. A current state VSM was created and analyzed for potential areas of improvement. Lean manufacturing techniques were used to create a future state. The VSM suggests that a better lead-time reduction through the use of line balancing.

Other Details

Paper ID: IJSRDV6I40281
Published in: Volume : 6, Issue : 4
Publication Date: 01/07/2018
Page(s): 194-197

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