Prepared By: K.

Sasikumar
o Low Productivity
o Longer Production Lead time (=Through put time + Wait time)
o Too much work in progress
o Higher Idle time
o Poor flexibility on style changeover

Earlier days:
* Industries were getting bulk orders
* There is no need to worry about
changing layout at least for a month or
for two weeks

But nowadays:
* Small order quantities and complex
designs,
* Has to produce multiple styles even
within a day

The garment industries:
Run as family business
Lacking skilled personnel
Lacking in capital
Poor technologies
Low productivity
Less flexibility (Rigid to change)
In the outlook:
They are happy as long as they are sustaining their
business
But, In the ground :
They have no confidence about the future
Major problem:
Failure to meet delivery time
Huge WIP
Bottle necks
Poor quality


With the time , It starts:

Decreasing order size and Increasing number of
styles

The Challenge :

Order changes
Production layout: Hold minimum WIP &
flexible enough change the layout

Fashion changes
Work force: Capable enough to cope with
change

Now
global market demand & niche market

Need arose
This needs higher flexibility in volume and style change over

Development of lean manufacturing system
It was able to respond much more rapidly to changes in demand by
quickly switching production from one model to another

This will serve our purpose of :
I. Flexibility
II. Reducing production lead time
III. Reducing the inventory
IV. Increasing productivity
V. Training operators for multiple works
VI. Reducing rework
During Second world war, the economic
condition of Japan was heavily destroyed

What they did:
I. Produced a small batch of products
II. Reduced their inventories

The difficulty they faced:
Changing tools in production lines frequently

How they cope with situation
Multipurpose tooling systems
Trained their employees to multi-skill
Worked on less Machinery with High Efficient Workforce
All employees are more open to the improvement process
and everyone started giving their input to the company.

Then they found:
To meet customer demand on time
I. Have to eliminate non value added work from
the process
II. Have to minimize the work in progress inventory
III. Have to create flexibility of style changeover
IV. Have to reduce rework percentage
V. Have to create a pool of multi-skilled operators
who can respond quickly for changing style
Definition
It is a comprehensive set of techniques which when combined
allows you to reduce and eliminate the wastes. This will make the
company leaner, more flexible and more responsive by reducing
waste.

Main cause:
focused its operating system on responding to demand via
individual optimization from end to end

Reason of application of tools and techniques:
Eliminate the source of losses



It will cut down into half :
Human effort in the company
Manufacturing space
Investment in tools
Engineering hours to develop a new product
Time consumption
Can meet customer demand on time
Can minimize the work in progress inventory
Can create flexibility of style changeover
Can reduce rework percentage
Can create a pool of multi-skilled operators

The profitability depends on the utilization of its resources to meet
the customer requirement
Material moving rapidly
Man working constantly by adding value to the product
Machine running in a more productive manner
Principle 1:
Accurately specify value from customer perspective for both products and
services

Principle 2:
Identify the value stream for products and services and remove non-value
adding waste along the value stream

Principle 3:
Make the product and services flow without interruption across the value
stream.

Principle 4:
Authorize production of products and services based on the pull by the
customer.

Principle 5:
Strive for perfection by constantly removing layers of waste.
Definition:
Management that strives to eliminate sources of manufacturing waste
by producing the right part in the right place at the right time.

JIT is applied to achieve the following goals:
1. Zero defects
2. Zero setup time
3. Zero inventories
4. Zero handling
5. Zero breakdowns
6. Zero lead time and
7. Lot size of one.
Toyota manufacturing system developed after World War II, which
aims to increase production efficiency by the elimination of waste.
-By Taiichi Ohno, Toyota, Japan

Waste Reduction <---------- Efficiency Improvement

Analysis of wastage:
Overproduction
Waiting time
Transportation problems
Inefficient processing
More work in progress inventory
Defective products
1. Overproduction
2. Waiting
3. Unnecessary Transport
4. Over processing
5. Excess Raw Material
6. Unnecessary Movement
7. Defects
8. Unused Employee Creativity
1. Should have one-piece or very small lot of flow
2. The equipment should be right-sized and very specific
for the garment operations.
3. Is usually arranged in a C or U shape so the incoming
raw materials and outgoing finished goods are easily
monitored.
4. Should have cross-trained people within the cell for
flexibility of operation.
5. Generally, the cell is arranged in C or U shape and
covers less space than the long assembly lines.
1. Reduced work in process inventory
Because the work cell is set up to provide a balanced flow from
machine to machine.
2. Reduced direct labor cost
Because of improved communication between employees,
better material flow, and improved scheduling.
3. High employee participation is achieved
Due to added responsibility of product quality monitored by
themselves rather than separate quality persons.
4. Increased use of equipment and machinery:
Because of better scheduling and faster material flow.
5. Improve the flexibility
Allows the company higher degrees of flexibility to
accommodate changes in customer demand.
6. Promotes continuous improvement
as problems are exposed to surface due to low WIP and
better communication.
7. Reduces throughput time
Increases velocity for customer orders from order receipt
through production and shipment.
8. Enhances the employees skills
Train them on multi-skilled operations.
i) Volume of production
ii) The skill and expertise of man power
iii) Delivery dates for products
iv) Materials specifications
v) Accuracy requirements of products
1. Better utilization of equipments
2. Higher productivity
3. Greater efficiency
4. Better quality
5. Reduced production cost & hence lower unit price
6. Use of standardized methods