Lean-Manufacturing-Fizza & Waqas (Final)

8/7/2019 Lean-Manufacturing-Fizza & Waqas (Final)

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Group Members:FIZZA ASADWAQAS SHAMS



LEAN MANUFACTURING will reduce your COSTS whatever

business YOU run..

Lean manufacturing is an operational strategy orientedtowards achieving the shortest

possible cycle time by eliminating wastes.



In short, lean manufacturing means

doing more with� less time, � less Inventory, � less space, � less people and� less MONEY

Here are some of the basic truths ofLEAN and many of the tools you will find essential to implement in anyapparel unit.



PRINCIPLES OF LEANMANUFACTURING & TOOLS

USED



1. Recognition Of Waste

T he first step is to recognize what doesand does not create value from the

customer·s perspective.

Lead time

Valueadd



Value Adding (VA):Any activity that

directly adds value tothe product

Non Value Adding (NVA)But unavoidable with currenttechnology and material :

Any work carried out that does not

increase product value.

Waste:Any activity that does not

add value to the product

hence something you dont

want to be doing hence

waste



Value stream mapping is a set ofmethods to visually display the flow of

materials and information through theproduction process. T he objective ofvalue stream mapping is to identifyvalue-added activities and non value-

added activities.



2. Standard Processes

´Standard processµ means that production processes and guidelines arevery clearly defined and communicated.

Visual Management is a tool which enables factory workers to be well

informed about production procedures, status and other important information for them to do their jobs as effectivelyas possible.



Visual controls are simple, clear and

concise visible indicators such ascharts, diagrams, lights, measurements, floor markings, loc

ationsan

d sign

s.

What we can·t see we can·t improv e



3. Continuous Flow

Lean usually aims for theimplementation of a continuous

production flow free of bottlenecks, interruption, detours, backflows orwaiting. When this is successfullyimplemented, the production cycle time

can be reduced by as much as 90%.



Fromthis

Tothis

BATCHMANUFACTURE

Batch manufacture isoften organized bygrouping processes

however this can inhibit material flow

ONE PIECE FLOW

Inventory is eliminatedbetween processesallowing the product toflow through the value

stream

Reduce WIPReduce Lead timeReduce transportationFloor space savingImproved communication



4. Pull Production

Pull-production aims to produce onlywhat is needed, when it is needed.

Production is pulled by the downstreamworkstation so that each workstation should only produce what is requestedby the next workstation.



´KANBANµ is a pull-based material

replenishment system or tool that uses visual signals, such as color-coded cards, to signal to upstreamworkstations when inputs are requiredat a downstream workstation.



5. Quality at source

Lean aims for defects to be eliminatedat the source and for quality inspection

to be done by the workers as part ofthe in-line production process.

T he tool of cellular layout is used toachieve many objectives of lean manufacturing.



But the main benefit of cellular

manufacturing is that responsibilityfor quality is clearly assigned to theworker in a particular cell and he/shetherefore can not blame workers at upstream stages for quality problems.



6. Continuous Improvement

Lean requires striving for perfection by continually removing layers ofwaste as they are uncovered.



KAIZEN is a Japanese term or tool for´continuous improvementµ. A main theme

of Kaizen is to create a culture ofcontinuous improvement, largely byassigning responsibility to workers, andencouraging them, to identify

opportunities for improvement.



TRADITIONALMANUFACTURING

LEANMANUFACTURING

Orientation Supply driven Customer driven

Planning Orders are pushed

through factory basedon production plan orforecast

Orders are pulled

trough factory based on customer /down streamdemand

Batch size Large Small

Quality Inspection By QC inspectors In-line inspection by workers



TRADITIONALMANUFACTURING

LEANMANUFACTURING

Inventory Buffer of WIP between each production stage

Little or no WIPbetween each

production stageHand off of WIP Materials accumulate

into WIP storage

Material directly handed

off from one stage to

another

Production cycle time Long Short



LEAN MANUFACTURING IN

APPAREL INDUST RY OFPAKISTAN



Lean manufacturing is relatively new to

apparel industry of Pakistan but thereare lot training programs and work shopsare held by different institutions forcreating awareness.

For example GEN-PROM Punjab held a one day workshop for students andfaculty of University of Management and

Technology, Lahore, and representativesof the garment/clothing industry on ¶Lean Sigma Application in Garment Manufacturing·, on February 4, 2010.



CONCLUSION

T he lean manufacturing toolsdiscussed, should be implemented in

apparel industry in order to minimizewaste and hence reduce production time and production cost in order togain competitive advantage.



REFERENCES

www.leanmanufacturingguide.comhttp://www.1000ventures.comwww.gemba.comwww.lean.orgwww.leanmanufacturingsecrets.comwww.leanessentials.netReport from Google: Mekongs Capital·s-Introduction to lean manufacturing forVietnam (4-June 2004)

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