Prospect of implementation of lean manufacturing for apparel industries in Bangladesh
Journal Title: American journal of Engineering Research - Year 2017, Vol 6, Issue 9
Abstract
Lean manufacturing is a systematic approach to identifying and eliminating wastes (non-value added activities) through continuous improvement by conveying the product at the pull of the customer in pursuit of production. In a more basic term, more value with less work. Traditionally operated garment industries are facing problems like low productivity, longer production lead time, high rework and rejection, poor line balancing, low flexibility of style changeover etc. These problems are addressed by the implementation of lean tools like cellular manufacturing, single piece flow, work standardization, just in time production, visual lighting system etc in a lean line and compare with a traditional line for analyzing productivity as well as increasing sewing line efficiency. After implementation of lean tools, results observed were highly encouraging. Some of the key benefits entail production cycle time decreased by 8%, Waiting time reduced average 35%, number of operators required to produce equal amount of garment is decreased by 14%, rework level reduced by 80%, Transport time saves about 20%, production lead time comes down to a significant level, work in progress inventory stays at a maximum of 100 pieces from around 500 to 1500 pieces. Apart from these tangible benefits operator multi-skilling as well as the flexibility of style changeover has been improved. Considering all those facts this paper provides a roadmap as well as a framework to those manufacturing companies who are really operating significantly below their potential capacity.
Authors and Affiliations
*Afsana Haque1 ,, Talha Jubair1 ,, Kamruzzaman Khan2 ,, Sharjah Mohammad Saif1
Keywords
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