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TOPIC:LEAN MANUFACTURING IN APPAREL INDUSTRY
PRESENTER:
Ehsan Hameed BET-FA07-033
INTRODUCTION :
A systematic approach to identifying and eliminating waste through continuous improvement by flowing the product at the demand of the customer”. Lean is about doing more with less: Time, inventory, space, people, and money. Apparel manufacturers- pressed to deliver high quality garments at low costs.
HISTORY OF LEAN MANUFACTURING:
After the Second World War, Japanese industry underwent complete rebuilding
Manufacturers did not have the volume to justify Detroit-type mass production assembly lines, and needed a better way
Lean production principles were developed by Japanese engineers based on practical considerations, and are largely a matter of common sense
TOOLS & TECHNIQUES:
1 JIT (Just In Time).
2 5s.
3 Total productive maintenance.
4 QFD (Quality Function Deployment) 5 Kanban tooling
Just-In Time Manufacturing
Uses a systems approach to develop and operate a manufacturing system
Organizes the production process so that parts are available when they are needed.
A method for optimizing processes that involves continual reduction of waste
Principles Of JIT Manufacturing
Total Quality Management
Production Management
Supplier Management
Inventory Management
Human Resource Management
Advantages of JIT Manufacturing
Materials Cost Savings
Manufacturing Cost Savings
Sales Cost Savings
5-S
Creates a clean, ordered and disciplined work environment.
The first S focuses on eliminating unnecessary items from the workplace.
Sort – (Seiri)Sort – (Seiri)
Set in Order – (Seiton)Set in Order – (Seiton)
Painting floors Outlining work areas and
locations Shadow boards Modular shelving and cabinets
“A PLACE FOR EVERYTHING AND EVERTHING IN ITS
PLACE”
“A PLACE FOR EVERYTHING AND EVERTHING IN ITS
PLACE”
Once you have eliminated the clutter and junk that has been clogging your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement.
Shine – (Seiso)Shine – (Seiso)
Standardize – (Seiketsu)Standardize – (Seiketsu)
Workplace Layout and Design
Materials Handling Analysis
Clear and Concise Work Instructions
Well Defined Work Methods
Safe (Ergonomic) Working Practices
Cycle Time Reduction
Training
Documentation
Standardize means establishing “Best Manufacturing,
This is by far the most difficult S to implement and achieve.
Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S.
Sustain – (Seiketsu)Sustain – (Seiketsu)
Why 5-S
It is a foundation for Lean Reduces waste
Less searching
Decreased walking and motion
Reduced downtime
Fewer accidents
Fewer mistakes
Improved flow
Better use of space
Total Productive Maintenance (TPM)
” Ineffective equipment is a form of waste
TPM seeks to find the root causes of equipment problems, and fix them
Done using continuous improvement methods
Elements of TPM
Preventive maintenance done by operators
Restore and redesign equipment to make it better than new, and to extend its life
Eliminate human error in maintenance and operation Education and training
Improved maintenance procedures
Quality Function Deployment
Quality Function Deployment is a design planning process driven by customer requirements.
Quality: Meeting the specifications
Function: Function that forms quality
Deployment: Step-by-step deployment of that function
Benefits Of QFD
Customer Driven
Reduces Implementation Time
Promotes Teamwork
Provides Documentation
The Overall Goal
Increase customer satisfaction
= Increase business success
Kanban Systems
A Kan-ban is a card containing all the information required to be done on a product at each stage along its path to completion and which parts are needed at subsequent processes.
These cards are used to control work-in-progress production, and inventory flow. A Kan-ban System allows a company to use Just-In-Time Production and Ordering Systems that allow them to minimize their inventories while still satisfying customer demands.
Types of Kan-bans
1. Withdrawal Kan-ban 2. Production Kan-ban 3. Express kan-ban - used when shortages of
parts occur 4. Emergency kan-ban - used to replace
defective parts and other uncertainties such as machine failures or changes in production volumes
5. Through kan-ban - used when adjacent work centers are located close to each other. It combines production and withdrawal kan-bans for both stages onto one, through, kan-ban
REFRENCES:-
www.eng.usf.edu/~besterfi/class/capDOCS/qfd
www.sixsigmazone.com/assets/QFD_WCBFv4
www.freequality.org/documents/.../Quality%20Function%20Deployment
http://www.beyondlean.com/kanban.html