Lean Manufacturing in

Garments Industry

By Mr. Kotaro OTAKA

APO Expert
October 23, 2008
 Lean Manufacturing
A systematic approach to identifying and
eliminating waste (non-value-added
activities) through continuous
improvement
 Lean Manufacturing
Common benefits associated:
WIP reduction
Space utilization
Lead time reduction
Productivity improvement
Quality improvement
Enhanced teamwork and communication
Enhanced flexibility and visibility
 Lean Manufacturing in Garments
Industry

Production System of Apparel Industry

Supply Chain and Business Flow in
Apparel Industry
 TQM Lean JIT

5S / Muda Control
 Journey Towards Lean Manufacturing
Start from 5S

1. Seri
2. Seiton
3. Seiso
4. Seiktsu
5. Shitsuke
 Journey towards Lean Manufacturing

Seiri :To sort and throw away unnecessary items.

Seiton :A place for everything and every thing in its place.
Seiso :Maintain high standards of cleanliness.
Seiketsu:Standardize all procedures.
Shitsuke:Train and maintain Discipline.
 7(Seven)
(MUDA= waste or loss)
MUDA

MUDA of Overproduction
MUDA of Waiting
MUDA of Transportation
MUDA of Machine down
MUDA of Stock / Inventory
MUDA of Movement
MUDA of Defective product
Journey towards Lean Manufacturing
Initiate Improvement techniques along the
value chain
a. Pattern Making
b. Sample Room
c. Cutting
d. Sewing
e. Cropping
f. Quality Control
g. Finishing
h. Folding
i. Packing
Journey Towards Lean Manufacturing

Three Basic Elements need to be focused

1. Quality
2. On Time Delivery
3. Cost
Journey Towards Lean Manufacturing
Quality
High Rework 15 25 %
High rework is the main hurdle to adopt lean system
Lack of Supervision Skills
Ability to judge high quality products

Quality Control and Inspection

During process how to control quality
 Journey Towards Lean Manufacturing

On Time Delivery
Production Organization
Production Flow Chart
Production Plan for Company Profit
Planning
Actual Production
Monitoring
Re-Planning
 Journey Towards Lean Manufacturing

Cost Control
Reduce Manufacturing Cost
Reduce Inventory Cost
 Journey towards Lean Manufacturing

Maintenance
House Keeping
Machine Maintenance
Overhaul Maintenance

High WIP
 Journey towards Lean Manufacturing

Structure of Manufacturing Cost

Thank you