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Improving Productivity by Lean

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ANITHA BALA
ANITHA BALA

This is a case study regarding study on production problems in apparel industry and to improve productivity by Lean manufacturing

Education
1 of 54
IMPROVE PRODUCTIVITY IN APPAREL INDUSTRY BY LEAN ,[object Object],[object Object]
CONTENT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
1.INTRODUCTION ,[object Object],[object Object],[object Object]
2.LITERATURE REVIEW ,[object Object],[object Object],[object Object],[object Object]
PRODUCTIVITY ,[object Object],[object Object]
LEAN MANUFACTURING ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
LEAN ,[object Object],[object Object],[object Object]
HISTORY OF LEAN
OBJECTIVE OF LEAN ,[object Object],[object Object]
LEAN MANUFACTURING CONCEPT ,[object Object],[object Object],[object Object]
THE SEVEN WASTES ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
PRINCIPLES OF LEAN MANUFACTURING
LEAN TOOLS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
LEAN ENTERPRISE
Steps to achieve lean systems ,[object Object],[object Object],[object Object],[object Object]
LEAN PROCESS
BENEFITS OF LEAN ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
BARRIERS FOR LEAN IMPLEMENTATION ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
3.METHODOLOGY ,[object Object],[object Object],[object Object],[object Object]
3.1.STUDY PHASE ,[object Object],[object Object],[object Object]
SHIPMENT DELAY ,[object Object]
DELAY DUE TO VARIOUS PROBLEMS DELAY DUE TO VARIOUS PROBLEMS 84.35% 10.35% 4.69% 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% LOSS P E R C E N T A G E SEWING PRINTING SOURCING
IDENTIFICATION OF THE PROBLEM ,[object Object],[object Object]
3.2.IMPLEMENTATION PHASE ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
3.2.1.OVER PRODUCTION ,[object Object],[object Object],[object Object]
PRODUCTION QUANTITY ,[object Object],[object Object],[object Object]
3.2.2.PROCESS WASTE ,[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object]
WHAT IS TRAFFFIC LIGHT SYSTEM? ,[object Object],[object Object],[object Object],[object Object]
TRAFFIC LIGHT SYSTEM ,[object Object]
3.3.3. WAITING TIME ,[object Object],[object Object],[object Object]
Productivity loss due to waiting time. ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
RED FLAG SYSTEM ,[object Object],[object Object],[object Object],[object Object]
IMPLEMENTATION OF RED FLAG SYSTEM .
3.3.4. UNNECESSARY MOVEMENTS ,[object Object],[object Object],[object Object]
UNNECESSARY MOVEMENT IN MATERIAL HANDLING ,[object Object],[object Object]
The worker inserting the color card in the bundle. So, the helper will deliver the cut parts as per color code and hence no more ‘back and forth’ movement of bundle.
UNNECESSARY MOVEMENT IN INSPECTION ,[object Object],[object Object],[object Object],[object Object]
UN NECESSARY MOVEMENT AT PACKING ,[object Object],[object Object]
3.3.5.5s HOUSE KEEPING ,[object Object],[object Object],[object Object]
IMPLEMENTATION OF 5S
4.RESULTS AND DISCUSSIONS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
At the end, the defects found during final inspection are given below. ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
COST ANALYSIS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
4.2.PROCESS WASTE: ,[object Object]
REWORKS- COMPARSION CHART ,[object Object]
4.3.WAITING TIME ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
PRODUCTIVITY IMPROVED DUE TO REDUCTION IN WAITING TIME ,[object Object]
5. CONCLUSION ,[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object]
6.REFERENCES ,[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object]
[object Object]

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Improving Productivity by Lean

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  • 12. PRINCIPLES OF LEAN MANUFACTURING
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  • 22. DELAY DUE TO VARIOUS PROBLEMS DELAY DUE TO VARIOUS PROBLEMS 84.35% 10.35% 4.69% 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% LOSS P E R C E N T A G E SEWING PRINTING SOURCING
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  • 34. IMPLEMENTATION OF RED FLAG SYSTEM .
  • 35.
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  • 37. The worker inserting the color card in the bundle. So, the helper will deliver the cut parts as per color code and hence no more ‘back and forth’ movement of bundle.
  • 38.
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