Fashion, apparel, textile, merchandising, garments

1. Lean Manufacturing Takeaways SCLC / ECC Spring Meeting April 26 th , 2007

2. Waste Eliminated Lean constitutes a philosophy / culture of how to satisfy customers’ increasing demands for greater value. An ideal value-creation process exists when the fewest number of steps are properly sequenced and made to continually flow. Remember what Lean is?

3. PRODUCT SHIPMENT CUSTOMER ORDER Lean is a philosophy which shortens the time line between the customer order and the shipment by eliminating waste. Time Business as Usual Lean Manufacturing PRODUCT SHIPMENT CUSTOMER ORDER Time (Shorter) Waste Waste

4. Basic Lean tools you will need… Kanban 5S’s and Visual Factory Pull Standardized Work Process TAKT time Error Proofing Value stream mapping Total Productive Maintenance

15. Lean Pilot Results BEFORE PILOT IMPACT 88% more reliable process (Daily Schedule attainment) +/- 10% variation (Daily Schedule attainment) +/- 45% variation (Daily Schedule attainment) Variation in Process (Daily Schedule attainment) 33% reduction 2.1% daily 3.2% daily Absenteeism 13 times less units in inventory 0.3 units of WIP per unit produced 4 units of WIP per unit produced. WIP 93% reduction 0.27 days 3.7 days Lead Time 64% less sq. ft. per person 36 sq. ft. per person 102 sq. ft. per person Space 58% less defects 2.1% defects at final audit 4.6% defects at final audit Quality 60% Improvement 40 pr/person 25 pr/person Productivity