1. LEAN MANUFACTURING IN
APPAREL INDUSTRY

2. CONTENTS
• INTRODUCTION
• TYPES OF WASTE
• LEAN MANUFACTURING PRINCIPLES
• TOOLS & TECHNIQUES
• IMPLENTATION
• BENEFITS OF LEAN
• CONCLUSION
• REFERENCES

3. INTRODUCTION
• Lean manufacturing is a philosophy pioneered by
Toyota Motors (and codified by James P. Womak’s
The Machine that Changed the World: The Story of
Lean Production)
• Lean Manufacturing is a systematic approach for
achieving the shortest possible cycle time by
eliminating the process waste through continuous
improvement

4. TYPES OF WASTE
• Overproduction
• Inventory
• Transportation
• Defects
• Motion
• Extra Processing
• Waiting

5. PRINCIPLES

6. TOOLS AND TECHNIQUES
• Quality control Tools
• 5S
• Just in time
• Kanban
• Kaizen

12. IMPLEMENTATION

14. BENEFITS OF LEAN
KEY PARAMETERS RESULTS FROM LEAN
IMPLEMENTATION
Reduction in production cost 3.44% & 14.28%
Productivity improvement 10% to 50%
Reduction in production lead time 8% to 25%
Garment quality improvement 10% to 35%
Reduction in production cycle time 12.5% to 33%
Annual saving Up to 44%

15. Factor Mass production Lean production
Skill level of work
force
Narrow skilled
professional
Multi skilled
professional
Machine Layout Single purpose Multi purpose
Production method
High volume
standardized product
Customer focused
production process.
Inventory Large Buffer Stock
Minimum in process
inventory
Product Flow Single product Mixed flow
Lead time Very high Less

16. CONCLUSION
• Lean Production system reduces all forms of non-
value added activity
• Indian garment manufactures are hesitating to
implement Lean Manufacturing tool
• So as a Technologists and future ENTREPRENEURS
we must encourage to implement these kind of
systems in each and every industry to make quality
and economical production.

17. REFERENCES
• Latin D (2001): Lean Manufacturing, American
Society for Quality Journal, December, pp 2-9
• Hines, P., and D. Taylor, Going Lean, Lean Enterprise
research center, Cardiff Business School, 2000.
• Ohno, 1., Toyota Production System: Beyond
large‐scale production 1997.