Académique Documents
Professionnel Documents
Culture Documents
Lean Manufacturing
Six Sigma
GSD
GSD is used to evaluate all operations. Including Cutting, Decorative, Sewing, Pressing, Quality control and packing
Costing design Line balancing Investment Appraisal Pre-production planning Time standards Operator training Methods rationalization
PRODUCTION
60
75
Few example
Dispose
Sew
Before GSD SMV Pick up Pnls CAPACITY PRODUCTION 0.30 200 120 After GSD implementation 0.15 400 200
New Operator
Low Performer
Multi Skill
QQT Methodology
Physical fitness
Trainability assessment for tailors. Operations assigned Based on finger dexterity based on grade obtained in test & color blindness test the trainability assessment for Tailors and others i) Basic knowledge on machines ii) Paper exercises with time targets-6 nos i)Loop exercise No1: Speed ii)Loop exercise No 2: Speed and accuracy
BASIC TRAINING
i) Training given for semi skilled i)Training on specific operations(eg : Joining 2 parts operations directly by a straight seam)
SKILL TRAINING
ii) On gaining experience of ii)The operator attains about one year they are graduation at 80% trained on skilled operations(eg : Joining 2 or 3 parts by following notches, very long operations like bottom hem, side seam etc.) 1:20 TRAINERTRAINEE RATIO 1:15
1:3
2 To 4 months
4 to 8 days
Foundation Skills
Loop exercise No 1
Sew 2 meter loop in single burst. Single needle lock stitch machine running as fast as it can.
Loop exercise No 2
Sew 2 meter loop in single burst Single needle lock stitch machine running run as fast as it can. Follow the pressure foot margin and sew.
Loop exercise No 3
Sew 2 meter loop in single burst. Single needle lock stitch machine running run as fast as it can. Follow the pressure foot margin and sew. Stop between 2cm,1cm and 1 thick line .
40 cms
17cms
40 cms
17cms
Stitch at margin
Purpose: Practice skills from 1&2 Stop in sharp corner. Match cut marks
Lean Manufacturing
It is focusing on the
Value-Adding Activities
Transform materials and information into products and services the customer wants
Non-Value-Adding Activities
Wastes in Manufacturing
Up to 90+% of any Process is Wasted Time or Activity
Excessive Inventories Excessive Motion
(Walking to Next Task, etc.)
Defective Products
(Identifying, Handling, Fixing)
Overproduction
Transportation
(Make Parts Here, Take Upstairs For Assembly)
Causes of Waste
Layout (distance) Long setup times Incapable processes Poor maintenance Supervisory roles Irrelevant performance
practices Poor work methods Lack of training Lack of adherence Large batches
measures Ineffective production planning/scheduling Lack of workplace organization Supplier quality/reliability More
FRONT PANEL
F P
BACK PANEL
P F
F P B P
LOADING
W
END OF LINE CHECKING
P F
FRONT POCKET ATT
LOADING WAIST BAND BUTTON HOLE BACK POCKET FIINISH WAIST BAND BUTTON HOLE BRAND LABEL ATT WAIST BAND TACKING
SEAT SEAM
CONVENTIONAL LAYOUT
LEAN LAYOUT
w 1 w 2 w 3
SEAT SEAM
Due to Single Piece Movement and reduction in WIP the Lead time has significantly reduced and hence improved the Flexibility in terms of Style Changes
FRONT POCKET
WAIST BAND
BODY PANELS
FLY B
FRONT PLEAT
FRONT POCKET ATT & BONE SEW CROTCH SEW WAIST BAND ATT WAIST BAND EXTN SEW & TURN HOOK & BAR FRONT POCKET ATT & BONE SEW SIDE PKT FOLD & SEW SIDE SEAM INSEAM END OF LINE CHECKING
Right fly lining close
TRIMMING
SIDE SEAM
BONE SEW
B P
Best Possible Combinations to be close to the Takt Time NEW COMBINATIONS Method Study
OPERATIONS
Keeping Material Flow in Mind: Layout Modification INTRODUCTION OF SINGLE PIECE MOVEMENT AFTER LINE BALANCING Takt Time=465 mins / 450 pcs = 62 sec
OPERATIONS
Improvement
Characteristics Production / day Lead time (Days) 1.Efficiency% 3.Multi skill Index 4.WIP In line 5.Rework % Before 301 After
avg 430 1.52Days 94 min 59% 72% 3.43 5 530 pcs < 100 pcs 10.58% < 5% avg 94.70 min < 30 min
54
38
Lean
Simple and Visual
Excessive Inventory Speed Up ValueAdded Work Large Batch Production Long Lead Time Quality Inspected-in
Demand Driven Inventory as Needed Reduce Non-ValueAdded Small Lot Size Minimal Lead Time Quality Built-in
D M A I C C
Project Charter
SIPOC
Prioritization matrix
GEMBA
FMEA
Control chart
Defects Zone
A zone The defects of the garment
100 80 60 40 20 0
h it c
Percent
Uneven Cuff High Low Open Pocket Shape Out & Down Stitch Bottom Hem- Roping Untrim Thread
506 309 226 168 144 96 60 33.5 20.5 15.0 11.1 9.5 6.4 4.0 33.5 54.0 69.0 80.1 89.7 96.0 100.0
Top Defects
Side seam raw edge Cuff Uneven Collar down stitch
Bottom roping
Cause & Effect diagram was made depicting the causes category wise.
METHOD
MACHINE
MATERIAL
Control Phase
WCM
Work environment 5S - House keeping - Red tag Systematic improvement - Generating new Ideas Kaizen - Employee involvement Self Maintenance - Reduction M/C downtime - Monitor Spares consumption Technology management - New Machineries - Up gradation of new technology
Environment Health and safety - Awareness of seasonal diseases - Near miss Accidents - Visual display for safety People Management - Career Planning - Family Visits for employees - Employee satisfaction and plan
Thank you