Lean Manufacturing

-5S & Kaizen

Compiled By:
Prateek Agarwal
Shilpi
NIFT Mumbai

Lean

Lean manufacturing,lean enterprise,

orlean production, often simply,
"Lean," is a production practice that
considers the expenditure of resources
for any goal other than the creation of
valuefor the end customer to be
wasteful, and thus a target for
elimination.
Lean is the set of management
practices based on the Toyota
Production System (TPS). The phrase
Lean Production was coined by a
groupofMITresearcherswhowrotethe
bookThe Machine That Changed the
World.

Tools Of Lean

Jidoka:

Kaizen:

Continuous Improvement.

Kanban:

Jidokais about built in quality and encompasses ideas such

asAutonomation which is giving machines the human
touch so that they can stop when things are incorrect

A visualprocess managementsystem that tells what to

produce, when to produce it, and how much to produce.

TPM:

Total Productive Maintenance(TPM) is the machinery

equivalent of Total Quality Management (TQM) and
involves everyone in the organization in focusing on
eliminating the six big losses through the use of a
performance measure known asOEE.

7 wastes
The seven wastes of Lean Manufacturing are what we are
aiming to remove from our processes by removing the
causes of Mura and Muri as well as tackling Muda directly.

The Seven Wastes of Lean Manufacturing are;

Transport
Inventory
Motion
Waiting
Over-Processing
Overproduction
Defects

Process Mapping
Process mapping your value streamusing ideas and
techniques such as Value Stream Mapping (VSM) or
simple Flow charting or spaghetti diagrams are very
powerful ways to identify and highlight the wasteful steps
in your processes

5S
5S

Visual Workplace is a workplace organization methodology to

improve productivity (through eliminating waste) and Quality
(through reducing variation).
This structured approach can be used in a manufacturing,
distribution or office environment and in all types of industries.
Process of Implementation:
Have a Plan
Drive it from the top to the roots
Employee Involvement Establishment of 5S Action Team
Focus - Establish 5S Focus Areas with employee ownership
Zeroing in
Probable Solutions
Testing
Implementation
Results

Before Implementation

After Implementation

Before Implementation

After Implementation

Before Implementation

After Implementation

Costing for 1 Poly-bag

Stand

Labor cost for polybag stand construction:

Total time to construct 1 stand = 2.5 hours
Total working hours for 1 month for the
labor= 26x8= 208 hrs
Salary for 208 hours= Rs.8000
Cost for 2.5 hours= Rs 96
Total construction cost for 1 stand= material cost +labor
cost
= Rs 316

Costing for 1 Box

Labor cost for box construction: Total time to construct 1

box= 3.5 hours
Total working hours for 1 month for the labor= 26x8= 208
hrs
Salary for 208 hours= Rs.7000
Cost for 3.5 hours= Rs 118
Total construction cost for 1 box= material cost +labor cost
= Rs 403.5

Collar Hanging Board

Collar patterns
are kept in a box
away from the
collar section

40

20

COLLAR
PATTERNS
HANGING
BOARD

Side Attachment
Extra trolley used for
keeping missing back lining

After attaching an
extension rod

Kaizen
Japanesefor

"improvement", or "change for the better" refers to

philosophy or practices that focus upon continuous improvement
of processes in manufacturing, engineering, and business
management.
Kaizen is a system that involves every employee - from upper
management to the cleaning crew. Everyone is encouraged to
come up with small improvement suggestions on a regular basis.
Steps

for Implementing Kaizen:

Define

the problem
Document the current situation
Visualize the ideal situation
Define measurement targets
Brainstorm solutions to the problem
Develop Kaizen plan
Implement plan
Measure, record and compare results to targets
Create action plan, on-going standards for sustaining.

Fullness At Lapel
LOCATION OPERATIO
ISSUE
N
FRONT
Canvas
Cycle time for
SECTION tape fusing fullness dividing is
more.
55 sec for marking
fullness and
dividing it.

SOLUTION
Lapel marking Pattern
can be altered,
fullness dividing
operation will be
easier.

Timesaved=7secondsperpiece.
Totaltimesavedperday=56minutes/day

Machine Oil

The machine oil circulates

throughout
to
provide
lubrication to the machine
parts
Sometimes this oil
comes
down through the needle
when the machine is idle.
In the morning when the work
starts, this oil that drips
through the needle may stain
the fabric, especially in the
case of light lining fabrics.
SUGGESTION: Needle can be
inserted in the fabric bag
made up of wool filled with
cotton. Both are very good
absorbents.

Vent Marking At Sleeve

Vent Marking should be
done during the vent lock
press operation.
Time taken by the operator
at the sleeve lining attach
operation = 124 seconds
Time taken by the operator
for vent lock press = 40
seconds
Time taken by operator for
Elbow seam press =51.63
seconds.
If we ask the vent lock
press operator to do the
marking
which
takes
approximately 12 seconds
then time taken by the

Hand and Foot Movement

Handling of the first operator in the sleeve lining attach

operation.
Extra foot and hand movement.
Total time taken for the operation = 62.45 seconds.
After eliminating the unnecessary hand movement of aligning the
lining under the needle, there was a reduction of 3 seconds in
operation for each sleeve. Hence, a total reduction of 6 seconds.
Also she was asked to cut the fusing before hand and store it in
the box.

Video1
Video2
Proposedway

Gorge Seam

There was problem of gorge seam bend at the lapel

piping press operation.
A marking was done at the table and the operator was
asked to match the gorge and the lapel before passing
the piece forward.
Excel data 1
VIDEO 1
PROPOSED VIDEO
Excel data 2

Result

conclusion

Thankyou