Implementation of Lean Manufacturing Tools in Garment Manufacturing Process Focusing Sewing Section of Men’s Shirt

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Naresh Paneru

Implementation of Lean Manufacturing Tools in Garment Manufacturing Process Focusing Sewing Section of Men’s Shirt

Implementation of Lean Manufacturing Tools in Garment Manufacturing Process Focusing Sewing Section of Men’s Shirt

Naresh Paneru Master’s thesis Autumn 2011 Degree Programme in Industrial Management Oulu University of Applied Sciences

Author: Title of Thesis:

Naresh Paneru Implementation of lean manufacturing tools in garment manufacturing process focusing sewing section of Men’s Shirt

Thesis Supervisor: Degree: Graduation Year: Number of Pages:

Hannu Päätalo Degree Programme in Industrial Management Autumn, 2011 72 + 8

ABSTRACT
Traditionally operated garment industries are facing problems like low productivity, longer production lead time, high rework and rejection, poor line balancing, low flexibility of style changeover etc. These problems were addressed in this study by the implementation of lean tools like cellular manufacturing, single piece flow, work standardization, just in time production etc.

After implementation of lean tools, results observed were highly encouraging. Some of the key benefits entail production cycle time decreased by 8%, number of operators required to produce equal amount of garment is decreased by 14%, rework level reduced by 80%, production lead time comes down to one hour from two days, work in progress inventory stays at a maximum of 100 pieces from around 500 to 1500 pieces. Apart from these tangible benefits operator multi-skilling as well as the flexibility of style changeover has been improved.

This study is conducted in the stitching section of a shirt manufacturing company. Study includes time studies, the conversion of traditional batch production into single piece flow and long assembly line into small work cells.

Key Words: Lean manufacturing, Just In Time, Cellular manufacturing, Time study, Single Piece Flow 4

ACKNOWLEDGEMENTS

I would like to thank the Oulu University of Applied Science for giving me the opportunity to pursue Master’s Degree in Industrial Management.

I would like to thank my supervisor, Hannu Päätalo for his continued support throughout the course of this thesis.

Similarly, I would like to express my genuine appreciation for senior lecturer Mr. Tauno Jokinen who guided me throughout this thesis process.

I am obliged to all seniors and juniors in the industry, who coordinated and helped me directly or indirectly during the research process.

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CONTENTS

1 INTRODUCTION........................................................................................................ 12 1.1 Background ............................................................................................................ 12 1.2 Research Problems ................................................................................................ 13 1.3 Research Objective ................................................................................................ 14 1.4 Research Approach ................................................................................................ 15 1.5 Report Construction............................................................................................... 16 2 LITERATURE REVIEW............................................................................................. 17 2.1 History of Lean ...................................................................................................... 17 2.2 Definition of Lean ................................................................................................. 18 2.3 Lean Principles ...................................................................................................... 18 2.4 Toyota Production System .................................................................................... 19 2.5 Kind of Wastes...
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