Lean
Management
ASSIGNMENT 1
Submitted to - Prof Bikas Agrawal
Submitted by - Abrishan Khan
(BFT/20/371)
Pratik Kadukar
(BFT/20/829)
Assignment -
Study Respective Lean Tools implemented
in a Garment Factory. and produce ideas for
KAIZEN implementation in the
manufacturing facility.
ACKNOWLEDGEMENT
We would like to express my special thanks of gratitude to
Mr Bikas Agarwal sir for teaching us Lean Management,
arranging an Industry visit, and guiding us in completing
our project.
We would also like to extend my gratitude to Mr Mehir
Banerjee of Paridhan - The Garment Park for arranging
the visit and giving us his precious time for our visit and
explaining and guiding us about the process in the factory.
Abrishan
Khan Pratik
Kadukar
TABLE OF CONTENTS
01 INTRODUCTION 09 Improvised workstation
Condition
02 KAIZEN
03 Paridhan - The Garment 10 Conclusion
Park
04 Current Condition Analysis
05 Inventory waste
06 Cutting Room saftey
07 Stitching Room
08 Fabric Waste-poka yoke
LAYOUT OF THE FACTORY
INTRODUCTION -
We have visited Paridhan - The Garment Park and
manufacturing unit of Mac one, we have seen the warehouse,
cutting, sewing and packing. In this document, we are going to
discuss the problem that we have identified during the visit
and try to implement lean tools in those areas.
We mainly focused on fabric waste reduction by using poka-
yoke and organizing the workplace and inventory also the
safety by using The 5s lean tool.
What is Kaizen?
→ Kaizen stands for “continuous improvement” or “small incremental
improvements” of all areas of a company.
→ Kaizen word comes from the Japanese words “kai” which means
“change or improvement” & “zen” which means “for betterment.”
→ The Lean tool Kaizen includes the involvement of all employees, from
top management to bottom personnel.
Vision -
Benefits of Kaizen :
→ It Improves processes by eliminating waste.
→ Promotes personal growth of employees and the company.
→ Kaizen Improves quality, safety, cost structures, delivery, environments
and it improves customer service/satisfaction.
How to implement Kaizen at our
workplace:
⇢The Kaizen method is generally implemented in 5 different steps:
⇢ Identify an area having a problem.
⇢ Analyze the data and method for the current process method.
⇢ Testing and evaluating improvement possibility.
⇢ Implement improvements.
⇢ Analyze results and present them to top management for feedback.
Kaizen steps
Paridhan - The Garment Park
Paridhan, the Garment Park promoted by WBIDC is a composite
facility for garment/apparel manufacturing units catering to both
domestic & export markets. The International Standard park
provides state of the art facilities to the entrepreneurs at an
affordable price. The Park has been set up to promote the growth of
garment, hosiery, and apparel industry in the state.
Some of the major functional
units in the park are:
Mac one Fashion Pvt. Ltd.
Vedanta Fashions Pvt. Ltd.
Babyworld Pvt. Ltd.
Rupa & Co. Ltd.
Jagadhatri Trexim Pvt. Ltd.
Moustache International Pvt.
Ltd.
Senorita Creations Pvt. Ltd.
Citrus Fashions Pvt. Ltd.
Manish Creations.
Modern Tradecom Pvt. Ltd.
The Rajlakshmi Cotton Mills
Pvt. Ltd.
Current Condition Analy sis -
Inventory - Cutting -
Imported raw material stored in inventory Cutting the lay after spreading and if they
without any sequnece and proper find any major defects then they do Splicing
arrangment and fabric are not imported and also no safety tools for the worker who
accoridng to the required orders is using straight knife cutter.
Spreading - Bundling -
Directly spreading the fabric on the table They simply make a lot and tie it with
without any inspection just cleaning off the
ropes and send it to sewing room.
dust from the fabric roll
Sewing -
In Sewing room wokrers are joining pannels and if they found any defect in the
pannels then they reject the pannel and new panel in the sewing room were made on
the floor that lead to unorgnised workspace ,also the workers are using scissors instead
of trimmers that completely wasting the time and reducing prodcutivty.
Panel Rejection and pannel making
Workers were making panels on the floor that lead to more error and quality issues also
it can be avoided by a simple inspection in cutting room and it will avoid lot of rework
and improve quality and productivity
Unorganised Inventory -
Currently, importing of raw materials is uneven but it should be planned according to orders and
delivery date due to this there is so much Inventory waste (Inventory is the raw materials, work in
progress (WIP) and finished goods stock that is held) due to which the inventory looks so unarranged
and dirt particles stick on fabric rolls due to long term storage of raw materials.
It leads to problems such as fabric waste cause sometimes the fabric gets so much dirt that it can not
be cleaned even if it is cleaned it will be counted in Rework and waste of manpower and time also
uneven sorting can cause difficulty in finding the required fabric rolls and sometimes it needs
ironing .we can apply 5S tool here
Cutting Room Safety -
The workers are sitting on the table
and performing operation which is
very RISKY in terms of safety.
Currently, the workers in the cutting room are not using any safety equipment and also they
are using the straight knife cutter by sitting on the table itself, (the reason being the
wastes on the floor and unavailability of the workspace so )it can cause minor inaccuracy
that can produce defects and lead to fabric waste and rework. it can simply be avoided by
using hand metal mesh gloves for better safety and if, The 5S Lean tool is implemented
for safety and sorting.
Sewing Room -
In the Sewing room, there is so much unevenness , thread cutter should
be used instead of scissor to make operation efficient. Clothes are
hanging on the machine results very chaotic surrounding for
performing specific operation (Stitching). Machine are not aligned
properly.
Fabric wastage -
Saving small pieces of fabric loss from a piece cut can contribute a great role in
improving productivity. The important of the cutting process in the garment
industry was not over emphasized. Fabric is the most costly portion of any
garment content and can be approximately from 50%-70% of the garment cost .
Since waste a small quantity of fabric can reduce the profitability of the industry so
it should be treated carefully not only the fabric but we are also wasting
manpower and wasting time in rework and poorly optimized workplace.
Problems -
Very uneven
arrangements
Unorganized
room
All of this problems are so major and can cause
many consequences and non-productivity as a
results Lean industry is so important to tackle such
problems and difficulties.
Unorganized trims -
The trims are unorganized which make the complete
line of production haphazard also adds to the delay
of work and makes the workstation cluttered
Poka-yoke -
Advanced manufacturing technologies can only lead to minimization of potential
errors, because human mistakes are still common in the production environment
and potentially have a positive impact on the cost expenses. The implementation of
Poka-yoke in completely eliminating any kind of mistakes is still not very
widespread and a lot of managers are not even familiar with this term.
Poka-yoke can either detect defection after it has taken place or predict an error
that is about to transpire. This rather innovative technique commences with the
examination of possible problems, followed by identification of any parts in regard
to dimension, shape, size and weight and ends with the analysis of potential
deviation from the nominal processes.
The purpose of implementing Poka-yoke is to minimize or at best eliminate human
errors during the manufacturing procedure, so that a defect product of low quality
does not reach customers hands. The main idea behind this system is to be able to
prevent any causes that might lead to mistakes in the operation process by constant
monitoring all production stages. This requires synergy with workers, that can
apply corrective measures when Poka-yoke identifies the possibility of defects.
Improvised workstation Condition -
Inventory - Cutting -
Imported raw material should be stored in Cutting the lay after spreading and finding
inventory with proper sequnece according defects then Splicing and using safety tools (
to order requiremnt and proper stainless steel mesh metal gloves)for the
arrangment. worker who is using straight knife cutter.
Spreading - Bundling -
Spreading the fabric on the table and Bundling and ticketing will make the
Inspecting the roll after cleaning off the dust sorting easy and avoid the pannels from
from the fabric roll ,it will reduce fabric getting dirty also Monitoring the progress
waste and also no extra workers are required
of each specific garment will be easy and
all the correct parts are assembled
together, and. Compensate operators for
their work on each garment.
Sewing -
Now there will be no fabric defect so each worker just need to focus on stitching the panels
and it will increase the productivity and also bundling will help in finding any errors or
defects by the wokers
RECOMMENDED SUGGESTIONS TO APPLY LEAN
MANUFACTURING IN MAC ONE
Suggestion 1: 5S
Application of 5S is really required in the industry since one of the most prominent
problems is the unorganised set up of the unit. 5S implementation can solve the
majority of the problems that are found. Some suggestions for the implementation of
5S are as follows:
● One dustbin each can be allocated to 3-4 workers which help them to keep their
environment clean.
● Organisational containers can be issued to the workers where they can keep the
trims organised.
● Racks can be installed in the unit where the raw material and in-process bundles
of garments can be stored instead of being stored in sacks. The racks can have
compartments as shown below. These can also follow a label system to make the
organisational worker more comprehensive.
● The most important S that they need to follow is the 5th S i.e. Sustaining. They need to
follow the rules correctly to keep the unit organised.
Kanban System For Trims Inventory
Kanban system can applied for issuing the trims to the workers as it will lead
to reduction in wastage of the raw material which in turn will save space, time
and mone
Introducing Shadow
boards on the sewing
floor for easier access
to tools in case of any
machine breakdown
Introducing dispatch boxes for easier transfer of materials
Marking the floor
between the isle inorder
to maintain proper
distance and make the
material movement
smooth
Introducing Fire Extinguisher
near the staem iron table
and at frequent distances to
prevent from injurious
incidents
Emergency exit gate to be cleared
for easy passage in case of any
unforseen situation
Conclusion -
The lean tool is a potential means of eliminating wastes in an organization and is
recommended for identifying possible improvements in an organization.
During this project, we have found areas to implement lean tools in the mac one
garment industry, many potentials have been identified with the analysis of the current
state map. Also, we have given an improvised process flow. we have tried to
implement 5s and poka-yoke and proposed ideas for applying lean tools to the
garment factory which will lead to the following results -
1. Improved Manpower management
2. Less Fabric Waste
3.Less Rework
4.Improved Quality
5.Improved Workplace
6. Improved Productivity
7.Improved Saftey
Thank you
