Applying Lean Tools to Improve the Sewing Line Efficiency: A Case Study

Abstract

In a garments manufacturing industry for selling as well as exporting ready-made-garments, quality improvement is a vital task. Industry will not be able to build up a good business relationship with the buyer if they fail to timely dispatch quality samples and finished product to buyers. This paper aims to investigate the changes in various aspects such as productivity, efficiency, capacity etc. of a readymade garment industry in Bangladesh by applying the 5’s lean tool. There is an improvement in production, WIP (work in progress) inventory reduction, space utilization, transport by applying the lean tool compared to conventional method. This study is based on both primary and secondary data. Here, quantitative method for data analysis is used. Data are tabled firstly in accordance with traditional operation break down, then according to lean line operational breakdown. Here data for jacket operation are shown. Results are compared with the help of bar charts.  In this study the production data of Knitted Jacket are taken. The SMV data in two phases are considered, one with the traditional production process and the other one is with the implementation of Lean technique. Beside SMV (Standard Minute Value) data it has been shown productivity, efficiency, capacity etc. By comparing these data, it is assured that it is more preferable to choose Lean techniques to ensure better productivity level. This study is worked with 5’s and the 5’s will help a manufacturing company to increase its improvement and the company will turn into a self-improving company.