APPAREL QUALITY MANAGEMENT

Lean Manufacturing, 5s and kaizen

Assignment 2

Submitted by- Aditya

Nainshi
Nisha

Lean Manufacturing:-
Lean manufacturing, also known as lean production, is a systematic approach to
manufacturing that aims to minimise waste and maximise efficiency. It was originally
developed by Toyota in the 1950s and has since been adopted by many other companies
around the world.
The core principle of lean manufacturing is to create more value for customers with
fewer resources. This is achieved by identifying and eliminating waste in all forms,
including overproduction, waiting time, unnecessary transportation, excess inventory,
unnecessary motion, defects, and overprocessing. By reducing waste, companies can
improve quality, reduce costs, and increase customer satisfaction.
Lean manufacturing is a powerful approach to manufacturing that can help companies to
stay competitive in today's fast-paced and ever-changing business environment.
Benefits if lean manufacturing:-

There are numerous benefits of implementing lean manufacturing practices in an

organisation, including:

1. Increased efficiency: By eliminating waste and streamlining processes, lean

manufacturing can help companies operate more efficiently, which can lead to
cost savings, increased productivity, and higher profitability.
2. Improved quality: Lean manufacturing focuses on identifying and eliminating
sources of defects, which can lead to improved product quality and higher
customer satisfaction.
3. Reduced lead times: By implementing just-in-time (JIT) production and other
lean principles, companies can reduce the time it takes to produce and deliver
products, which can improve their responsiveness to customer needs.
4. Increased flexibility: Lean manufacturing practices can help companies
become more agile and adaptable to changes in the marketplace, enabling them
to quickly adjust to changing customer demands or market conditions.
5. Engaged employees: Lean manufacturing encourages employees at all levels of
the organisation to participate in continuous improvement efforts, which can lead
to higher employee engagement and morale.
6. Reduced inventory levels: By implementing lean manufacturing practices such
as JIT, companies can reduce their inventory levels, which can free up working
capital and reduce storage costs.
7. Improved safety: Lean manufacturing emphasises the importance of workplace
organisation and continuous improvement, which can lead to a safer work
environment and fewer accidents.

Lean tools:
Lean principles:
A prerequisite to successfully practicing the Lean manufacturing strategy is
understanding its core principles. To practice Lean Manufacturing, you can follow the
steps below.

1. Identify value: Specify what is the specific value that the customer desires.
2. Map the value stream: Identify the value stream cycle for each product or service
providing value to your customers and remove the ones that don’t add value.
3. Create flow: Once the value-adding steps are identified, aim to create a
continuous flow of value in your process.
4. Establish a pull system: Allow people to pull work instead of pushing work on
them
5. Pursue perfection: Continuously improve to reduce the time and steps required to
deliver value to your customers.

3M
Toyota has developed its production system around eliminating three enemies of Lean:
Muda (waste), Muri (overburden) and Mura (unevenness).

1. MURI, overburden, can result from Mura, and from removing too much Muda
(waste) from the process. When operators or machines are utilized for more than
100% to finish their task, they are overburdened. This means breakdowns when it
 comes to machines and absenteeism when it comes to employees. To optimise the
use of machines and make sure they function properly, preventative- and
autonomous maintenance can be implemented. To prevent overworked employees,
safety should be the focus of all process designs and all standard work initiatives.
For more information about Muri, go directly to the article: Finding Muri
(overburden) in your process.
2. MUDA, waste, can be defined in eight types, 7 defined by Toyota and ‘non utilised
skills’. These are: Defects, Overproduction, Waiting, Unused Talent, Transport,
Inventories, Motion and Excess processing. As Mnemonic device, the first letters
of these wastes form the acronym DOWNTIME (Panneman, 2017).There are
numerous tools available to identify and remove waste from your process, which
include Poke Yoke, Kanban, Takt Time, SMED and One-Piece flow . The most
common tool that helps to improve productivity by removing all 7 wastes,
however, is 5S (Panneman, 2019). In the article Finding Muda (waste) in your
process each of the types of waste are described and linked to tools which can be
used to eliminate them systematically.
3. MURA, unevenness, can be found in fluctuation in customer demand, process
times per product or variation of cycle times for different operators. In production
environments with low-volume, high product variation, flexibility is more
important than in high-volume, low-product variation environments. When Mura is
not reduced, one increases the possibility for Muri and therefore Muda. Mura can
be reduced by creating openness in the supply chain, change productdesign and
create standard work for all operators. These are described in the article: Finding
Mura (variation) in your process.

8 wastes in lean manufacturing:

5S

5S is a methodology that is commonly used in Lean Manufacturing to help improve

workplace efficiency and productivity.
It is based on five Japanese words that begin with the letter "S": Seiri, Seiton, Seiso,
Seiketsu, and Shitsuke.

Seiri (Sort): The first step is to sort through everything in the workplace and eliminate
anything that is not necessary for daily operations. This includes removing clutter,
disposing of unused items, and organising materials and equipment.

GOALS OF SORTING IN 5S

Identify and eliminate unnecessary items: Sorting helps to identify items that are not
required for the work processes and remove them from the workplace. This helps to free
up space and reduce clutter, making it easier to locate necessary items.

Improve efficiency: By eliminating unnecessary items, sorting helps to streamline work

processes and reduce the time it takes to find required items. This helps to improve
productivity and reduce the risk of errors.
Increase safety: Sorting helps to identify and eliminate items that are potentially
hazardous, such as broken tools, sharp objects, and expired materials. This helps to
create a safer work environment for employees.

Reduce costs: By eliminating unnecessary items, sorting helps to reduce the costs
associated with storage, maintenance, and replacement of items. This helps to improve
the bottom line of the organisation.

Promote continuous improvement: Sorting is not a one-time activity but a continuous

process of identifying and eliminating unnecessary items. By promoting a culture of
continuous improvement, sorting helps to create a more efficient and productive
workplace.

Seiton (Set in order): After removing unnecessary items, the next step is to
organise the remaining items in a way that makes them easily accessible and clearly
visible. This includes labelling, arranging tools and equipment in a logical manner, and
identifying specific storage locations for each item.
Goals of set in order:-
Increase efficiency: Set in Order helps to arrange necessary items in an optimal order,
making them easy to find and access. This helps to reduce time spent searching for
items, leading to increased efficiency.

Improve safety: Set in Order ensures that all items are stored safely and in designated
locations, reducing the risk of accidents and injuries caused by misplaced items.

Reduce clutter: Set in Order helps to organise items, making the workplace more
spacious and reducing clutter. This helps to improve the overall appearance of the
workplace and can reduce stress levels.
Simplify workflows: Set in Order aims to organise the workplace in a way that matches
the flow of work. This helps to simplify workflows, leading to better productivity and
improved quality.

Optimise space utilisation: Set in Order helps to optimise the use of space by making
sure that each item has a designated location. This can help to reduce wasted space and
improve the overall layout of the workplace.

Seiso (Shine): The third step is to thoroughly clean and maintain the work area on
a regular basis. This includes regularly cleaning equipment, floors, and work surfaces to
maintain a safe and organised workspace.

GOALS OF SHINE IN 5S

Remove dirt, debris, and other foreign matter from the workplace to create a clean and
safe environment for employees to work in.

Identify and eliminate any sources of contamination, such as spilled liquids, loose debris,
or broken equipment, that may cause accidents or harm to employees.

Inspect equipment and tools to ensure that they are functioning properly and are in good
condition, and to identify any potential problems before they cause production delays or
quality issues.

Create a culture of ownership and pride in the workplace by encouraging employees to

take responsibility for the cleanliness and maintenance of their work areas.
Improve productivity and efficiency by reducing the time and effort required to locate
tools, equipment, and materials, and by eliminating unnecessary steps in the production
process.

Seiketsu (Standardise): The fourth step is to create standard procedures and

practices to maintain the improvements made in the first three steps. This includes
creating standard operating procedures and training employees on how to use them.
Goals

Develop standardised work procedures and visual controls that clearly outline how work
should be performed, how materials and equipment should be handled, and how quality
and safety should be maintained.

Establish a system for monitoring and maintaining the improvements made in the first
three steps of 5S, such as regular audits or inspections, to ensure that the workplace
remains clean, organised, and efficient.

Create a culture of continuous improvement by encouraging employees to suggest new

ideas and improvements to existing processes, and by providing the resources and
support needed to implement those improvements.

Improve communication and collaboration among employees by establishing clear

expectations and responsibilities, and by providing training and coaching as needed.

Reduce waste, errors, and defects by standardising work processes and procedures, and
by eliminating unnecessary steps and activities that do not add value to the organisation.
Shitsuke (Sustain): The final step is to sustain the changes made in the first
four steps over the long term. This includes ongoing training and communication with
employees to ensure that the 5S principles are being followed and maintained on a daily
basis.

Establish a culture of continuous improvement by encouraging employees to maintain

the gains made in the first four steps of 5S, and to identify and address any issues that
may arise.

Develop a system for training new employees in the principles and practices of 5S, and
for regularly reinforcing those principles with existing employees.

Regularly review and update the standardised work procedures and visual controls
established in the Standardise step to ensure that they remain effective and relevant.

Monitor and measure the performance of the 5S system, using metrics such as safety
incidents, quality defects, productivity, and employee engagement, to identify areas for
improvement.

Continuously seek opportunities to streamline processes, reduce waste, and improve

efficiency, using the principles of 5S as a foundation.

Benefits of 5S

1. Increased productivity: By organising the workplace and eliminating clutter,

workers can find tools and materials more easily, resulting in less time wasted
searching for items and more time spent on productive tasks.
 2. Improved safety: Removing unnecessary items and organising materials and
equipment reduces the risk of accidents and injuries in the workplace.
3. Cost savings: 5S helps reduce waste, including excess inventory, unnecessary
equipment, and wasted time, resulting in cost savings for the organisation.
4. Improved quality: By eliminating defects and improving the overall organisation
and cleanliness of the workplace, 5S can lead to improved product and service
quality.
5. Better employee morale: A clean and organised workplace is a more pleasant and
inviting environment, which can boost employee morale and job satisfaction.
6. Enhanced teamwork: 5S promotes teamwork and collaboration by involving all
employees in the process of organising and maintaining the workplace.

Limitation of 5S:-

1. Time and resources: Implementing 5S requires time, effort, and resources. It may
be difficult to justify the cost of implementing 5S in smaller organisations or
those with limited resources.
2. Resistance to change: Implementing 5S may face resistance from employees who
are accustomed to working in a certain way. Some employees may view the
changes as unnecessary or a waste of time.
3. Lack of sustainability: 5S is a continuous improvement process, and sustaining it
requires ongoing commitment and dedication. Without a sustained effort, the
workplace may revert to its previous disorganised state.
4. Inflexibility: The 5S methodology may not be suitable for all types of workplaces
or industries. Certain workplaces may require flexibility in their organisation
methods due to the nature of their work.
5. Over-reliance on visual management: The visual management aspect of 5S, such
as colour-coding and labelling, may not be effective for all workers, particularly
those with visual impairments.
Case study of 5S:-
An XYZ Limited produces different types of products that require various sizes of
crankshaft, camshaft and tools.
In the following section how the company used each of five pillar: Sort, Set in
order, Shine, Standardise and sustain to successfully implement 5S is given

1.Sort Initially the inspection department occupied a large space, not organised
and untidy. A red tag campaign team was formed. The members of the red tag
team separated unnecessary items and necessary items in the inspection
department. The team then placed red tags on items that were not used .As a
result of this sort phase, the used space became free and all the unnecessary
items were disposed of.
2 Set in Order
After the sorting phase, the necessary items that remained were arranged
according to the job requirement in each station. A designated area was assigned
and left out necessary items were placed accordingly. This resulted in reducing
searching time. A visual approach was used as possible to ease the organisation
process and make work easier for the worker.
3 Shine
After the Set in order phase, the inspection department was cleaned. The cleaning
supplies shadow board was used to find cleaning supplies. This has resulted in
minimising searching time. When cleaning the workstation the associates were
able to find abnormalities in the workstation so that one can fix the deviations.
This has resulted in associates keeping their workstation clean.
4 Standardise
The associates from the company cleaned their workstation as part of their daily
routine. At the end of every week, a detailed cleanup is performed. This has
resulted in maintaining high standards of a clean and neat workplace. A plan was
developed to perform routine practices for cleaning and checking. Each and every
worker was given a task to perform daily clean up activity.
5 Sustain
At this final stage of 5S, the inspection department has established standards for
each step of 5S and has acquired self-discipline. An assessment was created for
the successful implementation of the 5S process. Each and every month the
observation was carried out and result analysis was performed.

Kaizen:-

Kaizen was pioneered by Imai Masaaki, who is also the founder and chair of the Kaizen
Institute. Kaizen philosophy is based on the starting point that everything can be
improved – every process, whether working well or problematic, can all be made better.
Kaizen involves everyone – both shop floor employees and managers. Supervisors, team
leaders and managers have a responsibility to encourage a kaizen culture. They should
proactively lead by example, organising training and putting in place mechanisms to
facilitate improvement. They have a responsibility to organise and facilitate Kaizen
events; targeted activities to solve problems and make improvements. To encourage
continuous improvement, managers should monitor the impact of improvement
activities, communicate successes, encourage future events and promote the questioning
attitude that underpins the philosophy.(Kaizen Institute, 2020)

Three pillars of Kaizen

1) Housekeeping

Housekeeping is the process of managing Gemba (workplace) to foster continuous

improvement. The goal is to have all items easy to locate when they are needed. Any
waste should be given a red tag and removed from the process to improve efficiency.(C
Tek Lean Solutions, Inc., 2021)

2) Elimination of Waste

Elimination of Waste Also called as Muda which means any resource that is currently
being used but does not actually add value eliminated from the process to ensure that
only valuable services and products are offered. eg-transportation, over-processing,
waiting, motion, defects, inventory, and overproduction.(C Tek Lean Solutions, Inc., 2021)

3) Standardisation

Producing products and services to pre-set specifications. It lowers costs, increases

productivity, and creates more stable workflows. A good standard should create the
safest, easiest, and most efficient way to perform a job.(C Tek Lean Solutions, Inc., 2021)
Process Kaizen

It focuses on changes to individual work areas to make work more efficient. This
approach to Kaizen requires workers to begin looking for small improvements they can
make in their work area within a day or two. Ideally, improvements should be focused on
eliminating waste (muda) and work processes that are overly difficult (muri)

example- Missing tools or supplies, which cause undue delays Tasks that require
workers to frequently leave their work area.(Graphicproducts.com, 2019)

Flow Kaizen

focuses on changes that improve material and information flow throughout the entire
business, making larger changes that impact multiple work areas, using
cross-departmental teams. These teams are empowered to make a change within a
predefined scope of responsibility.

example- eliminate errors caused by non-standard processes Reduce downtime

(waiting) caused by materials or supplies not being where they should Reduce rework
caused by miscommunication between departments(Graphicproducts.com, 2019)

sh a Kaizen team: Identify a group of individuals who will be responsible for leading the
implementation of Kaizen. The team should be cross-functional and include
representatives from different departments.

Implement improvements: Once the improvement opportunities have been identified, the
Kaizen team should develop an action plan for implementation. This plan should include
specific actions, timelines, and responsibilities.
Monitor progress: The Kaizen team should continuously monitor the progress of the
implementation and make necessary adjustments. This includes measuring the
effectiveness of the improvements and making changes where necessary

Evaluate results: After implementing the improvements, it is important to evaluate the

results. The Kaizen team should measure the impact of the changes and determine
whether they have achieved the desired results.

Standardize improvements: Once the improvements have been proven to be effective,

they should be standardised. This means documenting the changes and making them
part of the standard operating procedures.

Continuously improve: Finally, it is important to continuously improve. The Kaizen team

should continue to identify areas for improvement and implement changes to achieve
better results.(Singh, 2020)

10 Principles of Kaizen:-

1. Never Stop Improving

When a company implements the philosophy of kaizen, they are sending the message
that they will never be complacent or feel like they have achieved a service or product
that is “good enough.” They will always be looking for ways to improve their practice.

2. Eliminate Old Practices

An important part of avoiding complacency is getting rid of old and tired traditions that
are outdated.
 3. Be proactive
It is important to not let excuses get in the way of improvement, and for each person in
the organisation to take personal responsibility for making improvements.

4. Don't Assume New Methods Will Work

Just because a method is new does not mean that it is improved. It is important to move
far beyond the status quo in order to be successful in business. This will likely require
trial and error until success is achieved.

5. Make Corrections
Part of the trial-and-error process requires making corrections to practices or processes
that have something wrong with them. It is critical to continue to make corrections
throughout the process in order to keep improving.

6. Empower All Employees to Speak Up

Everyone who is involved in the success of the company—from the CEO to the line
workers—should be encouraged to offer suggestions and solutions for problems that can
be fixed, or improvements that can be made.

7. Crowdsource
Before implementing a change or possible improvement, talk to several people to get
their input. Having multiple opinions can not only add to a possible improvement, but it
may also offer a different perspective that will open up more new ideas.

8. Practise the “Five Why” Method

Before making any final decisions, get to the root of the problem by asking “why?” five
times. By repeatedly “why?” one can get past the layers of issues that can lead to the
root of the problem. Often, the assumed reason for a problem will actually lead to
another question and dig deeper into the issue.
 9. Be Economical
Watch your finances during the whole process of making an improvement. Look for ways
to save money while making small improvements, and then spend the saved money on
further improvements.

10. Don't Stop

Never consider yourself to be finished. Improvement has no limits, and can be continued
on an infinite level.(Develop Good Habits, 2019)
How to implement KAIZEN

1. Identify the problem or opportunity for improvement: The first step in the Kaizen
process is to identify a problem or opportunity for improvement. This could be a
process that is inefficient, a product that has quality issues, or a service that
doesn't meet customer expectations.
2. Analyse the current process: The next step is to analyse the current process to
understand its strengths and weaknesses. This could involve gathering data,
mapping the process, or conducting a root cause analysis.
3. Develop a solution: Once you understand the current process, you can develop a
solution to address the problem or opportunity for improvement. This could
involve brainstorming ideas, conducting experiments, or piloting a new process.
4. Implement the solution: After you have developed a solution, it's time to
implement it. This could involve training employees, updating standard operating
procedures, or making changes to the physical environment.
5. Measure the results: Once the solution has been implemented, it's important to
measure the results to see if the improvement has been effective. This could
involve collecting data, conducting surveys, or analysing financial results.
6. Standardise the new process: If the improvement has been successful, it's
important to standardise the new process so that it becomes the new way of
doing things. This could involve updating standard operating procedures or
training employees.
7. Continuously monitor and improve: The final step in the Kaizen process is to
continuously monitor and improve the process over time. This involves creating a
culture of continuous improvement and empowering employees to identify and
address problems as they arise.(Singh, 2020)
Benefits of Kaizen:-

1. Increased productivity: By continuously improving processes and eliminating

waste, kaizen can lead to increased productivity and efficiency. This can help
individuals and organisations achieve more in less time and with fewer resources.
2. Improved quality: Kaizen involves a focus on quality and the elimination of
defects. By continuously improving processes and products, kaizen can lead to
higher-quality outcomes that meet or exceed customer expectations.
3. Better customer satisfaction: By focusing on quality and continuous improvement,
kaizen can lead to better customer satisfaction. This can help organisations build
stronger relationships with their customers and improve their reputation in the
marketplace.
4. Reduced costs: Kaizen can help organisations reduce costs by eliminating waste
and improving efficiency. This can lead to savings that can be reinvested in the
business or used to provide better value to customers.
5. Empowered employees: Kaizen involves a focus on employee involvement and
empowerment. By giving employees the tools and support they need to make
improvements, kaizen can help foster a culture of innovation and continuous
improvement.
6. Greater agility: Kaizen involves a focus on flexibility and adaptability. By
continuously improving processes and products, organisations can become more
agile and responsive to changing customer needs and market conditions.
7. Improved morale: By involving employees in the improvement process and
recognizing their contributions, kaizen can help improve employee morale and
engagement. This can lead to a more positive and productive work
environment.(US EPA, 2016)
Case study of Kaizen:-

A garment manufacturing company in Bangladesh named Fashion Garments faced

several challenges in its operations, which included long lead times, poor quality, high
production costs, and low productivity. The company's management realized that it
needed to improve its operations to remain competitive in the market. The company
implemented the Kaizen philosophy to improve its operations.

The Kaizen principles adopted by the company included:

● Continuous Improvement: The company adopted a culture of continuous

improvement, where every employee was encouraged to identify areas that
needed improvement and suggest solutions to address them.
● Quality Improvement: The company implemented quality control measures to
ensure that its products met the highest standards. The company also
implemented a quality management system to monitor and improve its quality
standards continually.
● Productivity Improvement: The company implemented productivity
improvement measures to increase its output and reduce lead times. The
company introduced new production processes and streamlined its operations to
improve efficiency and reduce waste.
● Employee Empowerment: The company empowered its employees by providing
them with the necessary training and resources to improve their skills and
knowledge. The company also encouraged teamwork and collaboration to foster a
culture of continuous improvement.
Results Achieved: The implementation of Kaizen principles resulted in significant
improvements in Fashion Garments' operations. The company was able to reduce its lead
times, improve its product quality, increase its productivity, and reduce its production
costs. The company's employees were also more engaged and motivated, resulting in
higher job satisfaction and lower turnover rates. The company's improved operations also
resulted in increased orders from international buyers, contributing to the company's
growth and success.

References
Lean manufacturing Available at:
https://www.epa.gov/sustainability/lean-thinking-and-methods-kaizen.

https://resources.hartfordtechnologies.com/blog/the-ultimate-list-of-lean-manufacturin
g-tools#:~:text=35%20Lean%20Manufacturing%20Tools%3A%20The%20Ultimate%
20List

https://safetyculture.com/topics/process-improvement/lean-process-improvement/

https://www.mudamasters.com/en/lean-production-theory/toyota-3m-model-muda-mur
a-muri

https://kissflow.com/project/agile/8-wastes-of-lean/
5s Available at:
https://www.5stoday.com/what-is-5s/
https://www.graphicproducts.com/articles/what-is-5s/
https://www.gembaacademy.com/resources/gemba-glossary/5s

Kaizen Available at:

https://www.developgoodhabits.com/kaizen-continuous-improvement

Kaizen approach: 6 steps to continuous improvement. [online] appvizer.com. Available

at: https://www.appvizer.com/magazine/operations/bpm/kaizen-approach.