Group Members:

FIZZA ASAD
WAQAS SHAMS
 LEAN MANUFACTURING will
reduce your COSTS whatever
business YOU run..

 Lean manufacturing is an
operational strategy oriented
towards achieving the shortest
possible cycle time by eliminating
wastes.
 In short, lean manufacturing means
doing more with
• less time,
• less Inventory,
• less space,
• less people and
• less MONEY

 Here are some of the basic truths of

LEAN and many of the tools you will
find essential to implement in any
apparel unit.
 PRINCIPLES OF LEAN
MANUFACTURING & TOOLS
USED
1. Recognition Of Waste

 The first step is to recognize what does

and does not create value from the
customer’s perspective.

Value
add

Lead time
Value Adding (VA):
Any activity that
directly adds value to
the product

Non Value Adding (NVA)

But unavoidable with current
technology and material :
Any work carried out that does not
increase product value.

Waste:
Any activity that does not
add value to the product
hence something you don’t
want to be doing hence
waste
 Value stream mapping is a set of
methods to visually display the flow of
materials and information through the
production process. The objective of
value stream mapping is to identify
value-added activities and non value-
added activities.
 2. Standard Processes
 “Standard process” means that
production processes and guidelines are
very clearly defined and communicated.

 Visual Management is a tool which

enables factory workers to be well
informed about production procedures,
status and other important information
for them to do their jobs as effectively
as possible.
 Visual controls are simple, clear and
concise visible indicators such as
charts, diagrams, lights,
measurements, floor markings,
locations and signs.

What we can’t see we can’t improve

3. Continuous Flow

 Lean usually aims for the

implementation of a continuous
production flow free of bottlenecks,
interruption, detours, backflows or
waiting. When this is successfully
implemented, the production cycle time
can be reduced by as much as 90%.
BATCH ONE PIECE FLOW
MANUFACTURE
From To Inventory is eliminated
Batch manufacture is
this this between processes
often organized by allowing the product to
grouping processes flow through the value
however this can inhibit stream
material flow

Reduce WIP
Reduce Lead time
Reduce transportation
Floor space saving
Improved communication
4. Pull Production

 Pull-production aims to produce only

what is needed, when it is needed.
Production is pulled by the downstream
workstation so that each workstation
should only produce what is requested
by the next workstation.
 “KANBAN” is a pull-based material
replenishment system or tool that
uses visual signals, such as color-
coded cards, to signal to upstream
workstations when inputs are required
at a downstream workstation.
5. Quality at source

 Lean aims for defects to be eliminated

at the source and for quality inspection
to be done by the workers as part of
the in-line production process.

 The tool of cellular layout is used to

achieve many objectives of lean
manufacturing.
 But the main benefit of cellular
manufacturing is that responsibility
for quality is clearly assigned to the
worker in a particular cell and he/she
therefore can not blame workers at
upstream stages for quality problems.
 6. Continuous Improvement
 Lean requires striving for perfection
by continually removing layers of
waste as they are uncovered.
 KAIZEN is a Japanese term or tool for
“continuous improvement”. A main theme
of Kaizen is to create a culture of
continuous improvement, largely by
assigning responsibility to workers, and
encouraging them, to identify
opportunities for improvement.
KEY IMPLICATIONS OF
LEAN MANUFACTURING
 TRADITIONAL LEAN
MANUFACTURING MANUFACTURING
Orientation Supply driven Customer driven

Planning Orders are pushed Orders are pulled

through factory based trough factory based on
on production plan or customer /down stream
forecast demand
Batch size Large Small

Quality Inspection By QC inspectors In-line inspection by

workers
 TRADITIONAL LEAN
MANUFACTURING MANUFACTURING
Inventory Buffer of WIP between Little or no WIP
each production stage between each
production stage
Hand off of WIP Materials accumulate Material directly handed
into WIP storage off from one stage to
another
Production cycle time Long Short
LEAN MANUFACTURING IN
APPAREL INDUSTRY OF
PAKISTAN
 Lean manufacturing is relatively new to
apparel industry of Pakistan but there
are lot training programs and work shops
are held by different institutions for
creating awareness.

 For example GEN-PROM Punjab held a

one day workshop for students and
faculty of University of Management and
Technology, Lahore, and representatives
of the garment/clothing industry on
‘Lean Sigma Application in Garment
Manufacturing’, on February 4, 2010.
CONCLUSION

 The lean manufacturing tools

discussed, should be implemented in
apparel industry in order to minimize
waste and hence reduce production
time and production cost in order to
gain competitive advantage.
REFERENCES

 www.leanmanufacturingguide.com
 http://www.1000ventures.com
 www.gemba.com
 www.lean.org
 www.leanmanufacturingsecrets.com
 www.leanessentials.net
 Report from Google: Mekongs Capital’s-
Introduction to lean manufacturing for
Vietnam (4-June 2004)
 Images from Google