The never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. Due to fierce global pressure on reducing price and lead time, the textiles and apparel producers will have to banish all waste from their supply chain. Lean manufacturing which removes waste and smoothens the process flow is gaining popularity among textiles and apparel producers and will be a key element for the survival of the industry in the years ahead. An overview of various lean tools with a balanced mix of conceptual knowledge and practical applications in the context of apparel manufacturing Valuable industry information which managers and engineers can follow themselves without the need to hire outside consultants Case studies and examples from apparel manufacturing demonstrating how lean tools are being used successfully by leading organizations; an academician’s delight Possible use cases of several lean tools having potential use in the apparel manufacturing scenario
While there is pressure (from buyers), inclination (within self to do better) and a heightened aspiration among apparel manufacturers to use Industrial Engineering (IE) like other more industrialized sectors, there is no specific book as such dealing with IE in relation to apparel manufacturing. The existing books that are already written on IE possess academic rigour and generic functions applicable across industries, thus making it difficult for the practitioners to refer and clear discrete doubts related to apparel manufacturing. Undoubtedly, work study is the centrepiece of Industrial Engineering; however apart from work study, industrial engineers in apparel industry are also supposed to perform various other functions like preparing operation breakdown and operation flow chart, selecting machine type and attachment and workaids, planning machine layout for maximizing unidirectional material movement, optimising inventory and storage space and maintaining workplace health and safety. These are some of the areas that often lack significant attention. This practitioner’s handbook is an amalgamation of theory and practices, including steps of implementation and common mistakes. A balanced approached is taken to make it equally meaningful and useful for the academics as well as the industry. A unique section titled “industry practices” is incorporated at the end of each chapter which shares the typical practices, constraints and benefits accrued by the industry, which will give meaningful insight to the readers and help them relate theory with actual practice.
This book highlights the concepts of lean manufacturing that help to achieve the objectives of sustainability in a global competitive atmosphere. Lean can help to lower the manufacturing cost in the rising labour and material cost market. Lean is based on various fundamental concepts such as Kaizen, Kanban, Zidoka, 5S and Six Sigma, which aim at reducing process waste for efciency and productivity that are discussed in this book. In addition, the technological changes such as introduction of Internet technologies and Industry 4.0 are taken care by the lean concepts, which are also addressed in this book.
Author: Paul F. Bowes,Paul Collyer, Manoj Tiwari, Pradeep Jha, Mausmi Ambastha, Roberto Inglesi, Rajesh Bheda, Brad Mikes, Late Roger Thomas, Keerthi Abeywickrama, Pradeep Kumar Jha
Publisher: Apparel Resources Pvt. Ltd.
Category: Technology & Engineering
Productivity improvement means doing the same thing in a better and smarter way and continuing to work on improving the techniques for an individual or a team on the shopfloor. And this continuous improvement is the only way to achieve high profitability. Garment manufacturing involves number of operations carried out by different operators and all the activities starting from cutting, sewing till finishing are different from each other in terms of the way they are performed and the technology being used for them. So, it is always advisable to look at the working of four aspects and that are material, machine, men and method. However there are ways to build higher productive efficiencies which result in reduction in cost and bring in higher profit margin.. The book discusses different case studies from the shopfloor showing productivity improvements.
Master's Thesis from the year 2020 in the subject Business economics - Supply, Production, Logistics, grade: A, , language: English, abstract: In this thesis different apparel industries are overseen using interviews, secondary data and observations, a survey is also conducted to gather general information and effectiveness of lean and its tools. For the survival in the present race of industries it is very important to upgrade and calibrate the technology. Lean manufacturing concept is applied to Pakistan’s Textile trade. The determination of conducting this study is to check that how much lean is effective; it is a multidimensional approach only the major dimensions are discussed in this research like reducing waste and improving productivity in garment production. I Two lean tools are also implemented. Resultantly the data gathered concludes that lean approach is highly efficient, but still a long way to go on the road of lean. The conducted survey shows that there is a good awareness regarding the lean approach, management knows that lean manufacturing is very helpful but there are unable in implementation, there is a less implementation knowledge and training staff in the companies. Only two lean tools are implemented in this thesis and more tools can be implemented in the future.
I have been a Lean Management Consultant for the past decade and have been asked interesting questions by my prospects/clients. I’d have to say, the most made statement has been “Lean only works in the Automotive Industry and is not applicable to our industry…”. This misconception is what triggered me to write a book on Lean for the various industries that I consult in, i.e. one book for every industry. This book on the application of LEAN in Apparel Manufacturing, is my first foray into authoring a book. This book is an attempt to educate its readers on how to implement the practical aspects of LEAN, on the shopfloor. It begins with the dissemination of the interrelated elements of the Toyota Production System, the objective of TPS and its importance in Production Management. The concepts of LEAN and waste elimination are then explained with an overview of the Seven Types of Manufacturing Wastes. Value Stream Mapping, a frequently used tool to map the waste, has been elaborated in four chapters. These chapters explain concepts like Product Family Matrix, KPI definitions, guiding principles to design a Lean process and the construction of the ‘AS IS’ and the ‘TO BE’ Value Stream Maps. Individual chapters are devoted to the elements of TPS like 5S, Visual Management, Skill Management, Process Standardization and Single Minute Exchange of Dies. These chapters explain the concepts and their application in detail, equipping you with the required tools and techniques. The chapter on Balanced Score Card and Hoshin Kanri explains the mechanism of aligning the vision of the factory to the individual objectives. The chapters on A3 Problem Solving and Quality Management initiate the readers to a scientific methodology of problem solving. We follow up with chapters on Kanban Systems and WIP Management in order to get a sense of Pull systems. The chapter on Total Productive Maintenance lays emphasis on measurement of OEE% and the problem-solving cascade. We end this book with chapters on Shopfloor Control, sustaining a Lean culture and providing a Lean Implementation Model for Apparel Manufacturing. I would like to extend my gratitude to Deepak Mohindra, Chairman, Apparel Resources for his continued support and guidance. My wife Manali, my daughters Aishwarya & Arya and my mother Padma, have also been my constant motivators. I would also like to thank my past and current clients for implementing my advice. This book would be incomplete without mentioning Ashish Grover, who was a great support during preliminary Lean pilots on the garmenting shopfloor. This book is my tribute to him. I hope that this book creates more value for you and your organization. Wish you all the best in your LEAN journey!
Over time, the lack of understanding, failure to apprehend concepts and inability to find solutions results in myths that are passed down from one generation to the other. The Apparel industry, which is still largely depended on experience rather than education in many key departments, also has been carrying forward certain ‘myths’ or ‘untruths’ in various operations and processes that have stalled the growth of organisations. The gamut of myths ranges from simple processes like measuring work time to use of technology as in the case of CAD to understanding the fine line between Ironing and finishing. Surprisingly, no one has really attempted to move beyond the myths to uncover the truth and unlock the true potential of the process, technology or concept. Dr. Prabir Jana, takes a closer look at some of the popular myths that have hindered growth of not only organisations but also the industry and debunks the truth that lies beneath.
Garment manufacturing companies now a day's facing global competition. Garment manufacturers generally work on the principle of economies of scale. Here, the large fixed costs of production are depreciation-intensive because of huge capital investments made in high volume operations. So, garment industry needs some manufacturing management philosophies like lean manufacturing. The purpose of this work is to investigate the use of lean manufacturing and value stream mapping in the garment industry of Jaipur. In the first stage of study a questionnaire survey was used to explore adoption of lean manufacturing, lean manufacturing tools and techniques used, driving forces and barriers in lean implementation. In the second stage of study a value stream mapping was used to study current state and after studying it a future state map was created to eliminate waste. For elimination of waste takt time was calculated and the cycle time was maintained around the takt time. For value stream mapping the data was collected by means of stop watch time study. The survey results show that many of companies in the apparel industry are not working with lean manufacturing.
Lean manufacturing is a process used in production to maximize efficiency and minimize waste by considering sustainability and the environment. This book presents a comprehensive overview of lean manufacturing in various enterprises, including manufacturing, construction, and the fabric and textile industry, among others. Chapters cover such topics as barriers to lean manufacturing, enterprise modeling, lean practices and circular economies, and more.
This book reports on research and developments in human-technology interaction. A special emphasis is given to human-computer interaction, and its implementation for a wide range of purposes such as healthcare, aerospace, telecommunication, and education, among others. The human aspects are analyzed in detail. Timely studies on human-centered design, wearable technologies, social and affective computing, augmented, virtual and mixed reality simulation, human rehabilitation and biomechanics represent the core of the book. Emerging technology applications in business, security, and infrastructure are also critically examined, thus offering a timely, scientifically-grounded, but also professionally-oriented snapshot of the current state of the field. The book is based on contributions presented at the 3rd International Conference on Human Interaction and Emerging Technologies: Future Applications, IHIET 2020, held on August 27-29, 2020. It offers a timely survey and a practice-oriented reference guide to researchers and professionals dealing with design and/or management of the new generation of service systems.
This book presents the Proceedings of The 6th Brazilian Technology Symposium (BTSym'20). The book discusses the current technological issues on Systems Engineering, Mathematics and Physical Sciences, such as the Transmission Line, Protein-Modified Mortars, Electromagnetic Properties, Clock Domains, Chebyshev Polynomials, Satellite Control Systems, Hough Transform, Watershed Transform, Blood Smear Images, Toxoplasma Gondi, Operation System Developments, MIMO Systems, Geothermal-Photovoltaic Energy Systems, Mineral Flotation Application, CMOS Techniques, Frameworks Developments, Physiological Parameters Applications, Brain–Computer Interface, Artificial Neural Networks, Computational Vision, Security Applications, FPGA Applications, IoT, Residential Automation, Data Acquisition, Industry 4.0, Cyber-Physical Systems, Digital Image Processing, Patters Recognition, Machine Learning, Photocatalytic Process, Physical–Chemical Analysis, Smoothing Filters, Frequency Synthesizers, Voltage-Controlled Ring Oscillator, Difference Amplifier, Photocatalysis, Photodegradation, current technological issues on Human, Smart and Sustainable Future of Cities, such as the Digital Transformation, Data Science, Hydrothermal Dispatch, Project Knowledge Transfer, Immunization Programs, Efficiency and Predictive Methods, PMBOK Applications, Logistics Process, IoT, Data Acquisition, Industry 4.0, Cyber-Physical Systems, Fingerspelling Recognition, Cognitive Ergonomics, Ecosystem Services, Environmental, Ecosystem Services Valuation, Solid Waste and University Extension.
Author: Pradip V. Mehta, Dr. Rajesh Bheda, Rakhi Handa, Paul F. Bowes, G. Jayapal Nair and Late Dr. Rams
Publisher: Apparel Resources Pvt. Ltd.
Category: Technology & Engineering
Retaining customers in any industry is one of the biggest challenges today, and more so in the fashion industry, where competition is very high and customer loyalty very fickle, which has to be earned not just by the look of the garment but also through quality. Therefore, it is imperative that apparel brands world over follow strict quality guidelines right from product designing to quality of inputs to sewing and packaging the product. This critical journey even involves managing the quality of the machines on which the product is made to the way the after-sales services are carried out. Effectively managing quality of all the above materials and processes is a major challenge, mainly for the reason that the complete cycle requires human intervention and humans make mistakes. This book is an honest endeavour to comprehensively cover implementation of all the possible tools, techniques and methodologies which encompass the concept of ‘quality’ for the apparel industry such as quality control, quality assurance and total quality management system. All the concepts have been fortified by case studies on the implementation process with detailed discussion and final outcome. These would not only enable the industry to move forth on the path of consistent improvement but would also support it to remain in sync with the rapidly evolving technological world of today.