Implementation of lean tools in apparel industry for improving productivity

Abstract

To understand the benefits of the Lean manufacturing implementation in the Apparel Industry, a project was initiated in Pheonix International, Ludhiana (India). Different lean tools were implemented such as 5S, Kaizen, Poka-Yoke, Kanban, and Andon. Lean tools were implemented in all the departments including a fabric store, CAD lab, spreading and cutting department, sewing department, finishing and packaging department. Implementation of lean tools in apparel industry increases productivity by around 8%. The implementation of lean tools resulted in a reduction of cycle time. The lean tools also result in managing and reducing the garment manufacturing waste and thus increasing quality. At the same time, the organization must have to maintain the effectiveness of lean tools to gain benefits over a period.