IMPACT OF LEAN MANUFACTURING ON PRODUCTIVITY AND LAYOUT DESIGN IN SEWING SECTION OF A GARMENT INDUSTRY

Abstract

The adoption of lean manufacturing as a method for enhancing productivity that led to the reduction of waste and uniformity of cycle time is the subject of this research. In the fast-paced, dynamic, and ever-changing global economy, many businesses are employing the lean manufacturing approach to remove waste, improve processes, save costs, enhance innovation, and decrease time to market. Lean manufacturing is especially appropriate in Bangladesh because many Bangladeshi private garments manufacturing companies are operating below their actual capacity, or undergo late deliveries, due to problems with their traditional production systems and a lack of skilled personnel. A basic full-sleeve t-shirt sewing line was the focus in the study. Non-value-added activities such as a large number of work-in-process (WIP), unnecessary transportation, and product defects due to poor 5S (Sort, Shine, Set in Order, Sustain, Standardize) and lack of traffic light system (TLS) were observed. Researchers also noticed the indifference of the workers. They used time study, line target, process flow mapping, theoretically machine requirement, and line efficiency to assess conventional line productivity. After implementing lean techniques (5S, line balancing, just-in-time), the standard time was obtained using process flow and cycle time analysis. Thus, non-value-added tasks are reduced, resulting in an improvement in production. They compared the previous production line with the lean-implemented production line and they noticed a lot of changes. Results showed that, after lean implementation, SMV is decreased by 0.9 minutes, production is increased by 1,664 pieces per month, the number of workers is decreased by 2 (two) persons, alter percentages is reduced to 4%, spot quantity is reduced to 1.80%, the rejection rate is reduced to 0.68%, WIP is decreased by 7 (seven) pieces, 69.08% efficiency is achieved. Lean manufacturing brought about great improvements in the sewing sector by establishing a standard minute value, a smooth process flow, and productive operations, which made a significant contribution to the achievement of production targets. In this way, lean manufacturing tools and practices can change the overall scenery of a traditional sewing section of the garment industry. This paper gives the whole feasibility assessment for implementing lean manufacturing in the garment manufacturing process.