Improvement of raw material picking process in sewing machine factory using lean techniques

Abstract

This study demonstrates application of Lean techniques to improve working process in a sewing machine factory, focusing on the raw material picking process. The value stream mapping and flow process chart techniques were utilized to identify the value added activities, non-value activities and necessary but non-value added activities in the current process. The ECRS (Eliminate, Combine, Rearrange and Simplify) in waste reduction was subsequently applied to improve the working process by (i) adjusting the raw material picking procedures and pre-packing raw material as per demand, (ii) adding symbols onto the containers to reduce time spent in picking material based on visual control principle, and (iii) developing and zoning storage area, identifying level location for each row and also applying algorithms generated from a solver program and linear programming to appropriately define the location of raw material storage. Improvement in the raw material picking process was realized, cutting down six out of 11 procedures in material picking or by 55%, reducing material picking time from 24 to 4 min or by 83%. The distance to handle material in the warehouse can be shortened by 120 m per time or 2,400 m per day, equal to 86% reduction. Lean techniques proved to provide significant improvement in sewing machine company operations.