Application of Lean Thinking in Apparel Industry Lean Consulting Companies in Bangalore The Lean Manufacturing idea in the Apparel Industry can lessen the operational cost in assembling by clearing out the procedure squander, drawing in people with more unmistakable correspondence, growing the higher productivity in the execution system and changing the organization into a learning association. Lean Manufacturing is an exact procedure for achieving the briefest conceivable process duration by wiping out the procedure squander through continuous improvement. Along these lines making the movement beneficial and simply including esteem adding ventures from start to finish. In straightforward words lean is fabricating without squander. Key necessities for accomplishment of Apparel activities Steady quality with least adjust and improved First Time Right (Through) Productive tasks at Sewing and Finishing • •
Taking care of complex cutting prerequisites as far as taking care of low volume and high blend adaptations. Viable getting ready for On-time in Full Deliveries Overseeing activities with standard working hours (no extra time for any area). Expertise improvement for individuals Pulling in and maintenance of right representatives. Manufacturing plant is satisfying security guidelines and ever prepared for any purchaser visit or consistence reviews. Diminished Turn-around an ideal opportunity for money to money cycle through decreased Manufacturing Lead time. Ideal expense of assembling for the estimation of items. Regular situation watched and challenges looked in a run of the mill piece of clothing industry. High obstruction for change from old strategies to new techniques over the capacities. High wearing down of workers because of low assurance previously. Low ability levels Non-adaptability of individuals to work in various activities (incapable to come out of safe place) Un-unsurprising participation and absence of reliability. No possession for quality. Less collaboration among workers. Work completes just with substantial yelling. Substantial weight for shipments. Things won't move without extra time. Short shipments because of dismissal, stains, non-recognizability of good articles of clothing because of misunderstanding and so on. High working expenses because of a significant number of the above reasons. • • • • • • • • • • • • • • • • • • • • • The majority of the staff perform one to two levels underneath. What is Lean Thinking ?
Lean Thinking is an idea more or less spotlights on making an incentive to the client and wiping out non-esteem including exercises. It offers an incentive to the two clients and piece of clothing industry. Incentive from the client viewpoint is that any action that changes of size, shape, properties or uncommon highlights which client is eager to pay for. From Lean point of view, esteem expansion on an article of clothing in attire industry is under 1% for example on time slipped by from RM receipt to dispatch. A portion of the advantages which we have helped organizations accomplish in Apparel Operations are given in the table beneath: Metrics Benefits Overall improvement in product quality Customer delight, more business 1 2 Reduced Manufacturing Lead time Faster delivery, reduction in air-shipments, Overtime cost. 3 Increase in First-time- Right Reduction of re-work cost and rejection. 4 Increased efficiency Reduction in overall cost of manpower 5 Flexible work force with multiskilling Predictable output with good quality. 6 Reduction of change-overs Readiness for low volume, high mix, high profitable business 7 Stable operations Reduction in overtime costs. 8 System driven Consistency in performance over time 9 Transparency, fair practices Improvement in employee morale.
10 Reduced attrition Reduced cost of re-training 11 Reduced absenteeism and late coming Predictable delivery and quality. 12 Increased Cut-to-Ship ratio Better profitability Seven Steps Business change helps in sending of constant improvement culture in associations through their leader preparing programs directed through Seven Steps Academy of Excellence. Self-improvement Programs Nuts and bolts of Business Excellence Worth Added Quality Management Systems Absolute Productive Maintenance (TPM) Lean Thinking and Lean Management Authority Training Programs