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1. Welcome To The Presentation
Study on Lean
Manufacturing Process in
Garments Production

2. Abstract
Manufacturers are now a days facing intensive global
competition. The key to competing in the international market place
is to simultaneously improve both quality and productivity on
continual basis. The major purposes of the use of lean production
are to increase productivity, improve product quality and
manufacturing cycle time, reduce inventory, reduce lead time and
eliminate manufacturing waste. To achieve these, the lean
production philosophy uses several concepts like Kaizen, Kanban,
5’s, OEE, Just in Time (JIT) etc. This paper clearly explains the
lean concepts, its principle, importance and benefits. This paper also
addresses the approaches to implement lean practices in apparel
industry

3. Lean manufacturing
Lean Manufacturing is a systematic approach for achieving
the shortest possible cycle time by eliminating the process waste
through continuous improvement. Thus making the operation very
efficient and only consisting of value adding steps from start to
finish. In simple lean is manufacturing without waste.
Lean manufacturing=half the human effort in the company
+half the manufacturing space + half the investment in tools
+half the engineering hours =to develop a new product in half

4. Lean theories
Objective of lean manufacturing:
Lean Manufacturing, also called Lean Production, is a set of tools and methodologies
that aims for the continuous elimination of all waste in the production process. The
main benefits of this are lower production costs, increased output and shorter
production lead times. More specifically, some of the goals include:
 Defects and wastage - Reduce defects and unnecessary physical wastage,
including excess use of raw material inputs, preventable defects, costs
associated with reprocessing defective items, and unnecessary product
characteristics which are not required by customer
 Cycle Times - Reduce manufacturing lead times and production cycle times by
reducing waiting times between processing stages, as well as process preparation
times and product/model conversion times.
 Inventory levels - Minimize inventory levels at all stages of production,
particularly works-in-progress between production stages. Lower inventories also
mean lower working capital requirements

5. Lean theories
 Labor productivity - Improve labor productivity, both by reducing the idle
time of workers and ensuring that when workers are working, they are using their
effort as productively as possible (including not doing unnecessary tasks or
unnecessary motions);
 Flexibility - Have the ability to produce a more flexible range of products with
minimum changeover costs and changeover time.
 Output – Insofar Utilization of equipment and space - Use equipment and
manufacturing space more efficiently by eliminating bottlenecks and
maximizing the rate of production though existing equipment, while minimizing
machine downtime;
-as reduced cycle times, increased labor productivity and elimination of
bottlenecks and machine downtime can be achieved, companies can
generally significantly increased output from their existing facilities.
-Another way of looking at Lean Manufacturing is that it aims to achieve the same
output with less inputs – less time, less space, less human effort, less machinery,
less materials, less costs

6. What kinds of companies benefit most
from lean
 Lean is most widely used in industries that are assembly-oriented or
have a high amount of repetitive human processes. These are typically
industries for which productivity is highly influenced by the efficiency and
attention to detail of the people who are working manually with tools or
operating equipment. For these kinds of companies, improved systems can
eliminate significant levels of waste or inefficiency. Examples of this include
wood-processing, garment manufacturing, automobile assembly, electronics
assembly and equipment manufacturing.
 Since Lean Manufacturing eliminates many of the problems associated
with poor production scheduling and line balancing, Lean Manufacturing is
particularly appropriate for companies that don’t have ERP systems in
place or don’t have strong material requirements planning (MRP),
production scheduling or production allocation systems in place. Lean
Manufacturing is also appropriate in industries for which it is a strategic
priority to shorten the production cycle time to the absolute minimum as a
source of competitive advantage for the company

7. Traditional Garment Manufacturing
Process
 Effective utilization of capacities which results more products were
produced by lesser number of worker & infrastructures. (progressive
system)
 Work in process is very high around 3000 pcs /line
 Workers & Machines need not wait for the product
 Product spends more time in manufacturing just waiting
 Garment defects are very high.
 This system is not suitable in today’s scenario

8. Lean manufacturing concepts
Value Creation and Waste:
 In Lean Manufacturing, the value of a product is defined solely based
on what the customer actually requires and is willing to pay for.
Production operations can be grouped into following three types of
activities:
 Value-added activities are activities which transform the materials
into the exact product that the customer requires.
 Non value-added activities are activities which aren’t required for
transforming the materials into the product that the customer wants.
Anything which is non-value-added may be defined as waste.
Anything that adds unnecessary time, effort or cost is considered
non value-added. Another way of looking at waste is that it is any
material or activity for which the customer is not willing to pay.
Testing or inspecting materials is also considered waste since this
can be eliminated insofar as the production process can be improved
to eliminate defects from occurring.

9. Traditional Manufacturing Vs Lean Manufacturing:
Activity Traditional Lean
Inventory level High level Low level
Suitability For high order quantity For low order quantity
Higher product design Not suitable Highly suitable
Cost of production High Low
Bundle size Low High
Process waste High Low
Product inspection Sample based inspection 100% inspection
Work in progress High Low
Production type Stock production Custom production
Layout Functional layout Product layout

10. Advantages lean system in apparel
industry
 Waste Elimination
 Work place Standardization
 Effective plant layout
 Quality will be enhanced at source level.
 Increase the Productivity by 30% from the existing
level.
 Reduction of Production cost & other Overheads
 Reduce the Risk of non compliance and Late Delivery.

11. Principles of lean manufacturing
 Principle 1: Production of value
 Principle 2: Optimizing the Value Stream
 Principle 3: Converting the Process to Flow
 Principle 4: Activating the Demand Pull
 Principle 5: Perfection of All Products, Processes and Services

12. Tools and Techniques Involved in Lean
Manufacturing
 Quality control Tools
 5S
 Just in time
 Kanban
 Kaizen

13. Continue…..
1. Quality control Tools involved in lean manufacturing process:
 Pareto Chart
 Fish Born Diagram
 Histogram
 Control charts
 Scatter Diagram
2. 5 S System:
These 5 Tools are utilized for Workplace Standardization
 Seri (Sort)
 Seiton (Straighten)
 Seiso (Shine)
 Seiketsu (standardize)
 Shitsuke (Sustain)

14. Tools and Techniques Involved in Lean
Manufacturing
3. Just in time (JIT):
 This tool is one of the important tool for LEAN manufacturing .It defines the PULL
Demand model instead of PUSH Demand model in earlier system which is mostly
control the following activities
 Purchase
 Production
 Distribution.
4. KANBAN:
 This is also another important LEAN Manufacturing Tool. Which will mainly focusing
on over production. There are mainly two types of Kanbans.
5. Kaizen:
 Kaizen is the Japanese term for continuous improvement within a business, operations or
productive process. Some of the areas where kaizen activities and programs can be of great
benefit include:
 Individual plant and machinery
 Entire production lines
 Raw material procurement and utilization
 Labor utilization
 Production processes and tasks

15. Approaches to Implement the Lean
Production system in apparel industry
The Following approaches will convert the apparel
industry in to Lean based Production factory. These
approaches will be met through Effective Utilization of
above said LEAN TOOLS.
1. Minimizing the required inventory level
2. Zero down the defects
3. Reduce the process lead time (WIP)
4. Minimizing the production cost
5. Continues process improvement

16. Application of kaizen
 Continuous Improvement can be applied in all the garment
manufacturing operations .From cutting to finishing various
places are available for improvement .
 Improve the fabric handling practice while sewing.
 Reduce the Sewing pucker.
 Stitch & Seam failure can be controlled through continuous
improvement
 Minimizing the Standard Minute value for a given garment
 Once the new standard has been created, the factory floor
must follow it in addition to this KAIZEN activity should be done
continuously

17. Five Things Sales & Marketing Can Learn from Lean
Benefits Challenges
Produce increases in profitability
and market share
Require cultural / educational
change
Provide enormous competitive
advantage
Generally last several years
Possess clear best practices (we’ll
list some below)
Are often not understood at first
Have aspects that are easy to
accomplish
Require leadership commitment
from top Management
Have elements that are not at all
easy

18. Conclusion
The concept of lean manufacturing is new in Bangladesh, and
proactive organizations have already been observed to implement this
tool in their functional departments. This is primarily due to the
multitude of cost advantages which arise from having lean
manufacturing processes.

19. THANK YOU