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The never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. Due to fierce global pressure on reducing price and lead time, the textiles and apparel producers will have to banish all waste from their supply chain. Lean manufacturing which removes waste and smoothens the process flow is gaining popularity among textiles and apparel producers and will be a key element for the survival of the industry in the years ahead. An overview of various lean tools with a balanced mix of conceptual knowledge and practical applications in the context of apparel manufacturing Valuable industry information which managers and engineers can follow themselves without the need to hire outside consultants Case studies and examples from apparel manufacturing demonstrating how lean tools are being used successfully by leading organizations; an academician's delight Possible use cases of several lean tools having potential use in the apparel manufacturing scenario
The never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. Due to fierce global pressure on reducing price and lead time, the textiles and apparel producers will have to banish all waste from their supply chain. Lean manufacturing which removes waste and smoothens the process flow is gaining popularity among textiles and apparel producers and will be a key element for the survival of the industry in the years ahead. - An overview of various lean tools with a balanced mix of conceptual knowledge and practical applications in the context of apparel manufacturing - Valuable industry information which managers and engineers can follow themselves without the need to hire outside consultants - Case studies and examples from apparel manufacturing demonstrating how lean tools are being used successfully by leading organizations; an academician's delight - Possible use cases of several lean tools having potential use in the apparel manufacturing scenario
I have been a Lean Management Consultant for the past decade and have been asked interesting questions by my prospects/clients. I’d have to say, the most made statement has been “Lean only works in the Automotive Industry and is not applicable to our industry…”. This misconception is what triggered me to write a book on Lean for the various industries that I consult in, i.e. one book for every industry. This book on the application of LEAN in Apparel Manufacturing, is my first foray into authoring a book. This book is an attempt to educate its readers on how to implement the practical aspects of LEAN, on the shopfloor. It begins with the dissemination of the interrelated elements of the Toyota Production System, the objective of TPS and its importance in Production Management. The concepts of LEAN and waste elimination are then explained with an overview of the Seven Types of Manufacturing Wastes. Value Stream Mapping, a frequently used tool to map the waste, has been elaborated in four chapters. These chapters explain concepts like Product Family Matrix, KPI definitions, guiding principles to design a Lean process and the construction of the ‘AS IS’ and the ‘TO BE’ Value Stream Maps. Individual chapters are devoted to the elements of TPS like 5S, Visual Management, Skill Management, Process Standardization and Single Minute Exchange of Dies. These chapters explain the concepts and their application in detail, equipping you with the required tools and techniques. The chapter on Balanced Score Card and Hoshin Kanri explains the mechanism of aligning the vision of the factory to the individual objectives. The chapters on A3 Problem Solving and Quality Management initiate the readers to a scientific methodology of problem solving. We follow up with chapters on Kanban Systems and WIP Management in order to get a sense of Pull systems. The chapter on Total Productive Maintenance lays emphasis on measurement of OEE% and the problem-solving cascade. We end this book with chapters on Shopfloor Control, sustaining a Lean culture and providing a Lean Implementation Model for Apparel Manufacturing. I would like to extend my gratitude to Deepak Mohindra, Chairman, Apparel Resources for his continued support and guidance. My wife Manali, my daughters Aishwarya & Arya and my mother Padma, have also been my constant motivators. I would also like to thank my past and current clients for implementing my advice. This book would be incomplete without mentioning Ashish Grover, who was a great support during preliminary Lean pilots on the garmenting shopfloor. This book is my tribute to him. I hope that this book creates more value for you and your organization. Wish you all the best in your LEAN journey!
There are some very good books available that explain the Lean Manufacturing theory and touch on implementing its techniques. However, you cannot learn "how to be" lean from merely reading the theory. And to be successful in the real-work environment you need a clear comprehension of how lean techniques work, rather than just a remote understanding
This book provides an overview of current issues and challenges in the fashion industry and an update on data-driven artificial intelligence (AI) techniques and their potential implementation in response to those challenges. Each chapter starts off with an example of a data-driven AI technique on a particular sector of the fashion industry (design, manufacturing, supply or retailing), before moving on to illustrate its implementation in a real-world application
Garment Manufacturing Technology provides an insiders' look at this multifaceted process, systematically going from design and production to finishing and quality control. As technological improvements are transforming all aspects of garment manufacturing allowing manufacturers to meet the growing demand for greater productivity and flexibility, the text discusses necessary information on product development, production planning, and material selection. Subsequent chapters covers garment design, including computer-aided design (CAD), advances in spreading, cutting and sewing, and new technologies, including alternative joining techniques and seamless garment construction. Garment finishing, quality control, and care-labelling are also presented and explored. - Provides an insiders look at garment manufacturing from design and production to finishing and quality control - Discusses necessary information on product development, production planning, and material selection - Includes discussions of computer-aided design (CAD), advances in spreading, cutting and sewing, and new technologies, including alternative joining techniques and seamless garment construction - Explores garment finishing, quality control, and care labelling
Lean production is the gold standard in production systems, but has proven famously difficult to implement in North America. Mass production relies on large inventories, uses "push" processes and struggles with long lead times. Moving towards a system that eliminates muda ("waste") caused by overproduction, while challenging, proves necessary for improved efficiency. Often overlooked, value stream mapping is the essential planning stage for any Lean transformation. In Mike Rother and John Shook's essential guide, you follow the value stream mapping undertaken for Acme Stamping, for its current and future state. Fully illustrated and well-organized, Learning to See is a must-see for the value stream manager.
This book deepens the understanding of cultural conditions for implementing organizational and process changes in higher education institutions. Developing the humanistic and critical trend in Lean management research, it aims to define the notion and maturity of a Lean culture in higher education institutions as well as to determine its key dimensions and descriptions in the light of adopted ontological and epistemological assumptions. This book defines the notion of Lean Culture, proposes a model to assess its maturity, determines conditions for its implementation, and presents the tools of the Lean management model in a university. It supplements the issues related to the implementation of the Lean concept by adopting a humanistic approach.
Apparel Engineering is a term to explain the industrial engineering activities to be used in Apparel Production process, this will include methods to reduce Man, Machine and Material wastage in the Apparel Production process, it includes selection of right tools and machines, training to the operators for quality and fast production, material management, ergonomics to use in apparel industry, methods development and advanced production planning and development of method study and Workstudy applications in production process, Line balancing to product handling. The whole booklet is capsuled to easy knowledge by reducing long theories. Maximum real time data from industry are used to generate and explain the calculations so that the methods can easily be adapted to industries by their industrial Engineers. I this book, author has tried to explain the ideas of, Wastages, Facility Layout and Material Planning, Material Flow system, Plant Layouts, Factory layout, Economics of Material Handling, Production Systems, Capacity planning, Marker Planning & cutting, Processing of fabric faults, Marker utilisation, Cut order planning, Workstudy Procedures, Micromotion studies, Production studies, Work Measurement Techniques, Performance rating, Allowances, Industrial Ergonomics, Principles of Motion Economy, Production Planning Process, Line Planning, Capacity Planning, Line Balancing, WIP, Scheduling Orders, Manufacturing Lead Time, Load Levelling, Scheduling Bottlenecks, Operation Scheduling, Production Reporting, Job evaluation & Compensation, Designing wage structure, Incentive plan etc This book will serve as one best reference to the Apparel Engineers in the garment industry, asl well as learners and professions.