European Journal of Scientific Research ISSN 1450-216X Vol.73 No.2 (2012), pp. 235-244 EuroJournals Publishing, Inc.

. 2012 http://www.europeanjournalofscientificresearch.com

Garment Manufacturing through Lean Initiative-An Empirical Study on WIP Fluctuation in T-Shirt Production Unit
B. Senthil Kumar Asst. Professor, Department of Rural Industries & Management Gandhigram University, Dindigul E-mail: senthil.b1980@gmail.com Tel: 09003032041 V. R. Sampath Principal, Nanda College of Engineering, Perundurai Abstract Purpose: Due to higher manufacturing cost in garment production, high variation in product mix. It is very difficult to sustain in the global market. This paper will focus on customized implementation of Lean tool for minimizing the Work in progress (WIP), line setting time in a Knitted T-shirt Production Industry which in turn reduces the cost of production. Design/Methodology/Approach: This paper is based on the two fold objective of investigation of Value stream mapping in existing product line and to alter the same with new cellular based layout. Work in Progress (WIP) is analyzed in the sewing room product line of both cases and fluctuation of WIP is investigated through data obtained from sewing room production line Findings: The proposed Value Stream mapping (VSM) through the support of cellular layout reduces the WIP level significantly, which deliver many advantages in garment production system. The reduction in WIP in the production process will increase the profit by 20-25 %from the existing level. Practical Implication: This paper will provide the complete feasibility report for implementation of lean to General Garment manufacturing process particularly knitted manufacturing. Since the Garment construction process contains so much internal as well as external process variation .Customization towards the process will enrich the productivity and ultimately profitability.

Keywords: Kaizen, kanban cellar layout, 5S, Pull based manufacturing, single piece flow based on the product, Work in process (WIP).Value stream mapping (VSM),Value added(VA),Non value added(NV),cycle time(CT), progressive bundling system(PBS) Paper Type: Research Article

Garment Manufacturing through Lean Initiative-An Empirical Study on WIP Fluctuation in T-shirt Production Unit

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1. Introduction & Literature Survey

Lean Manufacturing(LM) is defined as systematic approach to identify & eliminate the process wastages through continuous improvement (S S Mahapatra et al) .Lean is the Pull based Manufacturing approach, also known as the Toyota Production system, which was established in the year 1970s by Taichi ohno and shigeo shingo at Toyota Motor company(Rajab Abdullah hokoma et al.2010). This results in an integrated and efficient manufacturing environment [Mc Muller Patrict R.] Lean has been developed and defined as elimination of waste (Womack et al 1990). In Lean Philosophy, value is determined by customer point of view. It refers what the customer is willing to pay for and, what creates value for the end product. Lean always optimizes the manufacturing process from the customer point of view. Value stream mapping towards the Value added and non value (NV) added activity is very essential for manufacturing a product from its raw material (Rother and Shook1999).With this understanding one can find out ways to minimize the non value added activity towards the value chain instead of replacing the useful value added activity .In a Lean organization people try to minimize the NV continuously (Womack and Jones 1996; McDonald et al. 2000). Cellular layout divides the manufacturing facilities in to small groups called cells which will be exclusively utilized for specific task (Nicoletti et al., 1998). A cell contains equipment and work stations that are arranged to maintain the smooth flow of product without waiting time (Farwaz .a Abdulmalek et al). The advantages of this cell based layout is to achieve single piece flow, improve the quality of the product, minimize the WIP, reduce the throughput time reduce the setup time and improve the productivity (Burbidge,1979).In addition to this the cellular layout will minimize the material movement between the production process (Thomopouus,1986) and create better understanding among the members in the cell( Richard et al,2003).

2. Problem Definition
The general sewing room of a Garment manufacturing unit is carried out with progressive bundling system (PBS).Each PBS will be setup for exclusive product. When Compared to other sections in the garment production, sewing room contains high skill jobs with high quality requirements.BPS system generates a high amount of WIP which is the major issue. Due to high WIP, throughput time as well as the rework time will be very high. Line balancing between the operations becomes a critical task. Defective parts also get hidden in between the products. This results in many garment professionals working like fire fighters. Secondly a BPS system does not provide flexibility to fit small order quantity, which is a crucial requirement for the garment industry in the present scenario, since most of Garment orders are having high level of product mix, in order to meet such requirements, product layout should be designed to hold minimum WIP between the process and give flexibility to change the order quickly with minimum line setting time.

3. Research Approach
The Present Study will analysis the Value Stream Mapping (VSM) of existing production facilities of T.Shirt Manufacturing unit at Tirupur in India. It is an attempt to and understand the root causes which increase the WIP between the process .The Study Subsequently will examine some of the suitable Lean tools and techniques for Proposing the new system of value stream mapping.. Finally the study will compare the WIP Variation between both the levels.

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4. Current State Value Stream Mapping

The Current VSM has been designed with the support of necessary data collected from the Sewing Room of the Garment factory such as Basic pitch time(BPT) of each operation , Personal fatigue allowance (Pf) between the operators who is performing the particular task in the Product line. Pf is derived based on the operation criticality. Time study and Method study were conducted at the floor on each operation in the T-Shirt production line .Subsequent to this experiment hourly production between the operation as well as Total Production from the entire product is monitored. To get better results, each operation is repeated for at least 15 cycles. BPT and pf Cycle time between the operations is calculated and tabulated at Table 1..

Garment Manufacturing through Lean Initiative-An Empirical Study on WIP Fluctuation in T-shirt Production Unit
Table 1: Value Stream of Existing T.Shirt Production line
Types of Sewing Machine 5 Thread O/L Flat Lock Machine/help Operato Helper er r 2 1 1 1 1 SNLS 5 Thread O/L SNLS SNLS 1 1 1 1 1 1 1 SNLS SNLS 1 3 1 1 1 1 5 Thread O/L 5 Thread O/L Flat Lock Flat Lock SNLS Flat Lock SNLS 2 1 2 1 1 1 2 2 1 1 1 1 Total 21 16 2 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 2 1 2 1 1 1 2 2 1 1 1 1 37 Basic Pitch time 0.81 0.273 0.205 0.238 0.228 0.128 0.153 0.192 0.222 0.25 0.228 0.193 0.326 0.903 0.207 0.214 0.141 0.158 0.828 0.242 0.834 0.167 0.226 0.224 0.588 0.825 0.222 0.238 0.272 0.276 10.011 Cycle Time 0.972 0.31395 0.246 0.2856 0.2736 0.1536 0.1836 0.2304 0.2664 0.2875 0.2736 0.2316 0.3912 1.0836 0.2484 0.2568 0.1692 0.1896 0.9522 0.2904 0.9591 0.2004 0.2712 0.2688 0.68796 0.99 0.25974 0.2856 0.3264 0.3312

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S.No Process 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Front back Matching Shoulder joint Shoulder cut mark Shoulder top Stitching Thread cut Make care label Join care label Neck Rib make width Neck Rib Fold tack Neck Joint Thread cut Cut twill tape Back neck elastic tape joint Back neck Elastic Top stitch Main label position mark Main & co label position Match sleeve pair Match sleeve and body sleeve joint Body turn Side seam Body folding after side seam Bottom hem tack sleeve hem tack sleeve hem churi hem raw edge cut Bottom hem bottom hem raw edge cut security tack Thread cut body turn

Allowance 20 15 20 20 20 20 20 20 20 15 20 20 20 20 20 20 20 20 15 20 15 20 20 20 17 20 17 20 20 20

Capacity/Hour 61.72839506 191.1132346 243.902439 210.0840336 219.2982456 390.625 326.7973856 260.4166667 225.2252252 208.6956522 219.2982456 259.0673575 153.3742331 55.3709856 241.5458937 233.6448598 354.6099291 316.4556962 63.01197227 206.6115702 62.55864873 299.4011976 221.2389381 223.2142857 87.21437293 60.60606061 231.000231 210.0840336 183.8235294 181.1594203 Mean WIP

WIP between operation 14 15 13 14 10 15 15 14 14 17 12 10 16 14 14 14 16 13 18 12 15 10 16 15 14 12 14 16 14 13 419

239 4.1. Cycle Time

B. Senthil Kumar and V. R Sampath

It is defined as how frequently a finished product comes out from the production facility ( Rother et al.,1999).Cycle time includes all types of delays occurred while completing a job.Here cycle time is calculated by multiplying the pf and BPT.

5. Future State Value Stream Mapping with Cellular Layout

The future VSM has been developed for the same product by segregating similar operations together .By keen observation on the current VSM, it is understood that many of operations are Non value added (NV) activities .As much as possible those NV activities have been eliminated from this new VSM. In addition to this, looking at the current state map large inventories which nearly 400 in Numbers and higher production lead time nearly 2 days require to deliver the first piece from the supply chain. Inventory and Lead time may be viewed as two related issues (Farwaz et al. 2006).
Figure 1: Shoulder making cell (U shaped Layout)

For creating new ideal VSM the cellular layout is utilized,which is a key Lean tools. Unlike PBS system the cellular layout is like a U shaped modular system. As the figure -1. BPT and pf Cycle time between the operations is found for this revised VSM and it is again tabulated at Table 2.

Garment Manufacturing through Lean Initiative-An Empirical Study on WIP Fluctuation in T-shirt Production Unit
Table 2: Revised Value Stream Mapping through Cellular Layout/Modular T-shirt Production Line
Types of Sewing Machine 5 Thread O/L Flat Lock SNLS SNLS Oper ator 1 1 1 1 1 1 Inspe ctor Allow ance 10 10 10 20 20 20 Cycle time 0.979 0.462 0.1408 0.1836 0.1692 0.1896 Total M/c in the cell 6 No of Machine Available in the Cell 3 2 0.5 0.5 Capacity/Hou r 183.8610827 259.7402597 213.0681818 163.3986928 354.6099291 316.4556962 Mean WIP in the cell

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S.No

Opera tion 1 2 3 4 5 6

Process Shoulder joint (including Front & Back matching) Shoulder top Stitching Make care label Join care label Match sleeve pair Match sleeve and body

BPT

Total WIP Between the operation 2 3 3 2 2 3 15

1 2 3 4 5 6

0.89 0.42 0.128 0.153 0.141 0.158

Table 3:
Operatio Process n 1 2 3 4 5 6 Neck Rib make width Neck Rib Fold tack Neck Joint with thread cut Cut the twill tape with Back neck elastic tape joint Main label position mark & attachment Main & co label position Types of Sewing Oper Machine ator 5 Thread O/L SNLS SNLS SNLS SNLS SNLS 1 1 1 1 1 1 Allow ance 10 10 10 10 10 10 No of Machine Available in the Cell 1 1 1.5 3.5 1 1 9 Total WIP Between the operation 2 3 4 2 2 3 16

S.No 1 2 3 4 5 6

BPT 0.192 0.222 0.38 1.032 0.207 0.214

Std Pitch Time 0.2112 0.2442 0.418 1.1352 0.2277 0.2354 Total M/c in the cell

Capacity/Hour 284.0909091 245.7002457 215.3110048 184.9894292 263.5046113 254.8853016 Mean WIP in the cell

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Table 4:
S. No 1 2 3 4 5 6 Types of Sewing Machine 5 Thread O/L 5 Thread O/L Flat Lock SNLS SNLS Opera tor 1 1 1 1 1 Allowan ce 10 10 10 10 10 10 Std Pitch Time 0.451 0.8822 0.495 0.5181 0.2992 0.5016 Total M/c in the cell

B. Senthil Kumar and V. R Sampath

Operation 1 2 3 4 5 6

Process Sleeve joint Body turn +Side seam+Body folding after side seam Bottom hem tack +Sleeve Hem tack Sleeve hem +Bottom Hem Security tack Thread cut body turn+hem raw edge cut

BPT 0.41 0.802 0.45 0.471 0.272 0.456

No of Machine Available in the Cell 2 4 1 2 1 2 12

Capacity/Ho ur 266.075388 272.0471548 121.2121212 231.6155182 200.5347594 239.2344498 Mean WIP in the cell

Total WIP Between the operation 2 3 2 2 3 3 13

Garment Manufacturing through Lean Initiative-An Empirical Study on WIP Fluctuation in T-shirt Production Unit 5.1. Grouping the Manufacturing Operation

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The first step in the new VSM is grouping the similar operation with respect to product families or grouping the operations which are all forming a common product. .Here there are 3 different cells were created 1.Shoulder Joining cell 2. Neck Attachment cell 3.Sleeve and hem Attachment cell. In general any garment contains these three important functions where as the style between the function may differ drastically .So these 3 cells can be utilized to prepare any kind of knitted mens Top garment. 5.2. U Shaped Cellular Layout Since the current PBS system creates higher WIP critical analysis has done on minimizing the WIP ,which reduces the internal inventory as well as the manufacturing cost subsequently.As per the earlier literature U shaped Celluar layout minimizes the WIP significantly .So the Researcher adopted this tool on the above 3 different groups of operation in a customized way. In the New cellular layout some of the operations were removed from the existing layout .First Quality checkpoint were removed because the initial operator should be aware of quality standard. On need basis some of the operation are combined in this new layout. For instance In the current layout there would be two operation like front & back matching and Shoulder joining where as in the new layout these are combined to form a single operation This will eliminate the movement from preparatory to assembly. In this layout there is no need for WIP storage area. Operators are not allowed to build WIP, rather they should change their operation immediately if WIP seems increasing. Quality checkers were completely removed from the operation and so the operator will be solely responsible for the quality as well.

5.3. Work Balancing Between Operators After defining work flow balancing the workload between the operators is a big challenge. Each operator should be given a equal amount of work To achieve this few key changes were made. All sitting operations were converted into stand up operations or rotary sitting chair has been made. This will make travelling between machines easy so that operator can handle multiple operations. Operators should trained in 3 to 4 operations of their respective workcell.This will help the operator to rotate the between the operations which is called cross training. To create pull based system .Which refers, the capacity of the final cell should be marginally higher than the other cells so that naturally other cells produce more. Number of operations are less than the work station. This will help balance the work load between the operators by rotating the operator. Floating balance

6. Result & Discussion

Implementation of Lean approach to production process in a T-Shirt based Garment industry has reduced the WIP Significantly .10 cycle reading were taken at various level of the cellular layout is shows that nearly 70% to 80% WIP has reduced from the PBs Layout to Lean based cellular layout .

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By reducing various Non Value activities in the Cellular layout the production lead time has reduce from 2 days to 20 min , which would enhance the manufacturer to go with short term order quantity also. Since this cellular layout ensures the floating balance the change in pitch time is around 70% as compared with the PBS type of Layout.

7. Conclusion
This Lean manufacturing implementation technique to the Garment sector adopted in a customized way has reduced the WIP drastically .High WIP is a big concern for the apparel manufacturers in India .This study carries evidence of genuine advantages of applying lean principles to Apparel industry. It is concluded that Lean initiative has addressed the present manufacturing issues like minimizing WIP & Pitch time, cost of manufacturing and Manufacturing lead time .

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