Lean for Apparel Industry - Part 1

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Lean for Apparel Industry - Part 1
As promised, my friend has sent me the first article on lean for apparel industry. As I always say, he also starts from 5S. Please read the article. If you like the article, tell the world by clicking on the LIKE button below. 5S is foundation for Lean If a company wants be a world class organization that company should drives and achieve below characteristics. • Zero Down time • Zero Waste • Zero Missed Opportunity • Zero Bureaucracy • Zero “Hidden” Problems To approach to this stage the path or main way is 5s. 5s Define as The Philosophy that lays the Foundation to create a Disciplined Mind, Which leads to disciplined thoughts which leads to Disciplined Actions – Action which improves Productivity, Quality, Cost, Delivery, Safety, Moral & innovation. Why we need 5s? 1. Get EVRY BODY’S Involvement at EVERY LEVEL - 5S is the activity that each person works on part - 5S is the activity that all members’ participation is possible

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That we can recognize going through the below categories. Reduces hierarchal mindset and bureaucracy at work place 10. Reduces physical & psychological stress of all employees 8. Strengthens Team Work. Thinking 3. Lack of Top Management support 8. 1. Depending on Audits to sustain. develops Leadership of all levels. Category Traditional Thinking New 5s thinking Objective Discipline Profit Pursuit Thinking Sustain Sustain & kaizen Action Operate Counter Measure Responsibility Spot Worker All The Members Result Production\Service Improve Support PSQDCM P-Productivity S-Safety D-Delivery C-Cost M-Morale are interested please contact me at azabadurdeen@yahoo. ► August (3) ► July (3) ► June (2) ► April (6) ► March (1) ► February (3) ► January (2) ► 2009 (37) ► 2008 (46) ► 2007 (52) ► 2006 (64) Click Here to suggest topics you want to learn workplace audit Toyota Business Practices lean thinking What is lean six sigma? process mapping Get Skribit | 5 of 9 suggestions Skribit: Social Suggestions How To Use This? LEARN LEAN Rajkot. Creates a Pleasant.Part 1 Lean for your industry All you need to know about lean in one package (wi. 5S is implemented to win competitions than real improvement. Action 4.Part 1 Page 2 of 7 .Lean for Apparel Industry . Malaysia reading Learn Lean Manufacturing Jakarta. Inventory and Work In Progress (WIP) Kuala Lumpur. more on pointing out than problem solving – “Here let us help you to keep this straight” To eliminate these failure factors first we have to identify where we stands on.Taking ownership of what the team members are doing My machine -> my area -> my dept > my company 5. Builds a Visual Work Place with Standard Work 4. buyers 4.au reading Lean manufacturing. Result Based on these categories we can compare the where we stands really. It’s designed to impress visitors.learnleanblog. forgets housekeeping is just a part\the pilot process of the whole journey which gives real time feedback on the plant culture and kick off of 5S 11...in reading Lean manufacturing for apparel industry Broadbeach.com.html 03-12-2010 . reduces internal conflicts 7. Unmasks the hidden organization But most of the companies failed in implementation of 5s because of below reasons. Indonesia reading Lean manufacturing and USEFUL LINKS WeLean Blog DMAIC Training lean manufacturing presentations Lean manufacturing principle Lean manufacturing tools Lean manufacturing definition History of lean manufacturing lean manufacturing concepts and principles explained Six Sigma Gemba Blog Daily Kaizen Blog The Lean Blog Lean Reflections Blog Human Side Of Lean Blog Lean Learning Blog SME Lean directions Lean Enterprise Site Six Sigma Blog Lean Services Blog TPM Blog grab widget • see Blog Directory Start Blogging http://www. Safe and work friendly environment 3. We implement 5S not “Practice” 5S 2. Australia arrived from google.com/2010/09/lean-for-apparel-industry-part-1. Aza Badurdeen HIGHLIGHTS What is lean sigma Lean Thinking What Is Lean Supply Chain What Is Lean Lean Store Lean Resources Lean News JOIN US ON FACEBOOK Click this link and then Click on Join this Group Button BLOG ARCHIVE ▼ 2010 (27) ► November (2) ► October (2) ▼ September (3) Lean for Apparel Industry . Lack of vision and missing link to the company vision & Hoshin 7. 5S implemented as “Look @ US” campaigns 3. Most of mistaken with Housekeeping. Responsibility 5. 1. Misunderstanding of driving 5S through delegation than the Site Leader on the saddle 9. after winning the competition no clear path forward 5.com warranties for the information or anything contained herein. Reduces the resistance to change 9.Participative Actions – Huge Results 2. 5S campaign itself becomes the goal 6.co. India arrived from google. Under estimating the power of 5S in team building 10. Objective 2. Develops Kaizen Minded People 6.

com/2010/09/lean-for-apparel-industry-part-1.16 August 2010 • Waiting is a waste.html 03-12-2010 .26 August 2010 • Easiest way to become lean . Keep your customers waiting?? 03 August 2010 • A lean lesson .19 July 2010 • Toyota Recalls Vehicles Again .learnleanblog.Lean for Apparel Industry .05 July 2010 Search FREE Download NOW! (For more information Click Here) http://www.Part 1 Page 3 of 7 LEAN MANUFACTURING BASICS Download E-Book "Lean Manufacturing Basics" for FREE ! Email: Name: SEARCH MOST POPULAR LEAN SITES RECENT POSTS • Result or Process? .

Continued commitment & support from the top management to follow PDCA. Keep in mind your true goal is achieving business excellence. 9. 4.com/2010/09/lean-for-apparel-industry-part-1. Everyone needs to be responsible for picking up “waste” including top management – no observers\no delegation – you do it first. To keep your process from getting bogged down. 7. Concrete headed people to be exposed. Incorrect ordering 4. Improper storage locations & methods 7. Duplicated ordering & delivering 8. Uncontrolled growth Challenge2 – Set In Order – “Seiton” Objective:. first get rid of all excess work in progress. Aged. Never let the 5S process itself become the goal. No “no man’s land” within the premises. 10.learnleanblog. 5. 3. combine. Separate) • Identify Losses & DT’s • Pick and Choose Supportive Tools • Identify “Loss Based” Skill Will Matrix – ETHOS Pillar • Training Plan on the philosophy • Untapped human Potential Why do unnecessary items accumulate? 1. Challenge1 – Sort – “Seiri” Objective:.html 03-12-2010 . others rewarded – stress individual participation. 6.What “SORT” of actions we need? Actions:• Red Tagging – every red tag has a why? Why? Analysis • Quarantine Area for Red Tagged items • Form Team Based Work Groups • Financially cumulating the value of the items in Red tag area • Disposal Policy & Scrap sales • Lay the foundation for PROCESS MAPPING to get rid of unwanted activities • ECRS ( eliminate. 2.Identify and collate unwanted items. near to the place where it’s needed – improved material & information flow (DEVELOP) http://www. Consider excess inventory as a major unneeded item to target. Sudden changes in the sales. Never Ever Walk by an Unsafe Act or Condition. obsolete equipment. activities and Thoughts(ATTRACT) Question:.Part 1 Page 4 of 7 10 Principles for implementing 5S 1. Lack of quality control 5.Lean for Apparel Industry .Locate a specific place for a specific item with the specific quantity. All employees must be trained – human knowledge appreciates. 8. Clerical & administrative departments should also be setup in U shaped cells to provide observable 5S example. If you setup and maintain a cellular concept flow will be created. production plan 2. Set KPI’s & include 5S to performance evaluating criteria. rearrange. Excessive ordering 3. material. Improper handling – Forced deterioration 10. methods 9. Lack of quantity control 6.

Question:. TIMWOOD • Set in order the standards for the people • Set in order a Visual factory to surface problems • Quick Change Over story boards • Create OPL’s for training on the set in standards • Build Upon the Culture of Problem Solving – Why? Why?. I Maintain” attitude • Start training team members according to the skill matrix • Seiton Preventions. 3.com/2010/09/lean-for-apparel-industry-part-1. sometimes used.How to “Shine”? Actions:• Cross check OPL’s. 6.Part 1 Page 5 of 7 7 1. 4.What actions should “SET IN”? Actions:• Team based work groups “engage” in counter measures for the identified opportunities from the Process Map • Start analyzing the Material and Information flow . 2.learnleanblog. plans to train every one on problem solving tools • Assessment team with a “How can I help you?” mindset • Set in order a system to prevent SEIRI. Seiton Principles Follow the FIFO method for material Assign each item a dedicated location All items & their locations should be identified by systematic labeling Place items so that they are visible to minimize searching time(frequently used.html 03-12-2010 . not used but must be kept) Place items so that agronomical conditions are addressed and can be handled easily Separate “Exclusive” from common Arrange the work place to cater flow – “Flow when you can. 5. Pull when you can’t” Challenge3 – Shine – “Seiso” Objective:.Cleaning\Continuous Inspection with a Meaning(ENGAGE) Question:. continue creating the OPLs • Establish Standards for CLIT • Train team members on using the 5 Senses • Provide specific tools for specified cleanings • Establish cleaning schedules • Address points of contamination – Error proofing • Enable hard to access areas • Fuguai Tagging system • Slowly build in The JH Pillar of TPM • TPM Story Board • PM:AM ratio • Lay the foundation for KK Pillar – PDCA • “Don’t Clean Keep it Clean” Culture • “I run.Lean for Apparel Industry .VSM • Set in order the standards of the admin areas • Set in order the standards of the processes – min\max. 7. kaizens Challenge4 – Standardize – “Seiketsu” http://www.

innovate • Establish Early Management System to prevent shine • “Never. one company. one voice. one vision To be continued…………. P OSTE D B Y A Z A BAD URDE E N AT 9 :2 1 AM   12 Ratings No rating 0 COMMENTS: POST A COMMENT Anything to say. http://www. targets for those who achieved • Start job rotation to pre-condition team members mindset.learnleanblog. ever walk by an Unsafe Act” • Establish the Lean Org Structure to support VA layer Challenge5 – Sustain – “Shitsuke” Objective:. Like 32 people like this.Part 1 Page 6 of 7 Objective:. Set platform for Raising Kaizens(ENGAGE) Question:.html 03-12-2010 .com/2010/09/lean-for-apparel-industry-part-1.INSPIRE Actions:• Establish the human system model for the plant • Servant Leadership • Aggressive catch ball on the Hoshin – Bottom up • Elements of coaching and Job Instruction training for new employees to shorten the mindset change • One system.Consolidate Efforts.What should be the standard? Actions:• Establish the agreed upon best method • Auditing & training to meet standard work • Establish SOPs • Establish revised KPI’s.Lean for Apparel Industry . Please feel free to leave your comment below. multi skilling – kick off E&T Pillar aggressively • Standards to reduce cost • “I run I maintain” attitude to “We run We maintain” • Turn most visual displays to visual management • Platform to Error proof.

com/2010/09/lean-for-apparel-industry-part-1.calculator http://www.com Try the free OEE .com Sample Manuals. Self-Learning Kits. Lean University Course www.  Post Comment Preview LINKS TO THIS POST Create a Link ISO9001-SixSigma-5S-SPC globalqualityvillage. and Software from India.Part 1 Page 7 of 7   Comment as: Select profile.uk/MSc Study 1st Lean Thinking MSc degree at the LERC.learnleanblog.. Buy Now.html 03-12-2010 . Cardiff University OEE World-Class-Manufacturing.LeanEnterprise.Lean for Apparel Industry .org..

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