An overview of Modern Production Tools in

Garment Manufacturing

By Dr. Anirban Dutta

Asst. Professor
Govt. College of Engg & Textile Technology Serampore ,
Serampore, W.B

Date: August-Sep 2022

 Contents …
◼ Lean Manufacturing concept in Garment
Manufacturing
◼ Implementation of Just-In-Time (JIT)
principles in Garment Manufacturing
◼ Implementation of KANBAN principles in
Garment Manufacturing
◼ Real Time Production Tracking System in
Garment Manufacturing
◼ Radio Frequency Identification (RFID) in
Garment Manufacturing
 Contents…
◼ Introduction to Modern PPC Software in
Garment Manufacturing
◼ Basics of Enterpriser’s Resource Planning
(ERP) in Garment Manufacturing
◼ Principles of Finite Capacity Scheduling
(FCS)
◼ Web-Ticketing Systems in Garment
Manufacturing
 What is Lean Manufacturing?
◼ The founders of the Lean Enterprise Institute and the
Lean Enterprise Academy, James Womack and Dan
Jones, wrote,
“Lean Thinking: Banish Waste and Create Wealth in Your
Corporation.”
(Source Url: https://blog.unex.com/five-principles-of-lean-
manufacturing)

◼ The lean manufacturing principles were formed in Japan.

◼ It was an effort to improve sales and increase profit, at Eiji
Toyoda company. The objective was to improve Toyota’a
manufacturing process and profit.
◼ Inspired by the Ford facility in Michigan
5 basic principles of Lean Manufacturing
◼ Identify Value
What is DFSS ? = Design for Six Sigma , What is DMAIC ?

◼ Map the Value Steam

What is PLC ? PLCM ? VSM = Value Stream Mapping
◼ Create Flow

◼ Establish Pull
-- KANBAN tool

◼ Seeking Perfection
-- Kaizen
Tool , TQM (Total Quality Management)
 Identify Value : DFSS , DMAIC , DMADV , IDOV

◼ Design for Six Sigma (DFSS) is an Engineering design

process, business process management method related to traditional Six
Sigma. It is based on the use of statistical tools like linear
regression and enables empirical research .

◼ Objective of DFSS: 1) To determining the needs of customers and the

business,
2) To implement those needs into the product solution so created.
3) It is used for product or process design .

Related Tools: DMAIC : Define—Measure—Analyze—Improve—Control

DMADV: Define, Measure, Analyze, Design and Verify
IDOV: Identify, Design, Optimize, Verify
Concept of DMAIC
Concept of DMADV
DMADV STEPS
Concept of IDOV
 Map the Value Stream

◼ Value stream mapping (sometimes called VSM) is a lean

manufacturing technique to analyze, design, and manage
the flow of materials and information required to bring a
product to a customer.

◼ Also known as "material- and information-flow mapping", is a

lean-management method for analyzing the current state and
designing a future state for the series of events that take a
product or service from the beginning of the specific process
until it reaches the customer.
VSM = Value Stream Mapping , Example
Map the Value Stream: PLC and PLCM
PLCM / PLM : Product Lifecycle Management
Establish Pull: What is Pull-strategy ?
 Benefits of Pull Strategy in case of
Manufacturing point of view

• Increased output
• Maximized volume of effective workspace
• Reduced inventories
• Elimination of both overproduction and
underproduction
• Elimination of errors/difficulties caused by
having too much WIP