Lean manufacturing and textile industry – II

OK, if you have read the article below, we had a question. Read it once more before you start reading this post.

Think about the garment you are wearing. What it has. It has fiber (or the leather as the case may be), and some sewing thread, buttons, a design and some motifs, few labels may be very few other items. Calculate the rough value of these items on the garment individually and add together and calculate the value of this. I am sure you will be shocked. It might be less than 10% of the amount you paid to buy your garment. Then why these big retailers are pricing them so high. They might be able to get a good market cover by selling these at lower price.

It is not that your retailers are making very high profits(although they earn very good money on the business). This is an inbuilt problem in garment making process. OK think now,

Do you really want to make a small strand of yarn from the cotton bale and again a even smaller yarn. These processed do not add value to your final product. Even do they need to produce yarn and then make them in to fabrics and then in to garments. I do to see a point in this if not for fashion reasons. The process has a inherent chain of wastes, which will take up most of the resources available in the process.

After going through all these wastes and making the fabric, somewhere around 20% of the fabric will be wasted as the cutting wastes in the apparel manufacturing. It is a waste on waste. This is how your garment price goes high.

I really want some of you to have a closer look in to this process so you will understand all the problems inherent to the system. All though I have done a good study I do not want to tell you all the information about this, since then you will loose the direction and surely will get confuse.

So think lean, and think about the process of apparel manufacturing. You will simply see the importance of lean manufacturing as a philosophy and as a system.

Lean manufacturing and textile industry – 1

Have you ever wonder “why I need to become a lean thinker”. If you have so, I have a very good example


Think about the textile industry. Think about the garments made out of these textiles.


Do you know how many processes in producing the fabric which makes your garment? First the cotton has to be cultivated. Then the cotton is harvested and then made in to bales of cotton. Then they are transported to the mill


In the mill, the bails are opened up and go through set of machines. Then these cotton fibers are made in to a thick sliver. Then these slivers go through another machine and made in to small strands. Then it goes through another machine and made into yarns.


These yarns then goes through many processes and then becomes the grey fabric. This grey fabric then becomes the finished fabric with an array of processes.


Then this fabric transported to apparel manufacturers. They do many operations and then cut them. Then they sew them in to the final garment.


So, complex enough. But it is said that less than 1% of cost of the finish garment is the cost of the fiber. But the fiber contributes for at least 80% of the weight of the garment. Funny isn’t it?


What is the reason for this?


I will explain in the next post



Lean manufacturing and world peace

I am a strong believer in lean manufacturing for it’s ability of stop wars J


Why people are fighting. In almost all the cases for some resource. Specially for the resources with limited supply. A good example may be oil.


Have you ever thought your car is a contributor to war in middle east. No, I am not talking about the war. But think…


If your car is 1% more efficient in fuel consumption, how much of oil this world might have saved. Think, the oil prices might not have this high of that has happened.


You might think this is not relevant to lean manufacturing. But for me, lean manufacturing is a philosophy, which talks about efficient use of resources. Lean manufacturing is a way of life. Think….


There is nothing in this world to be wasted. You might pay for some product, of cause you can use that, but you can not waste…..