tag:blogger.com,1999:blog-20419256.post3439966031290577313..comments2011-11-28T21:02:16.567-08:00Aza Badurdeenhttp://www.blogger.com/profile/05343896996385766727noreply@blogger.comBlogger9125tag:blogger.com,1999:blog-20419256.post-77896093348806934342011-11-27T07:58:21.041-08:002011-11-27T07:58:21.041-08:00Hi all,<br />Have a good day.<br />I am K. Selvakumar working as GM- Operations / Production in apparel industry from 1990. I am implemented LEAN concept in my units like 1 pc flow, zero tolerance, pull system, kanban, self &amp; successive inspection, JIT ect... And production targets set by the total cycle time and calculated based on cost per minute / unit and manpower used, so production results are pcs/person/hour as well as cost including in cutting also. This implementations proved that can reduce cost and increase productivity as the same number of workers. <br />As Anonymous said believe it or not...this is true!!Selvakumarhttp://www.blogger.com/profile/12667874049031687122noreply@blogger.comtag:blogger.com,1999:blog-20419256.post-89165499838374122182011-01-11T22:03:36.287-08:002011-01-11T22:03:36.287-08:00As per the Lean the WIP As much as possible the WIP should be minimum .But In any of the production system we cannot exactly bring drown the WIP to 1 level.As Akil said then the operator has to wait more.In response to the R.Duraiswamy i think conveyor can minimize the WIP some extend.But the entire Production system as you said Line concept(Progressive Bundling system) is not suitable for LEAN System.When you adopt the Lean to any product then the Product SMV should be very minimum.So Modular System is mostly suitable with Small SMV product.<br /><br />Senthil-ILFS CDI LTD-Senthil.b1980@gmail.comsenthilhttp://www.blogger.com/profile/04312604270825355400noreply@blogger.comtag:blogger.com,1999:blog-20419256.post-83016581953284595162010-12-05T17:32:05.296-08:002010-12-05T17:32:05.296-08:00One element of lean is continuous flow. Many of the apparel manufacturers use LINE concepts of manufacturing.<br /><br />Please share your views,whether having a conveyor will help in any way?<br /><br />R.Duraisamy<br />Lean expertAnonymousnoreply@blogger.comtag:blogger.com,1999:blog-20419256.post-86728546739830845772010-09-01T23:28:38.512-07:002010-09-01T23:28:38.512-07:00This is good thinking but when we talk about production this idea looks consuming more time rather than to cut a lay of 80 plies etc. In boths cases there are some merits and some demarits. Think in both cases we have to bundle and induct in the line. Somehow can we implement this theory in denim industry. If you have some sort of practical please forward me the information in figures and saving amount in terms of time at arfan.fsd.undp@gmail.com<br /><br />Muhammad Arfan Akram . . . . . . .Arfan Akramhttp://www.blogger.com/profile/11190491704914725323noreply@blogger.comtag:blogger.com,1999:blog-20419256.post-3947444239968997942010-08-29T23:47:39.399-07:002010-08-29T23:47:39.399-07:00hi all,<br /><br />i used to work in lean dept in garment manufacturing and for your information all the lean concept can be implemented on production such as 1 pc flow, zero tolerance, pull system, kanban, self &amp; successive inspection. production target set by the total cycle time and calculated based on cost per unit and manpower used, so production result are pcs/person/hour. this implementation proven can reduce cost and increase productivity as the same number of workers.<br />believe it or not...this is true!!Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-20419256.post-6541849655893786752010-05-20T04:27:49.380-07:002010-05-20T04:27:49.380-07:00Guy,<br /><br />Can any one tell, If the cutting and stiching is done in bulk but how will to cut down the time in for packing- i.e. 100 of pieces are cut n stitched in automated machine..how to reduce the time in packingAnonymousnoreply@blogger.comtag:blogger.com,1999:blog-20419256.post-30377409797175244712009-09-05T11:29:19.180-07:002009-09-05T11:29:19.180-07:00AKIL,<br /><br />according to me we can not adopt the lean concepts 100% in cutting department ,this is what senthil also try to clarify..single pcs cutting by using the sewing workers is not at all possible.bulk cutting is the reliable effective method .as for as consider the single pcs flow in the sewing lines also not possible ..that is a concept/target we have to run towards that by reduceing the bundle size depends on the complication in our style..the thing is redusing WIP in sewing lines will spead up the flow..and reduce the handling.WE HAVE TO TAKE CARE THAT THE BUNDLE SIZE SHOULD NOT BREAK THE FLOW OF THE PRODUCTION ..NO OPERATORS SHOULD WAIT FOR THE PCS.it is most commenly seen in the garment industries..so the line balancing based on takt time is most important for a lean manufacturer..Anonymousnoreply@blogger.comtag:blogger.com,1999:blog-20419256.post-35061057787522912312008-10-07T03:30:00.000-07:002008-10-07T03:30:00.000-07:00I have seen one company with this lean concept .but they are doing this bulk cutting with the existing laying procedure but not in a single ply cutting .here instead of pushing to the cut panels to the sewing dept ,the sewing dept pulls the inputs from the cutting section that reduce full time worker in cutting section ,which means the worker in the cutting section worker may be used for fabric section and other dept also.but planning is very essential for lean system<BR/><BR/>Senthil kumar-ILFS CDIsenthilhttp://www.blogger.com/profile/04312604270825355400noreply@blogger.comtag:blogger.com,1999:blog-20419256.post-63466113218710135532008-09-20T23:56:00.000-07:002008-09-20T23:56:00.000-07:00Hi there,<BR/>The concept explained in the article covers the need of companies handling boutique buyers or very small order quantity.<BR/>In mass production when we lay 100 plies at a time we consider it safe from shade variation or any such problem as they are going to be handled through bundle system.<BR/>Please suggest how can we apply these concets in mass production with laying more lays as well as using bundle system or assembly line?Akhilaccusam.comnoreply@blogger.com