Journal of Textile Science & Engineering

Analysis on Production Efficiency of Lean Implemented Sewing Line: A Case Study

Abstract

Murugesan B

In the Present research work, a study has been planned to hold a critical investigation on improving production (Sewing) Efficiency of Lean Manufacturing based system. Sewing department was seen as the principal area in apparel production and this particular department is also called as money making area because in this area the garment product is formed into finished goods. When this fabric is entered to sewing process, it has to be rechecked by each department related to line arrangement, machine preparation, product component preparation such as pieces of fabric, threads, embroidery, and other accessories, and all at once the result of sewing line layout and daily production target made by the IE department based on data records taken and count based on time study. Afterward, the merchandise goes into the sewing course, regular control must be practiced especially in the origin of production because many problems come up at this time, usually with quality, machines setting, operators target and line balancing problem. These work might help apparel manufacturers understand how to overcome basic difficulties and how to improve the yield in the sewing section. From the survey, it was observed that how the lean manufacturing organization can be implemented and to increase the productivity of the stitching department. Before embarking on a production procedure of a style, need to have a meeting with all department IE; Merchandiser, production, QA, IE, PPIC, and mechanic to discuss the manner which will get into production, so they all can do the preparation that will reach the production moving smoothly, avoid mistake in production and increase the yield. The work was planned with the techniques like time study, motion work, downtime report study, performance work, skill matrix, training evaluation, hourly monitoring report and then on from the work, the reason for low output was celebrated and the method to increase the production is also graded.