IEMS Module 6

Optimization & Lean Basic
Optimization in Cutting:
• Time Study for cutting room activities and setting Standard Time
• Making standard operating procedures (SOPs) for all cutting activities
• Measuring KPIs – An IE can measure cutting room KPIs. Like marker efficiency%,
fabric utilization percentage, cutting quality, and machine and manpower utilization.
• Designing cutting room layout
• Suggesting good material handling equipment
• Finding solution for cutting room issues
• Studying and analysing manpower requirement in cutting room
Optimization in Sewing Section:

• Conducting motion study and correcting faulty motions
• Hourly operator capacity check
• Conduct R&D for the garment
• Use best possible line layout
• Reduce line setting time
• Improve line balancing
• Use work aids, attachments, guides, correct pressure foots and folders
• Continuous feeding to the sewing line
• Feed fault free and precise cutting to line
• Training for Line supervisors
• Training to sewing operators
• Setting individual operator target
• Eliminate loss time and off-standard time
Prepared By: Asif Khan Cell No: 01719253996 E-Mail: [email protected]

EQRA Knowledge Center BGMEA-SEIP
• Real time shop floor data tracking system
• Using auto trimmer sewing machine (UBT)
• Installing better equipment
• Operator motivation
• Plan for operator’s Incentive scheme
Optimization in Finishing Section:

• Setting of Standard Time (SAM) for finishing jobs (activities)-
• Study existing finishing room workstations layout
• Suggest a better material handling method to finishing room workers
• Work on method improvement
• Maintain WIP in between two workstations
• Train checkers and other workers
Lean Manufacturing:
Lean manufacturing is the term referring to manufacturing methodologies based on maximizing
value and identifying and eliminating waste in the manufacturing process.

5 Principles Lean Manufacturing:
EIGHT WASTE OF LEAN:

D= Defect
O= Over-production
W= Waiting
N= Non-utilized Intellect
T=Transportation
I= Inventory
M= Motion
E= Excess-processing / Over-processing
5S: Workplace Organization

Based on Japanese words that begin with S, the 5S Philosophy focuses on effective work place
organization and standardized work procedures. 5S simplifies your work environment, reduces
waste and non-value activity while improving quality efficiency and safety.

5S Detail:

1st PILLER: SORT(Seiri)
• Sort means that you remove all items from the workplace that are not needed for
current production operations.
Necessary Items Unnecessary Items
• Example:
 Unneeded of equipment, trims and others tools for current production to avoid
obstacle to production activities.
Large quantity of inventory requires more space and management.
2nd PILLER: SET IN ORDER(Seiton)

• Set in order can be defined as arranging needed items so that they are easy to use
and labeling them so that they are easy to find and put away.
• Example:
 Identify a drawer for threads keeping them cleaned in determined area.
 All trims must be uniquely placed away organized in an identified and organized
place. Rack, Drawers, etc.
 Documents, Metals parts as trims, etc.
3rd PILLAR: SHINE (Seiso)

• Shine means sweeping floors, wiping off machinery and generally make sure
everything on the floor stays clean.
• However, maintenance tasks must be taking daily through defined checkpoints.
• Example:
 Machineries dust off and maintained.
 Floor are free of any object could create obstacles and danger to employees and the
product.
4th PILLAR: STANDARDIZE (Seiketsu)

• The first three pillars are activities to organize and maintain the workplace. But
standardize is the method you use to maintain the first three pillars Sort-Set in
order and Shine.

Example:
• Control methods
5th PILLAR: SUSTAIN (Shitsuke)

• Sustain making a habit of properly maintaining correct procedures.
• The first four pillar can be implemented without any difficulty if the workplace is
where employees commit to sustain the 5S conditions.
• Without Sustain the others four pillars will not last longer.
• 5S is not a technique and different than the other four pillar, result can not be
seeing.
Conclusion
Factory must create conditions or structures that will help to sustain a commitment to the five
pillars such as:
• Awareness: You and your employees need to understand what the five pillars are and
how to important to sustain them.
• Time: You need to have or make enough time in your work schedule to perform 5S
daily.
• Structure: You need to have support for your efforts from management, in terms of
acknowledgment, leadership and resources.
• Rewards & recognition: Your effort need to be rewarded.
• Satisfaction & Excitement: Implementation of 5 Pillars must be fun and satisfying for
you and the company. Excitement gets communicated from person to person allowing 5S
to build as it involves more people.


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Optimization & Lean Basic

• Making standard operating procedures (SOPs) for all cutting activities

• Designing cutting room layout

• Suggesting good material handling equipment

• Finding solution for cutting room issues

• Studying and analysing manpower requirement in cutting room

Optimization in Sewing Section:

• Hourly operator capacity check

• Conduct R&D for the garment

• Use best possible line layout

• Reduce line setting time

• Improve line balancing

• Continuous feeding to the sewing line

• Feed fault free and precise cutting to line

• Training for Line supervisors

• Training to sewing operators

• Setting individual operator target

• Eliminate loss time and off-standard time

Prepared By: Asif Khan Cell No: 01719253996 E-Mail: [email protected]

• Using auto trimmer sewing machine (UBT)

• Installing better equipment

• Plan for operator’s Incentive scheme

Optimization in Finishing Section:

• Study existing finishing room workstations layout

• Suggest a better material handling method to finishing room workers

• Work on method improvement

• Maintain WIP in between two workstations

• Train checkers and other workers

Prepared By: Asif Khan Cell No: 01719253996 E-Mail: [email protected]

EIGHT WASTE OF LEAN:

5S: Workplace Organization

Prepared By: Asif Khan Cell No: 01719253996 E-Mail: [email protected]

Prepared By: Asif Khan Cell No: 01719253996 E-Mail: [email protected]

Necessary Items Unnecessary Items

Large quantity of inventory requires more space and management.

2nd PILLER: SET IN ORDER(Seiton)

 Identify a drawer for threads keeping them cleaned in determined area.

 Documents, Metals parts as trims, etc.

3rd PILLAR: SHINE (Seiso)

• However, maintenance tasks must be taking daily through defined checkpoints.

 Machineries dust off and maintained.

4th PILLAR: STANDARDIZE (Seiketsu)

Prepared By: Asif Khan Cell No: 01719253996 E-Mail: [email protected]

5th PILLAR: SUSTAIN (Shitsuke)

• Rewards & recognition: Your effort need to be rewarded.

Prepared By: Asif Khan Cell No: 01719253996 E-Mail: [email protected]

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