Productivity Improvement

Session-01

Prepared By: K.Sasikumar

o Low Productivity

o Longer Production Lead time (=Through put time +

Wait time)

o Too much work in progress

o Higher Idle time

o Poor flexibility on style changeover

Main Issues:

Earlier days: * Industries were getting bulk orders * There is no need to worry about changing

layout at least for a month or for two weeks

But nowadays: * Small order quantities and complex

designs, * Has to produce multiple styles even within

a day

Fundamentals

The garment industries: • Run as family business• Lacking skilled personnel • Lacking in capital • Poor technologies • Low productivity • Less flexibility (Rigid to change)

In the outlook: They are happy as long as they are sustaining their businessBut, In the ground : They have no confidence about the futureMajor problem:

• Failure to meet delivery time• Huge WIP• Bottle necks• Poor quality

In developing countries….

With the time , It starts:

Decreasing order size and Increasing number of styles

The Challenge :

Order changes Production layout: Hold minimum WIP &

flexible enough change the layout

Fashion changes Work force: Capable enough to cope with

change

In developing countries…. continued

Now “global market demand & niche market”Need arose “This needs higher flexibility in volume and style change over”

Development of lean manufacturing system It was able to respond much more rapidly to changes in demand by quickly

switching production from one model to another

This will serve our purpose of :I. Flexibility II. Reducing production lead timeIII. Reducing the inventory IV. Increasing productivity V. Training operators for multiple worksVI. Reducing rework

In developing countries…. continued

“During Second world war, the economic condition of Japan was heavily destroyed”What they did:

I.Produced a small batch of productsII.Reduced their inventories

The difficulty they faced: Changing tools in production lines frequently

How they cope with situation Multipurpose tooling systems Trained their employees to multi-skill Worked on less Machinery with High Efficient Workforce All employees are more open to the improvement process and

everyone started giving their input to the company.

History of Lean

Then they found: To meet customer demand on time

I. Have to eliminate non value added work from the process

II. Have to minimize the work in progress inventoryIII. Have to create flexibility of style changeoverIV. Have to reduce rework percentageV. Have to create a pool of multi-skilled operators

who can respond quickly for changing style

History of Lean……Continued

Definition “It is a comprehensive set of techniques which when

combined allows you to reduce and eliminate the wastes. This will make the company leaner, more flexible and more responsive by reducing waste.”

Main cause:“focused its operating system on responding to demand via individual optimization from end to end”

Reason of application of tools and techniques: “Eliminate the source of losses”

Lean Manufacturing System

It will cut down into half : Human effort in the company Manufacturing space Investment in tools Engineering hours to develop a new

product Time consumption

Benefit of Lean Manufacturing System

Can meet customer demand on time Can minimize the work in progress inventory Can create flexibility of style changeover Can reduce rework percentage Can create a pool of multi-skilled operators

The profitability depends on the utilization of its resources to meet the customer requirement • Material moving rapidly • Man working constantly by adding value to the product • Machine running in a more productive manner

Advantage of using Lean Manu. System

Principle 1: Accurately specify value from customer perspective for both products and services

Principle 2: Identify the value stream for products and services and remove non-value adding waste along the value stream

Principle 3:Make the product and services flow without interruption across the value stream.

Principle 4: Authorize production of products and services based on the pull by thecustomer.

Principle 5: Strive for perfection by constantly removing layers of waste.

The major five principles of Lean

Definition:Management that strives to eliminate sources of manufacturing waste by producing the right part in the right place at the right time.

JIT is applied to achieve the following goals: 1. Zero defects 2. Zero setup time 3. Zero inventories 4. Zero handling 5. Zero breakdowns 6. Zero lead time and 7. Lot size of one.

Just in Time

Toyota manufacturing system developed after World War II, which aims to increase production efficiency by the elimination of waste. -By Taiichi Ohno, Toyota, Japan

Waste Reduction <---------- Efficiency Improvement

Analysis of wastage: Overproduction Waiting time Transportation problems Inefficient processing More work in progress inventory Defective products

Toyota Production System

1. Overproduction 2. Waiting 3. Unnecessary Transport 4. Over processing 5. Excess Raw Material 6. Unnecessary Movement 7. Defects 8. Unused Employee Creativity

Kind of Wastes

1. Should have one-piece or very small lot of flow2. The equipment should be right-sized and very specific

for the garment operations.3. Is usually arranged in a C or U shape so the incoming

raw materials and outgoing finished goods are easily monitored.

4. Should have cross-trained people within the cell for flexibility of operation.

5. Generally, the cell is arranged in C or U shape and covers less space than the long assembly lines.

Effective Manufacturing Practice

Garment Production System

Production Flow Chart

U-Shape Manufacturing LineSingle worker

U-Shape Manufacturing LineTwo workers

U-Shape Manufacturing LineThree workers

1. Reduced work in process inventory Because the work cell is set up to provide a balanced flow from machine to machine.

2. Reduced direct labor cost Because of improved communication between employees, better

material flow, and improved scheduling. 3. High employee participation is achieved Due to added responsibility of product quality monitored by themselves

rather than separate quality persons. 4. Increased use of equipment and machinery: Because of better scheduling and faster material flow. 5. Improve the flexibility Allows the company higher degrees of flexibility to accommodate

changes in customer demand. 6. Promotes continuous improvement as problems are exposed to surface due to low WIP and better

communication. 7. Reduces throughput time

Increases velocity for customer orders from order receipt through production and shipment.

8. Enhances the employee’s skills Train them on multi-skilled operations.

Benefits of Manufacturing over longer assembly lines

i) Volume of productionii) The skill and expertise of man poweriii) Delivery dates for productsiv) Materials specificationsv) Accuracy requirements of products

Key factors of process planning

1. Better utilization of equipments2. Higher productivity3. Greater efficiency4. Better quality5. Reduced production cost & hence lower unit

price6. Use of standardized methods

Specialization