Garments Manufacturing

5S+1 Seiri (Sort) Seiton (Simplify) Seiso (Sweep) Seiketsu (Standardize) Shitsuke (Sustain) + Safety Seiri √ Sort √ Necessary vs. unnecessary √ Right quantity when needed √ Tagging √ Cost √ Example Seiton √ Set in order √ Quick access √ Efficiency √ Organize/Labeling √ Frequency of use √ Visual √ A place for everything and everything in its place Seiso √ Clean √ Mess prevention √ Shine and check √ Causal analysis √ Cleaning schedule √ Cleanliness campaign Seiketsu √ Standardization √ Cleanliness √ Tools √ Visual controls √ Prevention √ Identical workstations √ Preventive maintenance √ Implementation steps Shitsuke √ Discipline √ Sustain √ Habit √ Rules √ Tools √ Standards Safety √ Uncluttered workplace √ Well maintained equipment √ Clean workspace Value Stream Mapping √ Flow of inventory and information √ Identify and eliminate waste √ Value as defined by customer √ Optim...

The Main One → Transportation → Inventory → Motion → Waiting → Over-production → Over-processing → Defects Transportation √ Definition: Any movement of materials, supplies or resources that does not add value to the internal or external customer needs √ Characteristics • Extra carts, fork lifts • Multiple storage locations • Complex inventory management • Extra facility space • Improper facility layout Inventory √ Definition: Any supply in excess to process requirements necessary to produce goods or services just in time √ Characteristics • Material between processes • Additional material handling resources • Additional investment / cost • Storage space • Perishable, damage and obsolescence • LIFO instead of FIFO Motion √ Definition: Any movement of people, resources or machines which does not contribute/add value to the product or service √ Characteristics • Human motion • Lack of visual controls • Looking for tools • Material too...

What is Lean? → Overview of Lean → Principles of Lean → Types of Waste → Lean Journey Overview of Lean √ Creating more value for customer with fewer resources √ Philosophy : To provide perfect value to the customer through a perfect value creation process that has zero waste √ Lean reduces cost, improves quality, and speeds delivery by eliminating non-value-added activity in a process by identifying and eliminating waste √ Lean is not a tactic or a cost reduction program, but a way of optimizing end to end processes Principles of Lean Types of Waste √ What is waste? √ Non-value-add activity √ Some types of waste with examples • Anything that could have been avoided • Customer is not willing to pay for it • Defects/rework √ The 7 types of waste √ Muda (Japanese word for waste) √ Uncommon common sense Lean Journey √ Lean journey is on the principle “I will believe it when I see it” √ Lowering the tide and uncovering more re...