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Analysis of Lean Manufacturing: A Cost Saving Approach in Garments Production Unit

Md Mehedi Hashan, Zhongmin Deng, Ke Wei, Ashique UL Haque, Md. Kawsar Hossain


Sewing process is one of the most important stages in labor intensive ready-made clothing enterprises. Quality faults occurring during this process adversely affect the product quality and product efficiency, and also increase the production cost. The aim of this study is to investigate whether the knitwear production process is under control in a knitwear production enterprise and to detect the processes with highest rates of sewing faults in sewing department and finally to make suggestions for improving the quality control. Among the Statistical Process Control methods; control list, product control chart were used in the study. “Product control chart” was used to test whether the production process is controlled in the enterprise. Furthermore, the statistical methods were employed to determine the issues that need to be done in the improvement efforts and to detect the relations between the process groups supposedly effective on faults occurring in knitwear production and the amount of faults. Also, the processes with highest amounts of sewing faults and the effects of these processes on fault rates were investigated. As a result, it was concluded that the production process was statistically not under control in the ready-made clothing enterprise. In addition, this study demonstrated that the investigation of each process group by drawing their product control charts would make significant contributions to foresee the results and prepare more effective the improvement plans.



Sewing; Extra time for fault; Hamper monthly; Cost Rectification; Causes and Remedies

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