Abstract:
This project is on “Application of Industrial Engineering In Garments Sewing Floor”.
Traditionally operated garment industries are facing problems like low productivity, longer
production lead time, high rework and rejection, poor line balancing, low flexibility of style
changeover etc. These problems were addressed in this study by the implementation of lean tools
like cellular manufacturing, single piece flow, work standardization, just in time production, etc.
After implementation of lean tools, results observed were highly encouraging. Some of the key
benefits entail production cycle time decreased by 8%, number of operators required to produce
equal amount of garment is decreased by 14%, rework level reduced by 80%, production lead
time comes down to one hour from two days, work in progress inventory stays at a maximum of
100 pieces from around 500 to 1500 pieces. Apart from these tangible benefits operator
multiskilling as well as the flexibility of style changeover has been improved. This study is
conducted in the stitching section of a shirt & pant manufacturing company. Study includes time
studies, the conversion of traditional batch production into single piece flow and long assembly
line into small wall cell.
