To Improve First-Hour Sewing Production Efficiency for a Garment Manufacturing Factory Using the Lean Problem-Solving Tool, Root Cause Analysis
This case study demonstrates lean-based alternatives to conventional problem solving:- a step-by-step procedure to implement root cause analysis in a garment manufacturing factory working on an overhead hanger-based unit production system in the sewing lines. The objective was to increase the first-...
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| Format: | Conference or Workshop Item |
| Language: | English |
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2022
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| Online Access: | https://repo.uum.edu.my/id/eprint/30695/1/7th%20ICSC%202022%20283-308.pdf |
| _version_ | 1825806231884791808 |
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| author | Garg, Yuvraj |
| author_facet | Garg, Yuvraj |
| author_sort | Garg, Yuvraj |
| collection | UUM |
| description | This case study demonstrates lean-based alternatives to conventional problem solving:- a step-by-step procedure to implement root cause analysis in a garment manufacturing factory working on an overhead hanger-based unit production system in the sewing lines. The objective was to increase the first-hour production efficiency and to decrease the “off-standard time” of the sewing production line for the fivepocket trousers manufacturing unit. The primary study involves a capacity study on the sewing operations, a root cause analysis; an optimization of the work-in-process leftover from the previous shift at the start; and an action plan to solve the major causes identified in the root cause analysis. The major factors from root cause analysis were: high “off standard time”, less/nonuniform low initial work-in-process leftover by the previous shift, operator idleness, start delay by operators, operator absenteeism, The implementation was done with the help of training, coordinating, optimizing the in-process inventory at the start of the shift, and implementing an action plan. The execution led to an increase in first-hour production efficiency of the sewing line to 74% from 43.7%; a decrease in the “off standard time” of the sewing line to 7.6% from 14.8%; an increase in the production efficiency of to 90.68% from 80.75%. |
| first_indexed | 2024-07-04T06:46:14Z |
| format | Conference or Workshop Item |
| id | uum-30695 |
| institution | Universiti Utara Malaysia |
| language | English |
| last_indexed | 2024-07-04T06:46:14Z |
| publishDate | 2022 |
| record_format | eprints |
| spelling | uum-306952024-04-02T11:23:59Z https://repo.uum.edu.my/id/eprint/30695/ To Improve First-Hour Sewing Production Efficiency for a Garment Manufacturing Factory Using the Lean Problem-Solving Tool, Root Cause Analysis Garg, Yuvraj HD28 Management. Industrial Management This case study demonstrates lean-based alternatives to conventional problem solving:- a step-by-step procedure to implement root cause analysis in a garment manufacturing factory working on an overhead hanger-based unit production system in the sewing lines. The objective was to increase the first-hour production efficiency and to decrease the “off-standard time” of the sewing production line for the fivepocket trousers manufacturing unit. The primary study involves a capacity study on the sewing operations, a root cause analysis; an optimization of the work-in-process leftover from the previous shift at the start; and an action plan to solve the major causes identified in the root cause analysis. The major factors from root cause analysis were: high “off standard time”, less/nonuniform low initial work-in-process leftover by the previous shift, operator idleness, start delay by operators, operator absenteeism, The implementation was done with the help of training, coordinating, optimizing the in-process inventory at the start of the shift, and implementing an action plan. The execution led to an increase in first-hour production efficiency of the sewing line to 74% from 43.7%; a decrease in the “off standard time” of the sewing line to 7.6% from 14.8%; an increase in the production efficiency of to 90.68% from 80.75%. 2022 Conference or Workshop Item PeerReviewed application/pdf en https://repo.uum.edu.my/id/eprint/30695/1/7th%20ICSC%202022%20283-308.pdf Garg, Yuvraj (2022) To Improve First-Hour Sewing Production Efficiency for a Garment Manufacturing Factory Using the Lean Problem-Solving Tool, Root Cause Analysis. In: 7th International Case Study Conference, 13 - 15 September 2022, Raia Hotel & Convention Centre, Terengganu, Malaysia. |
| spellingShingle | HD28 Management. Industrial Management Garg, Yuvraj To Improve First-Hour Sewing Production Efficiency for a Garment Manufacturing Factory Using the Lean Problem-Solving Tool, Root Cause Analysis |
| title | To Improve First-Hour Sewing Production Efficiency for a Garment
Manufacturing Factory Using the Lean Problem-Solving Tool, Root
Cause Analysis |
| title_full | To Improve First-Hour Sewing Production Efficiency for a Garment
Manufacturing Factory Using the Lean Problem-Solving Tool, Root
Cause Analysis |
| title_fullStr | To Improve First-Hour Sewing Production Efficiency for a Garment
Manufacturing Factory Using the Lean Problem-Solving Tool, Root
Cause Analysis |
| title_full_unstemmed | To Improve First-Hour Sewing Production Efficiency for a Garment
Manufacturing Factory Using the Lean Problem-Solving Tool, Root
Cause Analysis |
| title_short | To Improve First-Hour Sewing Production Efficiency for a Garment
Manufacturing Factory Using the Lean Problem-Solving Tool, Root
Cause Analysis |
| title_sort | to improve first hour sewing production efficiency for a garment manufacturing factory using the lean problem solving tool root cause analysis |
| topic | HD28 Management. Industrial Management |
| url | https://repo.uum.edu.my/id/eprint/30695/1/7th%20ICSC%202022%20283-308.pdf |
| work_keys_str_mv | AT gargyuvraj toimprovefirsthoursewingproductionefficiencyforagarmentmanufacturingfactoryusingtheleanproblemsolvingtoolrootcauseanalysis |