Lean Tools in Apparel Manufacturing
- 1st Edition - February 17, 2021
- Editors: Prabir Jana, Manoj Tiwari
- Language: English
- Paperback ISBN:9 7 8 - 0 - 1 2 - 8 1 9 4 2 6 - 3
- eBook ISBN:9 7 8 - 0 - 1 2 - 8 1 9 4 2 7 - 0
The never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. Due to… Read more
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Request a sales quoteThe never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. Due to fierce global pressure on reducing price and lead time, the textiles and apparel producers will have to banish all waste from their supply chain. Lean manufacturing which removes waste and smoothens the process flow is gaining popularity among textiles and apparel producers and will be a key element for the survival of the industry in the years ahead.
- An overview of various lean tools with a balanced mix of conceptual knowledge and practical applications in the context of apparel manufacturing
- Valuable industry information which managers and engineers can follow themselves without the need to hire outside consultants
- Case studies and examples from apparel manufacturing demonstrating how lean tools are being used successfully by leading organizations; an academician’s delight
- Possible use cases of several lean tools having potential use in the apparel manufacturing scenario
Engineers, managers, and consultants working in the textile and apparel manufacturing industry. Students and researchers of apparel manufacturing, lean management, production management, fashion technology and related programs globally.
- Cover image
- Title page
- Table of Contents
- Copyright
- List of contributors
- Foreword
- Preface
- 1. Lean management in apparel manufacturing
- Abstract
- 1.1 Introduction
- 1.2 Lean: definition, philosophy, and its evolution
- 1.3 Lean and different approaches
- 1.4 Apparel manufacturing and lean
- 1.5 Conclusion
- References
- 2. Lean terms in apparel manufacturing
- 2.1 Introduction
- 2.2 Lean Terms
- 3. Fundamentals of lean journey
- Abstract
- 3.1 Introduction
- 3.2 Value addition
- 3.3 3M of lean manufacturing
- 3.4 Types of wastes
- 3.5 The lean way for improvement and its challenges
- 3.6 Lean way of manufacturing
- 3.7 A framework to initiate lean interventions
- 3.8 Step-by-step implementation of lean tools
- 3.9 Conclusion
- References
- 4. Lean problem-solving
- Abstract
- 4.1 Introduction
- 4.2 Kaizen
- 4.3 Value stream mapping
- 4.4 A3 problem-solving
- 4.5 Standardized work
- 4.6 Plan–do–check–act cycle
- 4.7 Look–ask–model–discuss–act cycle
- 4.8 Define–measure–analyze–improve–control
- 4.9 Root-cause analysis
- 4.10 Conclusion
- References
- 5. Visual management
- Abstract
- 5.1 Introduction
- 5.2 Gemba
- 5.3 Visual factory
- 5.4 5S
- 5.5 Andon
- 5.6 Yamazumi charts
- 5.7 Turtle diagram
- 5.8 Affinity diagram
- 5.9 Dashboard
- 5.10 Conclusion
- References
- 6. Rapid setup
- Abstract
- 6.1 Introduction
- 6.2 Tool changeover
- 6.3 Style changeover in apparel manufacturing
- 6.4 Single Minute Exchange of Die in apparel manufacturing
- 6.5 Impact of rapid changeover
- 6.6 Conclusion
- References
- 7. Autonomation
- Abstract
- 7.1 Introduction
- 7.2 Jidoka
- 7.3 Poka-Yoke
- 7.4 Conclusion
- References
- 8. Process balancing
- Abstract
- 8.1 Introduction
- 8.2 Challenge of high inventory levels in apparel manufacturing
- 8.3 Continuous flow manufacturing
- 8.4 Constraint management
- 8.5 Production leveling
- 8.6 Kanban
- 8.7 Alternatives to Kanban
- 8.8 Conclusion
- References
- 9. Apparel manufacturing systems
- Abstract
- 9.1 Introduction
- 9.2 Manufacturing systems
- 9.3 Evolution of apparel manufacturing systems
- 9.4 Apparel manufacturing systems
- 9.5 Success parameters of a manufacturing system
- 9.6 Conclusion
- References
- 10. Lean quality management
- Abstract
- 10.1 Introduction
- 10.2 Lean philosophy and quality management
- 10.3 A brief history of statistical methods in quality
- 10.4 What is statistical process control?
- 10.5 Acceptable quality level
- 10.6 Six Sigma
- 10.7 Conclusion
- References
- 11. Lean human resources
- Abstract
- 11.1 Introduction
- 11.2 Lean human resource management
- 11.3 Lean and downsizing
- 11.4 The role of HR in lean implementations in the apparel industry
- 11.5 Harada method
- 11.6 Conclusion
- References
- 12. Total productive maintenance
- Abstract
- 12.1 Introduction
- 12.2 Basic concept of TPM
- 12.3 Benefits and challenges of TPM
- 12.4 TPM in the textile and apparel manufacturing industry
- 12.5 Smart maintenance
- 12.6 Conclusion
- References
- 13. Lean supply chain management
- Abstract
- 13.1 Introduction
- 13.2 Evolution of lean supply chain
- 13.3 Lean applications in retail supply chain
- 13.4 Conclusion
- References
- 14. Agile manufacturing
- Abstract
- 14.1 Introduction
- 14.2 Agile manufacturing
- 14.3 The symbiotic relationship between lean and agile
- 14.4 Key advancements needed to support agile in the future
- 14.5 Lean versus agile
- 14.6 Agile organization
- 14.7 Strategic tools for future agile firms
- 14.8 New horizons for lean manufacturing
- 14.9 Case study
- 14.10 Conclusion
- References
- Index
- No. of pages: 454
- Language: English
- Edition: 1
- Published: February 17, 2021
- Imprint: Woodhead Publishing
- Paperback ISBN: 9780128194263
- eBook ISBN: 9780128194270
PJ
Prabir Jana
Dr. Prabir Jana is a Professor at the National Institute of Fashion Technology, New Delhi, India. He has over 27 years of experience in the industry as well as in lecturing and researching in the field of apparel manufacturing. Currently, Prof. Jana is Shahi Chair Professor, Industry 4.0 at NIFT. He has authored several books and more than 250 articles and papers in leading national and international magazines and journals. He has also delivered various lectures at both national and international forums. His key interest area includes Apparel Technology Management, Industrial Engineering, Advanced Manufacturing Techniques, and Lean Manufacturing.
Affiliations and expertise
Professor, National Institute of Fashion Technology, New Delhi, IndiaMT
Manoj Tiwari
Dr. Manoj Tiwari is an Associate Professor at the National Institute of Fashion Technology, Jodhpur, India. He has 14 years of industry and academic experience including teaching, industrial training, research and development, and consultancy. He has an experience of leading an international project involving capacity building and consultancy in manufacturing and production management. He has presented and published over 50 research papers and articles in conferences and journals. The book “Industrial Engineering in Apparel Manufacturing: Practitioner’s Handbook” (ISBN: 9788193247204) has been coauthored with Prof. Prabir Jana. His key areas of interest include Industrial Engineering, Lean Manufacturing, Ergonomics, and Anthropometry.
Affiliations and expertise
Associate Professor, National Institute of Fashion Technology, Jodhpur, IndiaRead Lean Tools in Apparel Manufacturing on ScienceDirect