To Improve First-Hour Sewing Production Efficiency for a Garment Manufacturing Factory Using the Lean Problem-Solving Tool, Root Cause Analysis

• Main Author: Garg, Yuvraj
• Format: Conference or Workshop Item
• Language: English
• Published: 2022
• Subjects: HD28 Management. Industrial Management
• Online Access: https://repo.uum.edu.my/id/eprint/30695/1/7th%20ICSC%202022%20283-308.pdf; https://repo.uum.edu.my/id/eprint/30695/

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%.