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PREPARED BY
SAMUEAL G/HER
MEARG KAHASAY
KIBROM G/HER
ETHIOPIA
BAHIR DAR
2017
i
INVESTIGATING AND MINIMZING WASTE
THROUGH VALUE STREAM MAPPING (VSM): CASE
OF ALTEX
This thesis submitted to the Ethiopian institute of textile and fashion
technology (EITEX) for in partial fulfillment of the REQUIREMENT for
the degree of Science/Technology in
GARMENT ENGINEERING
prepared by
SAMUEAL G/HER
MEARG KAHASAY
KIBROM G/HER
Under the Guidance of
We hereby certify that we are the sole author of this thesis and that no part of this thesis
has been published or submitted for publication.
we certify that, to the best of our knowledge, our thesis does not infringe upon anyone’s
copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or
any other material from the work of other people included in our thesis, published or
otherwise, are fully acknowledged in accordance with the standard referencing practices.
Furthermore, to the extent that we have included copyrighted material that surpasses the
bounds of fair dealing within the meaning of the Canada Copyright Act, we certify that we
have obtained a written permission from the copyright owner(s) to include such material(s)
in our thesis and have included copies of such copyright clearances to my appendix.
we declare that this is a true copy of our thesis, including any final revisions, as approved
by our thesis committee and the Graduate Studies office, and that this thesis has not been
submitted for a higher degree to any other University or Institution.
KIBROM G/HER
Name Signature
SAMUEAL G/HER
Name Signature
MEARG KAHASAY
Name Signature
i
APPROVAL BY ADVISOR
To the best of my knowledge and as understood by the student in the Research Integrity
and Copyright Disclaimer, this thesis/project adheres to the provisions of guidelines,
policies and legislations of the Institute of Technology for Textile, garment and fashion
design during his research work and use of copyrighted material. The thesis is complete
and can be presented to the thesis evaluation committee.
ii
ABSTRACT
This project is aimed to use and apply lean tools as ways of improving manufacturing
systems that lead to reduction of wastes and reduction of lead time. The focus of this study
is to investigate and to minimize different waste by using a lean tool which called VALUE
STREAM MAPPING on a PANT in ALMEDA TEXTILE P.L.C
The main objective of the project paper is to identify various wastes occurs in the
production system. Additionally, it tries to find out some areas for improvement and
propose some improvement strategies. In this concern, this case study has been conducted
focusing cutting, finishing and on a particular production line of sewing section in a
selected garments factory. Value adding, non-value adding (necessary and unnecessary)
processes and different types of wastes have been identified by drawing the current state
map for cutting, sewing and finishing sections.
The project conducted in ALMED TEXTILE P.L.C in pant style no P4582 using personal
interviews, secondary data and observations. Quantitative data were analyzed by using
tables and graphs. directly observing the flow of information and material as they occur.
The current state map was developed after making necessary observations and calculations.
We use 5 WHY? analysis in order to developed and to identify key causes behind wastes
Then various improvement proposals had been identified based on Lean Manufacturing
theories and the future state map is developed by recommending some lean tools towards
some future improvement.
iii
ACKNOWLEDEMENT
At the very beginning we would like to express our sincere gratitude to the
Almighty God whose blessings made us capable of accomplishing this project
work.
We are greatly indebted to our supervisor Tesfu B. Department of garment
engineering for his constant guidance, cordial suggestion, help and care for the
completion of the project work. Without his continuous attention and care it
would never have been possible to accomplish our project paper.
We would like to express our gratitude to Tadese, mikiyas, Abraham, and all
Altex Garment department employee for their support and kindness.
In addition, thanks are due to those who helped us directly and indirectly
during the different stages of the project work.
Finally, we record with deep appreciation the patience, understanding and
encouragement shown by our family and friends throughout the period of our
study.
iv
TABLE OF CONTENTS
DECLARATION OF ORIGINALITY ............................................................................ i
APPROVAL BY ADVISOR ............................................................................................ ii
ABSTRACT ...................................................................................................................... iii
ACKNOWLEDEMENT .................................................................................................. iv
Table of Contents .............................................................................................................. v
LIST OF TABES ............................................................................................................. vii
LIST OF FIGURES ....................................................................................................... viii
List of acronyms ............................................................................................................... ix
CHAPTER ONE ............................................................................................................... 1
INTRODUCTION .......................................................................................................... 1
1.1 Research Background ............................................................................................... 1
1.2 Problem of The Statements ....................................................................................... 3
1.3. Objective of The Study ............................................................................................ 4
1.3.1. Main Objective.............................................................................................. 4
1.3.2. Sub Objective ................................................................................................ 4
1.4. Scope of The Study .................................................................................................. 4
1.5 Limitations of The Study .......................................................................................... 4
1.6 Benefit of The Study ................................................................................................. 5
1.7 Beneficiary of The Study .......................................................................................... 5
CHAPTER TWO .............................................................................................................. 6
REVIEW OF LITERATURE .......................................................................................... 6
2.1 Lean Manufacturing .................................................................................................. 6
2.1.1 What Is Lean .................................................................................................. 6
2.1.2 History of Lean Manufacturing ..................................................................... 6
2.2 wastes in lean manufacturing .................................................................................... 6
2.2.1. Types of Lean Waste .................................................................................... 7
2.3. Value Stream Mapping (VSM) ................................................................................ 8
2.3.1 Considerations for Waste Elimination ........................................................... 8
2.4. Different Literature Review On Different Company ............................................... 9
2.4.1 Case Study 1 .................................................................................................. 9
2.4.2 Case Study 2 ................................................................................................ 10
2.4.3. Case Study 3 ............................................................................................... 11
CHAPTER THREE ........................................................................................................ 12
3.1. Research Methodology .......................................................................................... 12
v
3.1 Data Collection Method .......................................................................................... 13
3.1.1 Primary Data Collection .............................................................................. 13
3.1.2. Secondary Data Collection ......................................................................... 13
3.2. Data Presentation, Analysis and Interpretation ...................................................... 14
3.2.1. Procedure .................................................................................................... 14
3.2.2. Product Information from The Customer View and Manufacturer Capacity
............................................................................................................................... 16
3.2.3 Cutting department analysis ......................................................................... 17
3.2.4. Sewing department...................................................................................... 18
3.2.5. Packing department ..................................................................................... 22
Drawing current value stream mapping ........................................................................ 24
CURRENT VALUE STREAM MAPPING.................................................................. 25
3.2.6. CUTTING DEPARTMENT ANALYSIS .................................................. 25
3.2.7. SEWING DEPARTMENT ANALYSIS .................................................... 26
3.2.8. PACKING DEPARTMENT ANALYSIS .................................................. 27
3.2.9 Profit loss ..................................................................................................... 28
3.3. Current waste in the ATEX.................................................................................... 30
3.3.1 Overproduction: ........................................................................................... 30
4.3.2. Inventory ..................................................................................................... 30
3.3.3. Transportation ............................................................................................. 31
3.3.4. Excess Motion:............................................................................................ 34
3.3.5. Rework and defect ...................................................................................... 35
3.3.6. Defect analysis ............................................................................................ 36
PROPOSED VALUE STREAM MAPPING................................................................ 41
CHAPTER FOUR ........................................................................................................... 42
4.1 Result and Discussion ............................................................................................. 42
CHAPTER FIVE ............................................................................................................ 45
Conclusion and Recommendation ................................................................................ 45
5.1 Conclusion .............................................................................................................. 45
5.2 Recommendation .................................................................................................... 47
Reference ......................................................................................................................... 49
Appendix .......................................................................................................................... 50
Value stream mapping icons and meaning ................................................................... 50
vi
LIST OF TABES
Table 1 product matrix...................................................................................................... 14
Table 2 cutting department value stream chart ................................................................ 17
Table 3 time study sheet p4582 ......................................................................................... 18
Table 4 Sewing Department value stream chart ............................................................... 19
Table 5 packing time study ............................................................................................... 22
Table 6 packing department value stream chart............................................................... 22
Table 7 Cutting Department Analysis ............................................................................... 25
Table 8 Sewing Department Analysis ............................................................................... 26
Table 9 PACKING DEPARTMENT ANALYSIS ............................................................... 27
Table 10 Profit loss ........................................................................................................... 28
Table 11 overproduction five why analysis ...................................................................... 30
Table 12 inventory five why analysis ................................................................................ 31
Table 13 transportation five why analysis ........................................................................ 32
Table 14 layout comparison current and new .................................................................. 33
Table 15 waste of motion five why analysis ...................................................................... 34
Table 16 Table 16 defect and rework five why analysis .................................................. 35
Table 17 company report quality control report .............................................................. 36
Table 18 Cause and effect broken stich ............................................................................ 37
Table 19 Cause and effect skip stich ................................................................................. 38
Table 20 Cause and effect slip out .................................................................................... 39
Table 21 Cause and effect uneven stich ........................................................................... 39
Table 22 Cause and effect open seam ............................................................................... 40
vii
LIST OF FIGURES
Figure 2 pant style noP4582 ............................................................................................. 15
Figure 3 Drawing current value stream mapping ............................................................. 24
Figure 4 current value stream mapping ............................................................................ 25
Figure 5 cutting lead time ................................................................................................. 25
Figure 6 cutting production ............................................................................................... 26
Figure 7 sewing lead time ................................................................................................. 26
Figure 8 sewing production .............................................................................................. 27
Figure 9 packing lead time ................................................................................................ 27
Figure 10 packing production ........................................................................................... 28
Figure 11 profit loss due to variation in smv .................................................................... 29
Figure 12 waste of overproduction ................................................................................... 30
Figure 13 waste of inventory ............................................................................................ 31
Figure 14 current layout ................................................................................................... 32
Figure 15 proposed layout ................................................................................................ 33
Figure 16 waste of motion ................................................................................................ 34
Figure 17 waste of Rework and defect .............................................................................. 35
Figure 18 pareto chart ....................................................................................................... 36
Figure 19 Cause and effect diagram broken stich ............................................................ 37
Figure 20 Cause and effect diagram skip stich ................................................................ 37
Figure 21 Cause and effect diagram of slip out ............................................................... 38
Figure 22 Cause and effect diagram of uneven stich ....................................................... 39
Figure 23 Cause and effect diagram of t open seam ........................................................ 40
Figure 24 Proposed value stream mapping ....................................................................... 41
viii
LIST OF ACRONYMS
T--transportation
I--inventory
M--unnecessary motion
W--waiting
O--overproduction
O--over processing
D--defect
ix
CHAPTER ONE
INTRODUCTION
1
decline the generation of wastes and increase the productivity in any industries.
So, it became very significant to identify lean wastes and its effects on
productivity and manufacturing cost of products. According to lean
manufacturing these wastes overproduction, more waiting time and
bottlenecks, over transportation, excess inventory, more processing (re -
works), excess motion and defects (Wilson, 2009). These lean wastes could
not contribute in adding value of different products.
This research is an attempt to identify the applicability of one of the most
important Lean Manufacturing tool called “Value Stream Mapping (VSM)” in
ALTEX garment production floor.
2
1.2 Problem of The Statements
Waste is unnecessary for any kind of industry because it raises the
manufacturing cost of products. lean wastes of “TIMWOOD”. These wastes
cannot be dedicated as they are not visual for our naked eyes but increasing
the lead time of the production and it also increase the production cost of the
product. Which leads to increase non -value added time simultaneously
decrease the value-added time. ALTEX also have different type of waste that
increase the lead time of the production if they investigated and minim izing
those wastes we can reduce the production time and production cost in order
to investigated and minimizing we have to use one of lean tool “VALUE
STREAM MAPPING” of the products. The Target is to minimize those wastes
in the production floor and investigating the lean waste also to minimizing lean
wastes by using leans tools.
3
1.3. Objective of The Study
4
must acknowledge the fact that lean manufacturing is a long-term
philosophy, and at the end of the day, it WILL give the desired goals.
5
CHAPTER TWO
REVIEW OF LITERATURE
6
necessary, in the event the existing supply process is radically changed. Such
waste is more difficult to remove in the short term and should be a target for
longer term or radical change.
c) Non-value adding activity: those activities which, in the eyes of the final
customer, do not make a product or service more valuable and are not necessary
even under present circumstances. These activities are clearly ‘wastes’ and
should therefore be the target of immediate or, at least, short term removal.
7
2.3. Value Stream Mapping (VSM)
A Value Stream Mapping (VSM) is a tool of lean manufacturing that helps to
understand the flow of material and information as products make their way
through the value stream. The value stream includes the value adding and non -
value adding activities that are required to bring a product from raw material
through delivery to the customer. In other words, Value Stream Mapping is an
outline of a product's manufacturing life cycle that identifies each step
throughout the production process. It represents a visual information of
material flow for a particular product family (Rother and Shook, 1999).
A value stream, as the name implies, flows to some specific end. This end is a
set of requirements, as expressed by the customers of the value stream. When
the value stream fails to meet the requirements it is intended to serve, it must
be improved. Customers have three simple requirements – price, quality and
delivery. In today’s market, competitive price and quality are basic
requirements for staying in business. On time delivery a t a cost that allows for
profitability is therefore the key to competitiveness. (Rother and Shook,
1999).
8
of developing the attitudes, systems and communication necessary for a true
pull system operating at customer takt should not be underestimated. A high
inventory system hides a multitude of problems, which will slowly be exposed
as batch sizes and WIP are reduced. The level of organization and
standardization required for one-piece flow are rarely found in companies with
traditional production planning and traditional management (Anders 2008).
9
for Case- A, workforce is reduced 47.05%., Required space is reduced 63.26
%, Over transportation is reduced 54.58 %., Inventory is reduced 97.64 %. In
which raw material inventory is reduced 100 %, a WIP is reduced 98.54 %. ,
Lead time is reduced 95.35 %., Efficiency is improved 58.86 %., Labor
productivity is improved 62 %.
For Case- B, workforce is reduced 47.05%, Required space is reduced 63.26
%, Over transportation is reduced 38.97 %., Inventory is reduced 97.64 %. In
which raw material inventory is reduced 100 %, WIP is reduced 98.54 %. Lead
time is reduced 95.35%. Efficient-cy is improved 58.86 %, Labor productivity
is improved 62 % (Masudul, Mohammad, Abdur and Mohdn, 2013).
10
Cause Effect Diagram. After completion of the data processing, the analysis
has been performed.
The result has significantly been improved over the current state map. By using
VSM on the company they improve.
Through this thesis work,
Value added activity has been increased from 0.62% - 1.1%
Waiting time has been reduced from 283.58 min. to 115.26 min.
Productivity has been increased 31.94 %
Lead time has been decreased 7.74 days to 4.42 days
Bottleneck point has been reduced from 0.72 min. to 0.49 min.
(Mostafizur and Chowdury 2015).
11
CHAPTER THREE
Data collection
Data Analysis
12
3.1 Data Collection Method
13
3.2. Data Presentation, Analysis and Interpretation
In Alameda textile p.l.c of garment department from temporary fabric storage
up to finished department huge inventory and high lead time between the
departments so decide to analyses the lead time through one of lean
manufacturing tool called “value stream mapping “by choosing on e product or
style
3.2.1. Procedure
Step 1 select the product to be mapped – by using simple matrix to identify the
product they use the same process in garment section. Value stream maps are
created for a single product, or a family of products. A family is a group of
products with similar routings, similar process times, and customers with
similar needs and demand rates. ‘Similar’ means that while there may be some
variation, it is recognizable that all members of the group have a core set of
operations that are the same. Products may vary by color, size, minor features,
or one or two steps in the production process.
Table 1 product matrix
Process steps
Cut Band Fusing Embroidery Printing Washing Packing
knife
Pants X x x Family A x
Shirt X x x x
Woven
Products
Polo t- X x x x x
shirt
Knitted
t-shirt X x Family C x x
Singlet x x Family D x
Step 2 choosing the product based on this product family I choose family A
because of highest volume production also they have a high SMV when we
compare to other products. Those pants are produced to export and their
customer called DUNGUNAME it’s a Korean priv et company that produce a
different garment in different country. The pants are used in hospitals and
14
clinics. Their fabric property has difficult to handle for the operators during
sewing production because of the smoothness and other properties of the fa bric
Back Front
15
Available Work Time. Per shift of a process (in seconds, minus break,
meeting, and cleanup times.)
Number of Operators. Required personnel for a process
3.2.2. Product Information from The Customer View and Manufacturer Capacity
Customer DONGUNAME
Style no P4582
Total order quantity 35000
Delivery date June 15-2017
Sewing capacity
NO Operator 33
Smv 36
Working hr. 440
target @ 100 p/day 407
target @ 85% p/day 346
target @80% p /day 326
target @80% p /hr. 44
target @85% p /hr. 47
target @100% P/hr. 56 Style no p4582
16
3.2.3 Cutting department analysis
Table 2 cutting department value stream chart
17
3.2.4. Sewing department
Table 3 time study sheet p4582
CUSTOMER DONG NAM ARTICLE Trouser STAYLE NO 4285P DATE 26/ 04/2017
18
20 top s/t front Waist 1 SNLS 23 20 23 25 21 112 0.31 0.37
21 sew side seam 1 5th 86 90 92 87 95 450 1.25 1.50
23 close in seam 1 5th 56 58 64 59 63 300 0.83 1.00
24 tack corner Waist 1 SNLS 49 43 46 43 47 228 0.63 0.76
25 close back Waist 1 SNLS guide 57 61 53 55 58 284 0.79 0.95
26 tack back Waist 1 SNLS 56 51 54 50 53 264 0.88
&lable 0.73
27 hem side vent 1 SNLS guide 99 96 103 95 10 494 1.65
1 1.37
28 bottom hem 2 SNLS guide 164 167 159 16 16 820 2.73
8 2 2.28
29 Bartak 1 barta 61 65 66 63 60 315 1.05
k 0.88
30 Trimer 3 table trim 295 290 287 29 28 1455 4.85
ming 6 7 4.04
31 Qc 205 209 214 20 21 1047 3.49
Table 7 2 2.91
33 35.68
CUSTOMER DONG NAM ARTICLE Trouser STAYLE NO 4285P DATE 26/ 04/2017
19
16 back pocket top s/t 1 SNLS CR1/8 9:31:21 9:42:15 0:10:54
17 Waiting 9:42:15 9:45:17 0:03:02
18 top s/t side pocket mouth 1 DNLS 9:45:17 9:59:56 0:14:39
19 Waiting 9:59:56 10:01:02 01:01:02
20 close side pocket bag 1 5th 10:01:02 10:22:09 0:21:07
20 Waiting 10:22:09 10:23:41 0:01:32
21 sew back rise &front rise 1 5th 10:23:41 10:39:00 0:15:19
23 Waiting 10:39:00 10:41:49 0:02:49
24 top s/t back rise & front 1 MH 10:41:49 10:52:29
rise 0:10:40
25 Waiting 10:52:29 10:53:59 0:01:30
26 tack side pocket side 1 SNLS 10:53:59 11:03:29
Waist 0:09:30
27 Waiting 11:03:29 11:04:32 0:01:03
28 cut mark&tack elastic 1 SNLS sizer 11:04:32 11:23:17
Waist 0:18:45
29 Waiting 11:23:17 11:26:19 0:03:02
30 preper Waist belt 1 SNLS folder 11:26:19 11:36:24 0:10:05
31 Waiting 11:36:24 11:37:21 0:00:57
32 cut &tack Waist belt 1 SNLS 11:37:21 11:46:21 0:09:00
33 Waiting 11:46:21 11:47:42 0:01:21
34 attach elastic with Waist 1 5th 11:47:42 11:57:43 0:10:01
35 Waiting 11:57:43 11:59:06 0:01:23
36 mark&make butten hole 1 BH pattrn 11:59:06 12:12:24
Waist 0:13:18
37 Waiting 12:12:24 12:15:41 0:03:17
38 attach front Waist 1 SNLS 12:15:41 12:30:46 0:15:05
39 Waiting 12:30:46 12:31:53 0:01:07
40 tack belt &close front 1 SNLS 12:31:53 12:56:13
Waist 0:24:20
41 Waiting 12:56:13 12:59:17 0:03:04
42 top s/t front Waist 1 SNLS 12:59:17 13:05:17 0:06:00
43 Waiting 13:05:17 13:06:19 0:01:02
44 sew side seam 1 5th 13:06:19 13:29:09 0:22:50
45 Waiting 13:29:09 13:32:06 0:02:57
46 close in seam 1 5th 13:32:06 13:47:06 0:15:00
47 Waiting 13:47:06 13:49:08 0:02:02
48 tack corner Waist 1 SNLS 13:49:08 14:00:48 0:11:40
49 Waiting 14:00:48 14:01:51 0:01:03
50 close back Waist 1 SNLS gaid 14:01:51 14:16:11 0:14:20
20
51 Waiting 14:16:11 14:17:19 0:01:08
52 tack back Waist &lable 1 SNLS 14:17:19 14:30:39 0:13:20
53 Waiting 14:30:39 14:32:41 0:02:02
54 hem side vent 1 SNLS gaid 14:32:41 14:57:11 0:24:30
55 Waiting 14:57:11 14:59:41 0:02:30
56 bottom hem 2 SNLS gaid 14:59:41 15:40:41 0:41:00
57 Waiting 15:40:41 15:43:43 0:03:02
58 Bar tak 1 bartak 15:43:43 15:59:18 0:15:35
59 Waiting 15:59:18 16:01:26 0:02:08
60 Trimer 3 table triming 16:01:26 17:14:41 1:13:15
61 Waiting 17:14:41 17:16:45 0:02:04
62 Qc Table 17:16:45 18:09:20 0:52:35
63 Waiting table 18:09:20 18:11:51 0:02:31
33 585MIN per
bundle
21
3.2.5. Packing department
Table 5 packing time study
No Operation Machine Man Cycle time Average Allowance SMV
power 1 2 3 4 5 min
1 Press pocket, back Ironing 2 50 50 52 48 50 0.8 1.2 1
and front rise
2 Press side seam &all Ironing 6 82 85 82 85 86 1.4 1.2 1.7
seam parts
3 QC Manual 5 82 78 83 80 81 1.3 1.2 1.6
4 Tag Manual 1 21 23 20 19 19 0.3 1.2 0.4
5 Folding Manual 1 29 31 28 32 31 0.5 1.2 0.6
6 Insert poly bag Manual 1 14 13 15 14 16 0.2 1.2 0.3
Total 5.31
22
Drawing current value stream mapping
24
CURRENT VALUE STREAM MAPPING
25
3.2.6. CUTTING DEPARTMENT ANALYSIS
Table 7 Cutting Department Analysis
Total lead time 231.33 min
Total value added time 194.4 min 84.92%
Total non-value added time 36.3 min 15.69%
Inventory 2280
25
PRODUCTION
SMV (MIN) INCLUDING NP ACTIVITIES 873
SMV (MIN) EXCLUDING NP ACTIVITIES 1455.18
Series 1
34 35 36 37 38 39 40 41
Total lead time Total value added time Total non-value added time
26
14520
daiy production = X 60% = 242.2 pices/day
36
SMV (MIN) INCLUDING NP ACTIVITIES
𝐓𝐨𝐭𝐚𝐥 𝐦𝐚𝐧 𝐦𝐢𝐧𝐮𝐭𝐞𝐬 𝐚𝐯𝐚𝐢𝐥𝐚𝐛𝐥𝐞 𝐢𝐧 𝐚 𝐝𝐚𝐲
d𝐚𝐢𝐲 𝐩𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐨𝐧 =
𝐒𝐀𝐌 𝐗 𝐀𝐯𝐞𝐫𝐚𝐠𝐞 𝐋𝐢𝐧𝐞 𝐄𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲
14520
daiy production = X 60% = 217.8 pices/day
40
sewing production
260 243
240 218
220
200
SMV (MIN) EXCLUDING NP SMV (MIN) INCLUDING NP
ACTIVITIES ACTIVITIES
Series 1
34 35 36 37 38 39 40 41
27
SMV (MIN) EXCLUDING NP ACTIVITIES
𝐓𝐨𝐭𝐚𝐥 𝐚𝐯𝐚𝐢𝐥𝐚𝐛𝐥𝐞 𝐦𝐚𝐧 𝐦𝐢𝐧𝐮𝐭𝐞𝐬
= (𝐓𝐨𝐭𝐚𝐥 𝐧𝐨. 𝐨𝐟 𝐨𝐩𝐞𝐫𝐚𝐭𝐨𝐫’𝐬 𝐱 𝐖𝐨𝐫𝐤𝐢𝐧𝐠 𝐡𝐨𝐮𝐫𝐬 𝐢𝐧 𝐚 𝐝𝐚𝐲 )
Total available man minutes = (16 x 440 ) = 7040 min
𝑻𝒐𝒕𝒂𝒍 𝒎𝒂𝒏 𝒎𝒊𝒏𝒖𝒕𝒆𝒔 𝒂𝒗𝒂𝒊𝒍𝒂𝒃𝒍𝒆 𝒊𝒏 𝒂 𝒅𝒂𝒚
𝑑𝒂𝒊𝒚 𝒑𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 =
𝑺𝑨𝑴 𝑿 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑳𝒊𝒏𝒆 𝑬𝒇𝒇𝒊𝒄𝒊𝒆𝒏𝒄𝒚
7040
𝑑𝑎𝑖𝑦 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑋 60% = 717.4 𝑝𝑖𝑐𝑒𝑠/𝑑𝑎𝑦
5.8975
SMV (MIN) INCLUDING NP ACTIVITIES
𝑻𝒐𝒕𝒂𝒍 𝒎𝒂𝒏 𝒎𝒊𝒏𝒖𝒕𝒆𝒔 𝒂𝒗𝒂𝒊𝒍𝒂𝒃𝒍𝒆 𝒊𝒏 𝒂 𝒅𝒂𝒚
𝑑𝒂𝒊𝒚 𝒑𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏 =
𝑺𝑨𝑴 𝑿 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑳𝒊𝒏𝒆 𝑬𝒇𝒇𝒊𝒄𝒊𝒆𝒏𝒄𝒚
7040
𝑑𝑎𝑖𝑦 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑋 60% = 641.94 𝑝𝑖𝑐𝑒9𝑠/𝑑𝑎𝑦
6.58
p ackin g p r od u ction
720 714.4
700
680
660
641.94
640
620
600
SMV (MIN) EXCLUDING NP ACTIVITIES SMV (MIN) INCLUDING NP ACTIVITIES
Series 1
profit loss
profit loss
8000
7000
7179
6000
5000
4000
3000
2000
1000 1875
1368
0
Cutting Sewing PACKING
29
3.3. Current waste in the ATEX
3.3.1 Overproduction:
To produce sooner, faster or in greater quantities than the absolute customer
demand. Overproduction can occur with individual processes or across the
entire value stream
Over
production
4.3.2. Inventory
This refers to inventory that is not directly required to fulfill current customer
orders. Inventory includes raw materials, work -in-process and finished goods.
All types of Inventory require additional space and handling equipment
30
WIP
RAW MATERIAL
Figure 12 waste of inventory
Table 12 inventory five why analysis
why analysis
WASTE Reason Possible solution or
TYPE recommendation
Why 1 Miss communication between the Establish a visual link between
Inventory
=98.40%
3.3.3. Transportation
This is unnecessary motion or movement of materials; such as work -in-process
(WIP) is being transported from one operation to another.
31
Figure 13 current layout
Table 13 transportation five why analysis
why analysis
WASTE TYPE Reason Possible solution or recommendation
32
Therefore, it travels 275.5-meter distance between work centers and the 263
meter is unnecessary but happened due to poor layout and this unnecessary
transportation is one of the wastes in lean manufacturing principle thereby
leads to work in progress.
Transportation time between works centers are:
From knit fabric store to knit cutting section 180 second.
From woven cutting section to Edward sewing s ection 124 second.
From military sewing section to finishing section 65 second.
Proposed layout
33
3.3.4. Excess Motion:
Motion is the movement of “Human or human body parts. This term refers to
the extra steps taken by employees and equipment to accommodate inefficient
process layout, defects, reprocessing, overproduction or excess inventory
Excess
motion
Why 2 Not proper Use of folding boards & tools to reduce folding &
work study packing time
34
3.3.5. Rework and Defect
A defect is a component, which the customer would deem unacceptable to pass
the quality standard and will not pay for it .
Why 1 Lack of motivation & training Training & motivation for workers
Rework
Defects
35
3.3.6. Defect analysis
Table 17 company report quality control report
type of Dates
defect 1 2 3 4 5 6 7 8 9 10 total Cumu Cumulat
lative ive %
Skipping 15 8 15 16 15 5 12 9 16 14 125
stich 125 19.26
Slip out 8 10 15 12 11 15 10 9 14 9 113 238 36.67
Puckering 14 11 7 12 9 15 9 13 13 8 111
stich 349 53.78
Broken 11 7 8 10 15 13 15 8 12 11 110
stich 459 70.72
Open stich 15 11 8 9 7 10 9 10 11 12 102 561 86.44
Uneven 8 9 12 12 11 12 9 4 3 8 88
stich 649 100
defect 71 56 65 71 68 70 64 53 69 62 649
Checked 65 790 800 670 900 840 710 690 810 732 7592
pieces 0
Defect percentage
𝑻𝒐𝒕𝒂𝒍 𝑫𝑬𝑭𝑬𝑪𝑻𝑰𝑽𝑬 𝑷𝑰𝑪𝑬𝑺
𝐷𝐸𝐹𝐸𝐶𝑇 𝑃𝐸𝑅𝐶𝐸𝑁𝑇𝐴𝐺𝐸 =
𝒕𝒐𝒕𝒂𝒍 𝒄𝒉𝒆𝒄𝒌𝒆𝒅 𝒑𝒊𝒄𝒆𝒔
649
= 𝑥 100=8.54%
7592
pareto chart
140 120.00
36.67 40.00
40
20 19.26 20.00
0 0.00
Skipping stich Loss stich Puckering stich Broken stich Open stich Uneven stich
cumme
36
Cause and effect diagram broken stitch
Machine
Man
Broken
stich
Weak thread
Material Method
Figure 18 Cause and effect diagram broken stich
Table 18 Cause and effect broken stich
Cause Cause Suggested Solutions
Type
Machine inappropriate thread tension Tension of the thread properly adjusted
Needle plate, pressure foot, Inspect the needle point at regular intervals and
needle check for sharp or burred points.
holes may have sharp edges Sharp edges should be removed.
Method Wrong needle size and thread Needle size and thread size should be
size synchronized
37
Table 19 Cause and effect skip stich
Cause Type Causes Suggested Solutions
Man Operator inefficiency Provide adequate training to the operators
Machine Hook, lopper or needle is not able to Timing of hook or lopper with needle should
hold the thread loop in proper time be adjusted Properly
the thread take up spring is not adjust Adjust the thread take up spring correctly
correctly
Needle deflection or bending adjust the needle height and testing before
bulk sewing
Tension variation in lopper and Adjust tension properly
needle thread Choice of sewing thread in accordance with
the needle size.
Select good quality thread which is free from
flaws.
Method Loop size needle is small Adjust needle and thread size
Improper handling of cut pieces Reduce gap between presser foot and the
hole of needle plate
38
Table 20 Cause and effect slip out
No Causes Remedies
1 If hook looper and needle are not Examine the setting and timing between
needle and hook or looper
interested in loop of thread in time
Placing of needle properly
More secure needle should be used
2 Irregular thread tension on upper or The tension of thread should agin be adjusted
lower loop
3 Due to needle deflection Needle to be changed
4 If needle thread loop size is too small Needle size and thread size must be adjusted
39
Figure 22 Cause and effect diagram of t open seam
Table 22 Cause and effect open seam
40
PROPOSED VALUE STREAM MAPPING
41
CHAPTER FOUR
42
Departments SMV (min) Output pcs SMV (min) Output Variation
excluding NP /shift(A) including NP pcs/shift (B)
(A-B)
Activities Activities
Cutting 2.09 1768.42 2.54 1455.18 313pices
Sewing 36 242.2 40 217.8 25 pieces
Packing 5.8975 717.4 6.58 641.94 76 pieces
Average 138pices /shift
1500
1000 717.4 641.94
500 242.2 217.8
0
Cutting Sewing Packing
PROFIT LOSS
Because of the production loss due to variation of SMV excluding non -
productive activities and SMV (min) including non -productive activities the
company loss a profit when we investigate the total profit loss per shift was
10,442 birr/shift
Defect and rework
To prevent the defect generation and minimize occurrence of defect it is
necessary to study and analyze them in this direction, we have realized a
presentation of defects typology with a classification of defects and causalities.
All are necessary to establish solution. After implementation of the solution
the positive results are overcome. The major defects were identified and
partially reduced in some amount. Based the solutions provided by this project,
some corrective actions were taken
43
Proposed value stream mapping
As we see from the above investigation we have found different waste in order
to minimizing those lean wastes we have been proposed a new VALUE
STREAM MAPPING
1. Transportation: Re-layout of the production floor in order to reduce the
distance between the departments
2. Inventory; reducing by using Kanban system and pull production rather
than push and creating a visual link between the departments
3. Defect: by collecting the quality control department and analyzing the
defect through pareto chart in order to know the highest percentage
defect and we identify the cause and effect for the defect and providing
a new solution
4. Waste of motion: there is no standard operating procedure this go to
decrease the comfort and waste of motion so this problem should be
solved through preparing standard operating procedure(sop) and by
training the operators
Waste Existing Proposed
Inventory 3050 500
Lead time 3099.28 549.28
Lead time / pcs 84 46
Transportation 275.5-meter 12.5 meter
Waste of motion No standard operating Preparing standard operating
procedure procedure
Profit loss 10,442 birr/shift
Production system Progressive bundling system Single piece flow system
Defect percentage 8.54%
44
CHAPTER FIVE
5.1 Conclusion
A value stream includes all activities required to transform a product from raw
material into the finished goods. Value Stream Mapping scrutinizes business
processes from beginning to end and a visual representation map is drawn of
every process involved in the material and information flows. Then a future
state map is drawn to show how things should work for best competitive
advantage. Value Stream Mapping helps to identify the current flow of material
and information in processes for a family of products, highlighting the
opportunities for improvement that will most significantly impact the overall
production system.
The main goal of this thesis was to find out the scope of VSM technique
application in garments factory. On a selected product of the studied garments
factory VSM was implemented to find out the amount of wastes in cutting,
sewing and finishing section; because the selected product had a long lead time
and was unable to meet the expected production rate.
In this study the suitable lean tools an d principle are used to analyzed the
(TIMWOOD) waste through VALUE STREAM MAPING and which minimize
the process wastages such as work in progress(WIP), through put time, change
over time, transportation, production space and loss of productivity in ALTEX
P.LC.
The problem of higher WIP is addressed through single piece flow principle.
In addition to this, VSM can indirectly supports for minimizing the working
area transportation, through put time, setup time, and waste of motion.
From this study 99.58% of the production lead time is spent in unnecessary
inventory from this result it also increases the production cost and production
lead time. if minimizing the unnecessary inventory and other waste it
minimizes the production lead time and it also increase the productivity of the
45
company. In this current production l ead time for one pcs it takes 84 minute if
applying the proposed VSM it almost takes 46 minute.
From this result if changing the production system from progressive bundling
system in to single piece flow system it increases the production rate on the
sewing section
From this study if the defect rate also can be minimizing on the future by
implementing total quality management (TQM) through the entire
manufacturer procedure
46
5.2 Recommendation
Modern managers find it difficult to identify the key areas and practices, which
can be used to eliminate waste in their processes. Based on the practical
validation conducted, it can be seen that VSM can be effectively applied to
apparel industry as the initial step of waste identification. Using this tool, it is
possible to map the current status and subsequently analyze to achieve waste
elimination
The case study presented in this paper, has shown that the wastes such as
transport, inventory and defects can be reduced which in turn improves the
productivity of the organization. In order to accomplish this task, the managers
of the case company have to implement approaches l ike 5S, One-piece flow,
etc. Thus, VSM helps the managers to visualize the present level of wastes
occurring in the organization and the future possibilities of reducing or
eliminating them. In order to continuously reduce or eliminate waste,
management of companies need to apply different Lean tools and techniques
accordingly while giving adequate training to their employees.
Therefore, organizations of similar type can use the research outcomes as a
knowledge base to identify their wastes and come up with suitable remedies.
Findings of this research can be valuable to other organizations of Ethiopia
garment industry, which hope to implement Lean Manufacturing in the near
future.
For improvement of production system of the selected garments industry,
below some recommendations are proposed:
Value stream mapping should be applied to determine the current
scenario of production and to identify various types of wastes.
Kanban supermarket pull system should be implemented to reduce
unnecessary raw material inventory and waiting time.
To reduce other waste various technique such as zero defects, setup time
reduction, line balancing, SMED, 5S, and Poke-Yoke can be applied.
Layout needs to be improved to reduce unnecessary transportation
wastes.
47
Bottleneck point should be identified and removed to get the maximum
output from the production line.
Proper and adequate training should be provided to employees and
workers so that they can gather proper knowledge and consciousness
about the operation of various machine to maintain desired quality.
In this study, flow of value, waste and waste sources in the value stream was
tried to clarified by using value stream mapping. The current state was
analyzed and ideas for improving system performance were proposed.
Value stream mapping should be repeated periodically in order to achieve
better system performance with continuous improvement view. They must be
establishing leaning department to introduce different lean tools like single
piece flow system, takt time, Kanab and total productive maintenance we can
increase the productivity and also, we can minimize the production cost of the
garment. And reducing the production of lead time.
48
REFERENCE
1. Ana, R. (2008), “Implementing Lean Manufacturing”: the Annals of
“Dunarea De Jos” in Machine Building, pp: 2 -10
7. Rother M. and Shook J. Learning to see: value stream mapping to add value
and eliminate MUDA, The Lean Enterprise Institute, Brookline, MA, 1999.
49
APPENDIX
Material Pull Icon: supermarkets connect to downstream processes with this "Pull"
icon that indicates physical removal.
VALUE STREAM MAPPING INFORMATION ICONS
Production Control Icon: This box represents a central production scheduling or
control department, person or operation
Manual Info Icon: A straight, thin arrow shows general flow of information from
memos, reports, or conversation. Frequency and other notes may be relevant.
Electronic Info Icon: This wiggle arrow represents electronic flow such as
electronic data interchange (EDI), the Internet, Intranets, LANs (local area network),
WANs (wide area network). You may indicate the frequency of information/data
interchange, the type of media used ex. fax, phone, etc. and the type of data
exchanged.
Go See Icon : gathering of information through visual means
Kaizen Burst These icons are used to highlight improvement needs and plan kaizen
workshops at specific processes that are critical to achieving the FSVSM
Kanban signals A location where Kanban signals reside for pickup. Often used
with two-card systems to exchange withdrawal and production Kanban.
50
51
Value stream mapping study sheet
Queue Cycle Change Std. Units WIP Distance to Comments :
Department Operation Step Time Time overtime Inventory Processed Finished next process
52