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.

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Abstract

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%.

Item Type:	Conference or Workshop Item (Paper)
Uncontrolled Keywords:	Off Standard Time, Work-In-Process, High Waiting Time, Capacity Study, Root Cause Analysis, Sewing Production Line, First-Hour Efficiency
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management
Divisions:	Institute for Management and Business Research (IMBRe)
Depositing User:	Mrs Nurin Jazlina Hamid
Date Deposited:	02 Apr 2024 11:23
Last Modified:	02 Apr 2024 11:23
URI:	https://repo.uum.edu.my/id/eprint/30695

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