IMPROVING PRODUCTIVITY OF APPAREL MANUFACTURING SYSTEM USING VALUE STREAM MAPPING AND PRODUCTION CONTROL TOOLS FOCUSING ON PRINTING SECTION

Md. Ahasan Habib, A.M.M. Nazmul Ahsan, Md. Bony Amin

Abstract: Traditional printing works in maximum garment industries are facing different problems like low productivity, longer production lead time, high rework and rejection, low flexibility, lower quality product, high non-value added work etc. In this study these different problems were identified by using numerous effective production control tools like process analysis, layout of work station, motion and time study, work standardization etc. The encouraging results after implementing these tools give the way to go forward and thrust to reach at the end point. Some key benefits of this implementation are decrease in sample rejection level by 70%, reduction of work level for repairing works by 80%. Value stream mapping has been used to identify the most bottleneck process. Eliminating bottleneck process results in reduction of excess motion and non-value added works by 50%. As a result, total processing time for final output is decreased. After the implementation of these tools effectively, the result shows a significant improvement of the production than before.

Keywords: Value stream mapping, Production control tools, Process analysis, Motion study, Time study.

DOI: https://doi.org/10.15623/ijret.2013.0209091