Kaizen in Improving the Productivity of Garment Sewing
Keywords:
Kaizen, Improving Productivity, Critical success factors, motion economy principle, Time-study, Bottleneck
Abstract
One of the most crucial strategies for managing continuous improvement is kaizen. Because lowering cycle times and manufacturing costs is our goal. One of the first steps in that direction is the elimination of bottlenecks in the production line. In order to go toward our goal, a meeting was first scheduled with the production and IE teams to explore potential areas for improvement. Then, using a time study and a capacity graph, we determined the workable area. By videotaping the bottleneck process, analyzing the arrangement of the workstations, and managing the machines, we were able to assess the micro-movements. Then, in order to improve the procedure, we shared the motion economy and point kaizen concepts with the relevant department and scheduled a training session for the staff. We implemented the improved method on the selected workstations. At last, the follow-up responsibility was handed over to the responsible authority.
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References
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3. Amit Kumar Arya, S. C. (2015, 10 12). Assessing the application of Kaizen principles in Indian small-scale industry.
4. Anass Cherrafi, S. E.-R. (2019, 05 10). Green and lean: a Gemba–Kaizen model for sustainability enhancement. Production Planning & Control, 30(5-6), 385-399. doi:10.1080/09537287.2018.1501808
5. Aoki, K. (2008, 05 23). Transferring Japanese kaizen activities to overseas plants in China. International Journal of Operations & Production Management, 28(6), 518-539. doi:10.1108/01443570810875340
6. Barone, A. (2020, November 13). Bottleneck. Bottleneck, p. 1.
7. Bashar, A. H. (August 1,2018). Lean Manufacturing Awareness and its Implementation Status in the Apparel Industry in Bangladesh. 3.
8. Basu, M. B. (April, 2012). Kaizen System in Textile Industry.
9. Brian Vo, E. K. (2019, 06 10). Kaizen event approach: a case study in the packaging industry. International Journal of Productivity and Performance Management, 68(7). doi:10.1108/IJPPM-07-2018-0282
10. C. BUNGAU, F. B. (2014). KAIZEN IMPLEMENTATION FOR COST REDUCTION IN MANUFACTURING PROCESS PRODUCT "DRIVER CONTROL BOARD".
11. C.P. Carvalho, L. M. (7.10.2017). Kaizen and 5S as Lean ManufacturingTools for Discreat Production Systems: A Study of the Feasit. 4(7).
12. Cardoso, W. B. (July - September, 2018). License 767 The Implementation and Use of The "5 5" And Kaizen Program . n.9, n.3.
13. Cheryl Tanner, R. R. (2006, 11 13). Kaizen leads to breakthroughs in responsiveness—and the shingo prize—at critikon. National Productivity Review, 13(4), 517-531. doi:10.1002/npr.4040130406
14. Danieal, D. (May 2021). Kaizen (continuous improvement). Newton, Massachusetts, United States: TechTarget's Enterprise.
15. Daniel Carnerud, C. J. (2018, 07 25). Kaizen and continuous improvement – trends and patterns over 30 years. The TQM Journal, 30(04), 371-390. doi:10.1108/TQM-03-2018-0037
16. Fasika Bete georgise, A. T. (2020, 09 21). Kaizen implementation in industries of Southern Ethiopia: Challenges and feasibility. 7(1). doi:10.1080/23311916.2020.1823157
17. Gao Shang, L. S. (2013, 04 05). Understanding the application of Kaizen methods in construction firms in China.
18. Journal of Mathematical, Engineering and Management Sciences, 04(02), 452-459. doi:10.33889/IJMEMS.2019.4.2-037
19. Kumar, S. (2018). Process improvement through Lean-Kaizen using value stream map.
20. MD. Abdul Quddus, A. N. (2014). A Shop-Floor Kaizen Backthrough Approach to Improve Working Environment and Productivity of a Sewing Floor. 8(4).
21. Md. Abdul Quddus, A. N. (2014). A Shop-floor Kaizen Breakthrough Approach to Improve Working Environment and Productivity of a Sewing Floor in RMG Industry. 8(4).
22. Md. Abdul Quddus, A. N. (2014). A Shop-floor Kaizen Breakthrough Approach to Improve Working Environment and Productivity of a Sewing Floor in RMG Industry. 8.
23. Mehdi Shojaei, A. A. (2019, 02 06). IMPLEMENTATION PRODUCTIVITY MANAGEMENT CYCLE WITH OPERATIONAL KAIZEN APPROACH TO IMPROVE PRODUCTION PERFORMANCE (CASE STUDY: PARS KHODRO COMPANY). International Journal for Quality Research, 13(2), 349–360. doi:10.24874/IJQR13.02-07
24. Mohd Norhasni Mohd Asaad, R. S. (2015 ). 5s, Kaizen and Organization Performance: Examining the Relationship and Level of Implementation Using Rasch Model in Malaysian Automotive Company. International Academic ResearchJournal of Business and Technology, 214-226.
25. Muhammad Saleem, N. K. (2012). An Analysis of Relationship between Total Quality Management and Kaizen. Life Science Journal.
26. Nguyen, T.-L. (2019, 02 07). STEAM-ME: A Novel Model for Successful Kaizen Implementation and Sustainable Performance of SMEs in Vietnam. Complexity in Manufacturing Processes and Systems 2019. doi:10.1155/2019/6048195
27. Omotayo, D. T. (2018). Critical Success Factors for Kaizen Implementation in the.
28. Pamela Mazzocato, T. S.-H. (2016, 07 07). Kaizen practice in healthcare: a qualitative analysis of hospital employees' suggestions for improvement. Medical management research, 06(07). doi:10.1136/bmjopen-2016-012256
29. Prashar, A. (2014, 08 05). Redesigning an assembly line through Lean-Kaizen: an Indian case. The TQM Journal, 26(5). doi:1754-2731
30. Puvanasvaran, A. M. (2010). A CASE STUDY OF KAIZEN IMPLEMENTATION IN SMI.
31. Rivera, J. L. (2013). Critical success factors for Kaizen implementation.
32. Saima Akter, F. R. (May 2015). Implementation of kaizen for continuous improvement of productivity in garment industry in Bangladesh . Vol 7, No. 3.
33. Silvia Pellegrini, D. S. (2012, 07). Study and Implementation of Single Minute Exchange of Die (SMED) Methodology in a Setup Reduction Kaizen.
34. Sua´rez- Barraza, M. F. (2010). Implementation of Lean-kaizen. 21.
35. Temitope Omotayo, B. A. (2020, 12 05). AHP-Systems Thinking Analyses for Kaizen Costing Implementation in the Construction Industry. Buildings, 10(12). doi:10.3390/buildings10120230
36. Wikipedia. (2020, August 30). Principles of motion economy. Principles of motion economy, pp. 1-2.
37. Wittenberg, G. (1994, 12 01). Kaizen—The many ways of getting better. Assembly Automation.
Published
2023-05-29
How to Cite
Reza, M. A., Swarna, S. S., Aktar, R., Rashid, K. M., Dola, D. R., Tasnim, L., & Altaf, H. (2023). Kaizen in Improving the Productivity of Garment Sewing. European Scientific Journal, ESJ, 17, 401. Retrieved from https://eujournal.org/index.php/esj/article/view/16782
Section
ESI Preprints
Copyright (c) 2023 Md. Alimur Reza, Sabrina Shahrin Swarna, Rozina Aktar, Kazi Mamunur Rashid, Dilshat Rubia Dola, Lamia Tasnim, Habiba Altaf
This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
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