Conducted by BatStateU
, Started on 2013 -
Completed on 2014
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This study aimed to use and apply lean tools as ways of improving manufacturing systems
that lead to reduction of wastes and standardization of cycle time. Model A in Line 1 at sewing section
was the focus of the study. The researcher used questionnaires, 5S Audit checklists, and Time Study forms
in information-gathering and cycle time-computation. Based on the observation done, the company does
not have a standard operation time. Similarly, the researcher observed non-value activities such as
unnecessary transportation and manual counting, and there were also product defects due to poor 5S and
WIP inventories. After considering lean tools, using process flow and cycle time analysis, the standard
time was determined. Likewise, the non-value added activities were reduced, thus productivity was
improved. After lean implementation, 100% efficiency was achieved, the rejection rate was reduced to
0.08% and zero WIP inventories in Line 1 became a practice. Lean tools brought significant changes in
providing smooth process flow and productive operations, which in turn, give a remarkable contribution
in achieving company’s goals, focus on the customers, giving quality products at the right time and at the
right place. Therefore, the full implementation of BY Garments would contribute in gaining more profits.