Dissertations/Theses - Department of Industrial and Production Engineering
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Item Study on implementation of lean manufacturing tools and techniques in the RMG industry(Department of Industrial and Production Engineering (IPE), 2010-03) Jahangir Parvez Masud; Abdullahil Azeem, Dr.Shifting customer demands, increasing variation in products and demand for perfect quality at competitive price with shortest lead time are the common difficulties faced by the manufacturers. Meeting these demands while dealing with complex distribution systems and multi-tiered chains of suppliers is better understood in light of system dynamics and finding ways to minimize their cyclical nature. In the competitive market place, most of the manufacturers tend to stay in business by optimizing the production cost through minimizing lead time and wastage of materials along with increasing employees effective skills rather than increasing prices. In this circumstance lean manufacturing tools and techniques are becoming the most intelligent parts. The paper is on the study of lean tools and techniques and present situation of the industry. The current state value stream mapping identifies the waste happening in frequent manner. This map shows what will be the future state map what is the possible scope of improvement. The future state map shows the possible waste reduction way that contributes to the production lead time. The analysis of 5S and change over time improve the space utilization and production loss time. There is a suggestive framework on how to implement lean techniques to get the maximum benefit from the business depending on the study feedback. To facilitate the conversion process, the studies point to three critical needs: increased receptivity to innovative process change, enhanced predictability to the likely regulatory constraints such equipment will operate under and timely responses to construction and modification actions. Lean manufacturing as a continuous improvement program shows the way to improve the process by eliminating waste, standardizing work, and creating flexible manufacturing. Typical tools used to achieve this improvement include: line smoothing, the 5 Ss, cycle time reduction, and work area reconfiguration. Implementing the lean methodologies is a long journey most likely a never ending journey that must be carefully planned and frequently revised if one is willing to succeed.Item Productivity improvement in readymade garments industry: a case study(Department of Industrial and Production Engineering (IPE), 2014-06) Mazumder, Sumon; Dhar, Dr. Nikhil RanjanIn case of readymade garments (RMG) industries, productivity improvement is a vital to decrease the production lead time as well as manufacturing cost. For productivity improvement it becomes essential to decrease the waiting time, process bottlenecks and increase the production line efficiency. Time study and line balancing are effective techniques to reduce the operation time and improve the productivity. Time study was performed in a furniture industry to increase its production efficiency and reduce the operation time and associated cost. Assembly line balancing technique was also used in some manufacturing industries for single production line to identify and remove the nonvalue added activities and increase the productivity. But, it becomes essential to apply time study and line balancing techniques for the number of production lines of various products in small and large RMG industries to improve its productivity. In this work, time study is performed on four different products of RMG industries and production lines are balanced through the distribution of works among the work stations by line balancing. Thus, new production layouts are modeled with the balanced capacity combining both modular line and traditional manufacturing system together. In new production systems, 6-64% production lead time is decreased for 27-78% reduction of waiting time, 10-179% improvement of labor productivity and 6-130% improvement of machine productivity for four products. Possible problem areas in the industries are identified by fishbone analysis and strength, weakness, opportunities and threats for productivity improvement were also identified by SWOT analysis. This research report provides pragmatic guidelines for the garments manufacturers to improve their industrial productivity and capacity by applying some essential tools like time study, line balancing and fishbone analysis.Item Lean conversion of an apparel assembly line: a case study(Department of Industrial and Production Engineering (IPE), 2012-04) Russel, S. M.; Abdullahil Azeem, Dr.To be competitive and meet ever increasing demand of apparel buyers to reduce cost, supply smaller quantity order at shorter lead time as well as increasing labor cost in the local market has forced the local manufacturers of Bangladesh to improve labor productivity, quality, to reduce lead time and produce small order quantity efficiently. Tools and techniques of Lean manufacturing may play an important role in their quest for meeting ever increasing demand of customers profitably. Lean manufacturing requires keeping far less than half the needed inventory on site, results in many fewer defects, and produces a greater and ever growing variety of products. Lean consists of best practices, tools and techniques from throughout industry with the aims of reducing waste and maximizing efficiency to achieve the ultimate customer satisfaction. The present study focuses on improving line efficiency, throughput time of an assembly line through identifying wastes using value stream mapping and other analyses, identifying opportunities for improvement and required tools and techniques of lean manufacturing and industrial engineering to implement. An assembly line in an apparel factory is considered to implement this study as well as line efficiency, throughput time, machine utilization, space utilization, WIP and other performance parameters are compared before and after implementing the tools and techniques of lean manufacturing and industrial engineering. Though outcomes of 5S and visual management are difficult to quantify, these tools are foundations for lean implementation.Item Reduction of change overtime applying SMED under lean manufacturing: a case study(Department of Industrial and Production Engineering (IPE), 2013-12) Azim Mohammad; Yesmin, TaheraThe basic idea behind lean manufacturing is to eliminate waste, which does not add value to the end product. Any garments industry can maximize their profit margin by reducing all types of wastes. Lean manufacturing is one of those activities that focus on cost reduction by eliminating non-value added activities. This thesis work addresses the application of lean manufacturing philosophy to the mass production sector with a focus on sewing section of the garments industry. The core idea behind the thesis work was to introduce lean manufacturing concept in RMG sector of Bangladesh. In this concern, Single Minute Exchange of Die tools and techniques have been applied. The Single Minute Exchange of Die (SMED) is one of the important lean tools to reduce waste and improve flexibility in manufacturing processes allowing lot size reduction and manufacturing flow improvements. SMED reduces the non-productive time by streamlining and standardizing the operations for exchange tools, using simple techniques and easy applications. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is the key to reduce production lot sizes and thereby improving flow. There has a great applicability of SMED method in RMG sector. Several implementations have proven that the SMED method really works in practice and reductions of changeover time. As RMG sector is a large industrial sector in Bangladesh; change over time reduction can play a vital role for improving productivity as well as economic development for the country. It is found that a significant amount of time per style, per month can be minimized by applying this method. The implementation lean manufacturing has enabled reduction in setup time, unnecessary task elimination, quality rework reduction, material and information flow time reduction through company's internal resources reorganizations without the need for significant investment.