Building a Lean and Sustainable Manufacturing System at Avadat Apparels

Abstract

This paper examines the effects of implementing lean concepts in enhancing the effectiveness of operations in the manufacture of denim products at Avadat Apparels. In particular, this work seeks to identify inefficiencies in processes, capacity limitations, and quality performance in the main operations carried out stitching, washing, and finishing. Primary data will be collected using factory visits and interviews. The instruments that will be utilized to evaluate the operations include TIMWOOD analysis, capacity, throughput and bottleneck analysis, and Pareto defect analysis. From the findings, the stitching operation appears to be the major bottleneck that limits overall capacity while the capacity levels in washing and finishing operations are higher. The time spent on work-in-progress and transportation of goods to the external washing department contributes to long flow times in the factory operations. The Pareto defect analysis indicated that variations in the shade of the stitching and washing are the most common defects. Nevertheless, because of stringent in-process quality checks, few defects occurred. Conclusion from the study reveals that while efficiency may be hampered by various challenges, improvement in processes and having a washing department in house gives Avadat considerable strengths.