Browsing by Author "Rathnayake, V"

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item: Conference-Full-text
Barriers for lean implementation in apparel industry
(IEEE, 2021-07) Fernando, DT; Rathnayake, V; Adhikariwatte, W; Rathnayake, M; Hemachandra, K
Lean manufacturing is one of the most widely used tools in the contemporary manufacturing industry to improve the business performance via achieving higher efficiencies at reduced cost structures. However, the apparel industry has not yet been able to realize the full potential benefit scheme of this change initiative. Thus, this research is formulated to identify key barriers faced by the apparel industry which hinder the utilization of the full spectrum of lean benefits. A comprehensive literature review was conducted along with the feedback from the industry professionals to identify key barriers of lean implementation which were categorized under six lean tools. A pilot study was conducted targeting lean practitioners and identified three lean tools (TPM, 5-S and Kanban) as the most decisive tools for further investigations. A detailed survey questionnaire formulated on those prioritized lean tools was distributed to lean practitioners (executives and managers) in lean implemented Sri Lankan apparel factories. Quantitative feedback was obtained using ‘1-5 Likert Scale’ and prioritized using ‘Relative Importance Index’ to identify the most critical barriers pertaining to the feasibility of lean implementation and continuation. A comprehensive list of recommendations was developed using the findings of the literature and the qualitative feedback from the survey.
item: Article-Abstract
Cellular manufacturing model to reduce WIP fluctuation in garment manufacturing
(2016-10-05) Rathnayake, V; Lanarolle, G; Perera, HSC; Marsh, J
Purpose – High Work In Progress (WIP) and its fluctuation are found to be common in garment manufacturing lines in Sri Lanka. The purpose of this paper is to demonstrate a lean cellular manufacturing model as a solution. Design/Methodology/Approach – The application of group technology/ lean cellular manufacturing techniques and its benefits are examined. The significance of the WIP and its fluctuation is investigated through the data obtained from several garment manufacturing lines. Root cause analysis on the problem reveals the major factors contributing to the problem. The sewing line is identified in few (more commonly four) clusters and each cluster behaves as a separate manufacturing cell termed as a ‘sub cell’. Findings – The hypothesis testing demonstrates that WIP fluctuation is significant in garment manufacturing lines. Poor line balancing is one of the major reasons for WIP fluctuation. Practical Implication - The proposed sub cell concept leads to reduce the WIP level and its fluctuation significantly and delivers many advantages. The validation of the model is tested by implementing the concept into a garment manufacturing company with 20 production lines. The results are promising with a 12% increase in the production efficiency, equivalent to US$ Million 1.23 annually. Originality/ Value –The existing cellular systems are dedicated to work on parts of few products. In garment manufacturing the lines are temporarily dedicated to manufacture only one product. The existing cellular manufacturing systems do not suit for manufacturing garments. Presently each garment manufacturing line behaves as one entity, where empowerment, team work are difficult to be promoted. The new sub-cell concept changes the organizational culture and makes the production lines more flexible through motivated, cohesive team. The operators are motivated with higher earning through higher productivity and dignity. .
item: Thesis-Abstract
Effect of social compliances on competitive advantage of apparel companies in Sri Lanka
Kariyawasam, LI; Rathnayake, V
Apparel industry plays a significant role in Sri Lankan economy as the number one foreign exchange earner and employment provider. Despite many pitfalls, industry continuously booms in the global market. Gained reputation over the years as an ethical and quality apparel supplier among competitors is a greatest strengths to industry. Issues regarding working conditions of the manufacturing facilities blemished the reputation of many world renowned buyers; hence social or ethical compliances were introduced as a remedy. Compliances can be voluntary or mandatory; standards become mandatory after promulgated into national law as a regulation. This research investigated the impact of Social Compliances related to apparel industry in Sri Lanka. The different Social compliance standards found to be more or less similar in core content. Hence 'Worldwide Responsible Apparel Producdon' (WRAP) being the most widely implemented compliance standard in the country was selected for this study. Out of twelve WRAP principles, only ten principles were taken into consideration as they were directly addressing the working conditions, labour issues and regulations related to them. Data collection of this study was through questionnaires and interviews with Human Resources and Compliance managers. From the total of seventy-six apparel manufacturing companies listed in WRAP official website, sixty four companies that were possible to cover under practical circumstances were selected to survey. Another opinion survey was carried out with hundred and ten execudves in sixty companies. Data were illustrated in descripdve charts and analyzed through Freedman test, Mann Whitney test. Anderson Darling test statistics were used to check normal distribudon. Implementing seven WRAP principles were found to be effective. Improvements in factory performance were observed after WRAP. Many WRAP indicators influenced productivity and quality. Effect on Competitive Advantage of Apparel companies was analyzed through Porter's Diamond model. All the three hypotheses: Social Compliances have an effect on working conditions of Apparel companies in SL, Social Compliances have an effect on Labour standards of Apparel companies in SL and Social Compliances have an effect on competitive advantage of apparel companies in SL were accepted.
item: Thesis-Abstract
Impact of lean manufacturing practices on employee job satisfaction in apparel industry
Pradeep, WMS; Lanarolle, WDG; Rathnayake, V
Apparel manufacturers all over the world are pressed to deliver high quality garments at low costs in shorter lead times. Most of the apparel manufacturers started following lean manufacturing concept due to its benefits and competitive advantage. Lean Manufacturing Practices (LMPs) are implemented through employees in the organization and it is essential to find out employee job satisfaction in a lean manufacturing environment. A comprehensive literature review was conducted to get necessary lean information. The objectives of the study are to identify the impact of LMPs on employee satisfaction in apparel industry and identify the most vital factors that affect the job satisfaction of the employee with the involvement of LMPs. Five dimensions of LMPs constructed include 6S, Empowerment, Kaizen, PDCA Methodology and Teamwork. This research focuses on empirically testing the framework under study. Data was collected from a randomly selected five lean implemented manufacturing organizations in apparel sector through a questionnaire. 125 completed responses were considered for the data analysis. The formal statistical analysis including frequency distribution of variables, validity and reliabilify analysis, descriptive statistical analysis, one-sample t-test and factor analysis, were carried out. The major findings of the research on LMPs directly affect the employee job satisfaction with a positive impact. Based on the statistical result, LMPs; 6S, Empowerment, Kaizen, PDCA Methodology and Teamwork help to increase the employee job satisfaction after the implementation of Lean Manufacturing. Among all five LMPs, Kaizen is the most vital factor that employee feels which has positively affected to the employee job satisfaction. Hence, an environment where mutual respect and positive recognition are fostered will help to increase job satisfaction
item: Conference-Full-text
Influencing factors of absenteeism of a small scale garment factory (case study)
(IEEE, 2021-07) Rathnayake, V; Udawatta, S; Adhikariwatte, W; Rathnayake, M; Hemachandra, K
Absenteeism is a major challenge for any organization in the current competitive world. Curbing absenteeism helps organizations achieve their targets, and increase productivity. This study explores the major causes of absenteeism in a small-scale garment factory under various factors that influence absenteeism such a work-related stress, working climate, superior commitment, illness and personal matters. The study helps to identify reasons for operator absenteeism in a small scale factory. Responses from all the sixty-four operators in a factory were considered for the study and the data were statistically analyzed. The study shows that major factors such as wages, other source of income, and bad relationships with supervisors contribute to the absence of employees from work. This clearly indicates that work environment, work relations and co-operation, facilities provided by the organization and job satisfaction were the main factors that cause employee absenteeism.
item: Thesis-Abstract
Study on setup time effect on small order quantities in apparel manufacturing
Mohomed, HMH; Rathnayake, V
As apparel manufacturers in today’s context, it is vital to concentrate on improving productivity by applying tools that can increase the efficiency of sub processes. It is a true fact that Sri Lankan apparel industry has a long history, but it is surprising that when comparing Sri Lanka’s ability with the regional countries/competitors in producing value added products, within a short lead time. Smaller order quantities are becoming increasingly demanding by the western world to sustain in the global apparel business. Due to product variation and small order quantities, it can be seen that there is a strong need to introduce a tool that can monitor the setup time taken to feed new styles without reducing the labour efficiency .This research tries to analyse, setup time in small quantity orders in apparel manufacturing industry through implementing single minute exchange of dies (SMED) with the selected factory. Some ofthe main importance topics of literature related to setup reduction, labour efficiency and employee related discussions are carried out in this survey. It further emphasized the paramount importance of the subject topic by collecting data from the selected manufacturing unit to study the setup time losses. Data collection of this study was through questionnaire and interviews with executives and middle management staffin the selected organization covering various departments. Setup related documentations such as style feeding charts, and other tools such as labour capacity study were used to analyse data. Collected data to cover Setup issues and related factors to understand the delays were collected from different sewing lines which produces variety of styles. Objective of the study will be concentrated to find out reasons to understand high setup time during style changes in sewing floor as well as to reduce setup time by implementing SMED techniques. Data interpretation confirmed the Setup time and its correlation between finance performances ofthe organization. Implementation ofSMED tool is after analysing the collected data proves the hypothesis of the survey confirming that the setup time impacts on financial performance ofthe organization.