Cellular manufacturing model to reduce WIP fluctuation in garment manufacturing

Abstract

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. .