Lean Manufacturing in Sewing Modules
Nowadays, Lean Manufacturing is the most flexible production system in Apparel Manufacturing. This system allows the maintenance of low inventory levels along the process, allows short delivery times, increases the flexibility towards the changes in style, raises the quality standards, and maintains a high degree of motivation in the workers.
A Production Lean Module is a team of people that work together towards a well defined goal
“To produce the greatest number of garments that will fulfill the quality requirements determined by the client, while optimizing the skills of each member of the team”
The difference between the traditional production lines and a Modular System is that the latter shall be, in the long run, a self-directed system where each operator understands the module goal and his or her responsibility towards collective success.
This makes work more satisfactory due to the increase of participation of each member of the team in the decisions that affect the results of the Module, ranging from the assignment of operations to each member, all the way to the suspension of a team member, if necessary.
In a Mature Module, operators are compensated based on a group incentive system, in which all the team members are equally remunerated according to the daily output of finished garments. This encourages the module to work as a unit, helping its members produce complete, high-quality garments very efficiently.
Modules work with very low work-in-process inventory, usually in a “piece-by-piece” manufacturing environment. Inventories typically range between 0.2 and 1 day, depending on the product and the maturity of the system. A “piece-by-piece” setup requires operators to perform one operation and pass the piece to the next operator to keep inventory levels to a minimum.
It also requires operators to sew most operations at high capacities, and to develop a sense of urgency to keep production continuously flowing.
Lean Manufacturing is not an Experiment.
It is performed with techniques that have been proven world wide with excellent results. Unfortunately, modular production requires a different type of work from the Staff as well as ideology changes towards productivity that are menacing to the Command interests of obsolete leaders.
You can download Important information regarding MODULAR PRODUCTION MANUFACTURING here
Power point presentation of Advanced Integrated Modular Manufacturing
Our objective is to assess a company’s readiness for modular. We gain an understanding of company goals and culture, resources, products and current practices.
Module Design
In this step, a module for the pilot team(s) is engineered. We verify standards, establish proper operation sequencing, determine equipment requirements, operator movement rules, cross training requirements, and produce a physical layout
Modular Manufacturing Training
Our training ensures all employees understand the requirements for successful modular manufacturing and the new roles of management and direct labor. This critical step includes classroom training for management and production employees, supervisory
Follow-Up Support
Positive reinforcement is a very important part of any learning process. Because of this, we conduct follow-up coaching sessions after the team has been in production for two weeks, and again two weeks after that.
Supervisory Development
As teams mature it is imperative that their supervisors continue to develop their skills as well. If not, teams begin to stagnate. This step provides one-on-one coaching for supervisors to help them transition from “front line cop” to “side line coach.” These sessions provide training and real-time feedback on topics such as time management, effective communication, conflict resolution and group dynamics.
A Well-trained Staff, as well as an analysis to minimize the initial impact, are essential to be able to succeed in this conversion
Modular production is not an experiment. It is a serious conversion phase towards the Flexibility so much looked for by the Manufacturers.
Lack of real balance in the sewing lines creates a chaos in inventories and unproductive times. Only 30% of the engineers really know how to make an effective line balance.
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