After many well-received workshops in India, Apparel Resources Pvt. Ltd. successfully organized and conducted a two-day workshop on ‘Implementing Lean Sigma in Apparel Manufacturing’ on 4th & 5th September 2015, at Laurel Hotels, Dhaka, Bangladesh. The workshop, which focused on Implementing Lean Sigma and Best Practices in the Apparel Industry, was attended by representatives of many key apparel companies, including from the manufacturing segment as well as the buying and service sectors. Some of the well known companies that sent their representatives to attend the workshop include Synergy Sourcing Bangladesh, Crystal Martin Apparel Bangladesh, Zas Apparels Pvt. Ltd., Ewings Garment’s & Textiles Int’l Ltd., Epyllion Group, Intertek Testing Services Bangladesh, Union Fashions, F H L Fashions Ltd., Palmal Group, Ananta Group, Independent University Bangladesh, Edinburgh Woollen Mill (EWM) to mention some.
During the day, a fun-filled game to demonstrate the ‘Team Work’ methodology for developing lean culture was enjoyed by the participants. A detailed roadmap was presented by Chandrark Karekatti, Head Projects and Training – Apparel Resources on the various aspects of lean manufacturing along with its implementation in garment factories. In order to maintain interest of the participants and involving them in the learning process, simulation lean assembly game was played by them to understand the methodology of developing a lean production system and how it helps in improving throughput, WIP and productivity.
The concepts of single piece flow, justin-time, continuous improvement, error proofing, and Right First Time, among others, were explained in detail. The participants thoroughly enjoyed the funfilled training session which included simulation exercise on value stream mapping and work place management. The presentation also explained exactly how these tools and processes can be applied to apparel industries. The concept of best practices that help transform factories into world class manufacturing facilities was also discussed.
Another area of focus was on a structured approach to ‘Quality Improvement Process’ through root cause analysis and top down charting. The thought process of the delegates was brushed up through detailed discussion on how to improve the quality and reduce the cost of poor quality. The key advantages of a Lean Sigma Processes, like reduced non-conformance, improved workplace, defect perception standardization, improved process flows, systems and MIS were discussed.
The forum also focused on inputs on the pressing requirement of factories in reducing style change over time by implementing Single Minute Exchange of Dies (SMED). The methodology of reducing changeover time by segregating internal and external tasks was very much appreciated by the participants. Hand on implementation exercises on use of Poka-Yoke in apparel manufacturing scenarios for eliminating defects at the source made participants wanting more on this tool. Use of other Lean Sigma tools such as Andon for defects highlight and flow manufacturing for reducing the in-process WIP demonstrated the methodology of developing an agile production system.
Many participants expressed immense satisfaction at the quality of information sharing at the event.
The Technology Forum 2015 is a part of the workshop series that addresses key challenges for the apparel industry. In response to huge industry demand, repeat workshop on ‘Lean Sigma Implementation in Apparel Manufacturing’ is scheduled on 23rd & 24th October 2015 in Dhaka, Bangladesh.
