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International Journal of Modern Engineering Research (IJMER) Vol. 3, Issue. 6, Nov - Dec. 2013 pp-3653-3672 ISSN: 2249-6645
Waste Identification in Production Line of a Selected Ready Made Garment Industry Using Lean Concept in Bangladesh Noman Sikder1, Taslima Akther1, MD. Abdur Rahim2, Raj Narayan Acharjee3, Mohd. Rifat Khan3, MD. Fazle Rabbi3, Anup Saha3 1, 3
2
Dept. of Industrial and Production Engineering, Shahjalal University of Science and Technology, Bangladesh Dept. of Industrial and Production Engineering, Bangladesh University of Engineering and Technology, Bangladesh
Abstract: The ready-made garment (RMG) industry in Bangladesh is now enjoying the status of being the largest garment exporter and the largest exporter of knit garment to the European Union. The competition with other countries like China and India in Asia is not only on the basis of productivity but also on the basis of quality. That is why it needs continuous monitoring and improvement for mass production by reducing or eliminating any kinds of waste like over processing, excess motion, work in process inventory, transportation, waiting on production floor. Most of the garment industries of Bangladesh have been facing the problem of low productivity because of these wastes. So in this paper, a research has been made for identifying the dominating causes of waste and the quantitative measure of its influence on productivity by using the quality tools histogram, cause-effect diagram and process flow chart. By applying these tools it is possible to increase productivity as well as the efficiency of production line. Keywords: Excess Motion, Inventory, Over Processing, Productivity, Transportation
I.
INTRODUCTION
The spectacular growth of garment sector in Bangladesh in recent years has dramatically changed the landscape of export composition of the country. Once heavily dependent on exports of primary products lead by Jute, the economy of Bangladesh is now experiencing almost 76% [1] export contribution from Readymade garments (RMG). The sector has now occupied an important place in our national economy. With the blessings of cheap labor, pressure for globalization of production based on location economies as well as the favorable treatment from developed countries, Bangladesh and some other developing countries have gradually become the global players in international trade in RMG. However, the Multifiber Arrangement facility, which was extended to favor the least, developed countries in exporting garments and textile has phased out after 2005. Consequently, the beneficiaries of MFA, including Bangladesh are facing severe competition in the unprotected world market. At present, this sector is facing numerous challenges nationally and globally. The competition with other countries like China and India in Asia is not only on the basis of productivity but also on the basis of quality. That is why it needs continuous monitoring and improvement for mass production by reducing or eliminating any kinds of waste like over processing, excess motion, work in process inventory, transportation, waiting on production floor. Most of the garment industries of Bangladesh have been facing the problem of low productivity because of these wastes. To survive in this sector Bangladesh must take immediate pragmatic policies enabling itself to compete more efficiently in the changing business environment through minimization of waste. Therefore it appears that in the present situation Bangladesh RMG industry will not be able to compete successfully in the international market for the existence of unusually waste management. This is specifically the main problem area of present research. To compete successfully in the fiercely competitive post-MFA global free trade market, the manufacturers must be adequately equipped with the latest knowledge of scientific management in minimizing lead time and other management deficiencies [2]. We have to give all out support to this sector and have to build up the backward linkage industry to reduce the dependence on imported raw materials and to minimize waste. Therefore, we need to find out some alternative ways to reduce or minimize the waste on production line. Here in this study steps also will be taken to focus on the waste management by presenting some successful and unsuccessful operations in the waste management process. The purpose of the present study is about analyzing the existing situation specially the waste management on sewing section in the RMG sector of Bangladesh.
II.
DATA COLLECTION AND ANALYSIS
This section presents the findings of the case study. This case study has been conducted in a selected garments industry. This case study deals with various types of waste exists in sewing section more specifically time waste. The information as well as data has been gathered through the observation. The data and information was collected through the observation of the production floor and some past record from the industrial engineering of the selected industry. Finally all data has been analyzed by using various types of tables, graphs and some tools such as cause effect diagram, Histogram, process flowchart and time and motion study.
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