A Time Based Correlated Logical Methodology for Choosing Optimum Lean Tools and Techniques in Garment Manufacturing Scenario

Abstract

Lean tools and techniques have been emerged to eliminate manufacturing waste and thus increase operational efficiency in garment manufacturing process. Implementing lean tools and techniques requires a huge amount of resources and in practice; manufacturers meet difficulties to choose optimum lean tools and techniques within their resource constraints and to find the perceived value of manufacturing waste elimination in garment manufacturing process. There is currently no logical methodology is available for selecting suitable lean tools and techniques within a manufacturer‘s resource constraints. This research goal is to develop time based mathematical models and a logical methodology for choosing optimum lean tools and techniques. Mathematical models were formulated and a logical methodology was developed for calculating the perceived value of lean tools and techniques to manufacturing waste elimination and a stage-by-stage methodology is provided for choosing optimum lean tools and techniques to maximize the manufacturing performance within their limited amount of available resources constraints to eliminate their determined wastes. A computer programme has been developed in MATLAB to solve the developed equations to attain optimum result. Developed MATLAB programme is achieved to find optimum lean tools and techniques for identified wastes within the manufacturer resources constraints using the methodology and mathematical model. A waste relations matrix (WCM) has been proposed to establish the relations between the manufacturing wastes and lean tools and techniques. Using waste relations matrix, utilizing the proposed methodology and developed mathematical model for maximize perceived value of elimination of a manufacturer‘s wastes by implementing suitable lean tools and techniques within their resources constraints. Results also establish that the perceived value of elimination of manufacturing wastes can meaningfully be altered based on manufacturer polices. The planned methodology can also be used dynamically by altering the input in the programme developed in MATLAB. Thus by finding suitable lean tools and techniques for particular garment manufacturing wastes, a manufacturer can better prioritize implementation efforts and resources to maximize the success of implementing lean tools and techniques in their garment industries.