Abstract
Most of the Indian clothing Industry follows mass production system are so called Progressive Bundling System (PBS). This typical system creates high amount of non-value added activity, longer production lead time due to higher Work in progress (WIP). Which in turn affects smooth production flow. In this research the researcher approached to address the cited problems with various lean manufacturing tools such as VSM, cellular layout, Single piece flow, and kaizen at ABC clothing Ltd, India. The current state VSM map was developed by mapping all the information and product flow at ABC towards the selected product line. This includes machine cycle time, inventory, setup time, and information flow such as how customers place the order. The current state of Value stream mapping (VSM) for mentioned the product was studied and the target areas of improvement were identified to eliminate the process wastages revealed by current state map at ABC. The future state VSM is designed by incorporating cellular layout, Single piece flow, Kaizen.
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