Abstract
Pull system and Kanban are effective lean manufacturing tools. Though many companies in various manufacturing fields have successfully implemented pull manufacturing using Kanban systems, such studies in apparel manufacturing are rarely found. Kanban system was implemented in an apparel manufacturing company, which had implemented some of the lean manufacturing tools. The apparel manufacturing line was identified in four different sub sections and separate Kanbans were used in each sub section. The system was evaluated using two parameters: the number of Kanban cards in each point; the production output. Correct number of Kanban cards were found at all the time of the monitoring period of two weeks-the production efficiency has increased by 22%.
Highlights
Pull manufacturing is a lean manufacturing methodology that controls production from the end of the process [1]
This paper presents the Kanban system implemented at an apparel manufacturingthe selected company has implemented the lean manufacturing techniques such as 5S, Setup reduction, total productive maintenance (TPM) and total quality management (TQM)
The pull system incorporated with Kanban system is a proved to be highly effective in manufacturing industries
Summary
Pull manufacturing is a lean manufacturing methodology that controls production from the end of the process [1]. Pull system operates as a backward motion- the products are produced when there is an order from the customer [2] delivers parts at each work station as per the production sequence from the finished goods towards upstream operations [3]. Pull system controls the flow of resources in a production process by replacing only what has been consumed, and at the same rate the finished or semi-finished goods are consumed [4]. Pull System smooths the flow of Work In Progress (WIP) [1], [3]. Pull system supports to avoid large inventories by making the production immediately and delivering to the internal or external customers. Heizer and Render [6] state that a company never achieves a low-cost strategy without good inventory
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