Hey guys!! I need your hands to come up with an idea in how can the one piece flow concept be applied in apparel industry.

We are a men shirt manufacturer. Anyone can help? :thanks:

The prospect of an improvement to one piece flow is much the same across all industries, even in the office.

Where I would start is here,
1) Evaluate the work area and current value steam. While preforming a VSM of the process is highly recommended, you can do without if the process is simple enough.
-understand the reasons (whether fact or fiction) of why things are the way they are.
-Know the quantity and time that the customer needs to determine the takt.
2) Does the area, operation/processes operate in a cell currently? Often, most desirable is a cell that is catering to a product family.
3) Consider the layout, does it work? Can it work for a new concept on one-piece flow? What is the layout of machines (or processes of people), is is sequential? What is the shape? Typically it is recommended to consider a U-shape or L Shape, to permit single piece flow and flexible deployment of human effort and allow raw materials to smoothly flow to be transformed to finished goods.
The purpose is to have an arrangement of people, machines, materials, and methods in such a way that one piece flow (or in some cases controlled small batch) is maintained through the sequence of process, in well timed continuous flow. Again, the principles are the same for all work places, just dependent on your current operations, space, products etc.
4) How will this affect the other systems?
In the venture to one piece flow, you may find that you are going to affect the upstream and the down stream, so be careful to evaluate and consider such effects before blazing through and changing the line. In house inventory, customer and suppler relations included.

Hi Dante, thanks for your recommendations!!

1. Actually I used VSM before to familiarize myself to the production but seem it can't tell much especially in terms of document flow, signoff etc. Did I have a problem?

2. Not exactly, we are still using a very traditional production method. Transforming to a cell is already challenging for us.

3. Much benefit from point no.3, thanks!! But I still have a question on this. How could I explain a U-shaped line is better than a straight line? What is the tangible advantage?

4. Well, still investigating...

I'll just stick with our number system here.


1. VSM and good investigation should tell you the whole picture, or enough to get you the big picture. It may take much auditing and sleuthing.

2.In my current workplace, that has come much later, and needs lost of work too, so you may experience the same. Many other things may need to transform first, to give way to such structure.

3. A different shape of workstation = different flow. It may not be better, but different flow can change a lot. There are some lines that are better in a straight line.
When I change flow or the shape of flow, it usually starts with an observation of any one or a combination of the following: bottle neck, batch production, raw material delivery is awkward, WIP is congested, FG has risk of losing ID or getting lost, excessive worker movement, high defects due to poor flow, poor ergonomics or other safety issues, excess time on process, waiting, a back and fourth flow of information, materials or people (go left to right, then right to left, then back to the right... more common then you would think). Sometimes you get the whole meal deal, where everything is broken-- supper sized! Change those first and you save big time, and you get the clout to SHOW how it works.
People will still resist. I have had to stand at a line for 2hrs once to constantly assure and support processes and subdue the insatiable need to mess up a new flow that is clearly a good thing. After coaching, people will "get it" and typically say, something about how it is better, and be all surprised-- despite everything that happened in that 2 hours!
So that is a long winded answer. Simply, find where it will work and yield something measurable (tangible), then do it with a team drive. If there is no team, and you are empowered, do it anyway... just be fair and listen to people. Charisma and integrity will win most people.

I am not a 'Lean' guy but from what I know of this industry over here, some people use a modified system involving 'small batches' known as 'transfer batch' because the processing time for a single piece of work is just too short.

A very detailed explanation, ur help has been very useful for me.

1. When I look around on VSM, I couldn't understand what "sequential pull" icon means? What is the difference between it and "Material Pull" icon?:confused:

2. I see. There is no way out unless we just go prepare those preceding tasks. :agree1: And...I imagine what if we implement the project from nothing instead of transforming the existing one?

3. Haha!! Amazing!! Really can't imagine how were you spending the 2-hr time to achieve ur target... anyway, I benefit much from you.:thanks:

1. Sequenced pull (typically a ball shape): Gives instruction/signal to immediately produce a predetermined type & quantity of a unit. It is a pull system for sub assembly process without the use of a supermarket.
Material Pull I am assuming you mean the FIFO icon that is the transfer of controlled quantities of raw or WIP materials between processes? If so, this is used to indicate a device (could be visual, mechanical, structural) to limit and ensure FIFO flow of material between each process, with maximum quantity.
For VSM, I highly recommend the text, Learning to See, by Mike Rother & John Shook, Ver. 1.3; The Lean Enterprise Institute, (2003).

2. Something from nothing? Works for God, and on occasion Change Agents!
Yes, you could build a new cell structure, and slowly integrate the product families or like products.

3. :)That is the price of reshaping the mind, and what I am hired to do, where required.
It often saves thousands and much turmoil to "inline coach" and engage in the workers work. Often the failing of Managers and Supervisors is to take the quality and quantity time with workers.
When I say "stand at a line" that means, sit in their chair, do the tasks, ask questions, engage, observe, time, measure, articulate, get to know the people... nemawashi . Do this right, and in the end they think improvements were their idea!

1. :confused: Sorry that's not what I meant. The material pull icon is the arrow in an arc shape for 3/4 circle. Thanks for suggestion me the godfather book. :lol:

2. For me, actually, hardware/equipment is not a problem. The problem is... when I try to balance the line and inevitably combine a couple of processes into one, operators rather stay on their own talent instead of learning other processes. In garment industry, we still pay them as piece rate. Learning other processes will make them earn less. :(

3. I think I've got exactly what you mean. You're going to tell me, as a lean revolutionist, we should deal with the same issue in person as operator does, shouldn't you? :cool:

1. Bah, sorry about that on my part. I should have known, brain fart!:o

The pull icon is simply indicating the physical action of pulling from a supermarket inventory. Or as far as I can best describe!

Hope this all makes sence now. I fear I may have added more confusion there!

2. Unless changes can provide higher throughput with less labour, OR balanced work flow and a higher piece rate. :cool:
It takes time, but those options, and more may be possible. Also, cross training, though breaking tradition and comfort zones, is highly favorable, but you likely know that... choose your battles though, else people get really messed up. You have to gauge the workforce and how much of what, and when changes.
No one may believe you at first in all this-- part of the fun.

Perhaps you could share more details on this as you go and seek more input; I would like to visualize this more-- VSM, photos, objectives, etc.
I would like to hear others thoughts on this point in particular.

3. See, it works, it was your statement, not mine... here is where I say, good idea!"


Cheers,

Hi there, I'm busy on the new site searching lately.

By the way, how should we calculate the man-power required per ONE unit of cell line? :confused: