Lean Six Sigma

Lean manufacturing is a production process based on the ideology of maximizing productivity while simultaneously minimizing waste within a manufacturing operation.

Lean Tools we have adopted and plan to get onboard

  • 5S
  • Bottleneck Analysis
  • Continuous Flow
  • Gemba (The Real Place)
  • Jidoka (Autonomation)
  • Just-In-Time (JIT)
  • Kaizen (Continuous Improvement)
  • Kanban (Pull System)
  • KPIs (Key Performance Indicators)
  • Muda (Waste)
  • Overall Equipment Effectiveness (OEE)
  • PDCA (Plan, Do, Check, Act)
  • Root Cause Analysis
  • Single-Minute Exchange of Dies (SMED)
  • Total Productive Maintenance (TPM)
  • Value Stream Mapping

Lean Tools we have adopted and plan to get onboard

  • 5S
  • Bottleneck Analysis
  • Continuous Flow
  • Gemba (The Real Place)
  • Jidoka (Autonomation)
  • Just-In-Time (JIT)
  • Kaizen (Continuous Improvement)
  • Kanban (Pull System)
  • KPIs (Key Performance Indicators)
  • Muda (Waste)
  • Overall Equipment Effectiveness (OEE)
  • PDCA (Plan, Do, Check, Act)
  • Root Cause Analysis
  • Single-Minute Exchange of Dies (SMED)
  • Total Productive Maintenance (TPM)
  • Value Stream Mapping

Our Process Layout

  • First step towards manufacturing is designing a layout for processes.
  • Lean tools we incorporated in designing layout are:
    • Continuous Flow
    • Kanban (Pull System)
    • Visual Factory
  • Our facility has all manufacturing processes under one roof, which makes us visualize real time organizational view.

Our Process Layout

  • First step towards manufacturing is designing a layout for processes.
  • Lean tools we incorporated in designing layout are:
    • Continuous Flow
    • Kanban (Pull System)
    • Visual Factory
  • Our facility has all manufacturing processes under one roof, which makes us visualize real time organizational view.

Machinery Selection and Lean Manufacturing

  • Meanwhile designing a layout, equipment becomes the second most important element, Lean helps us to identify the best way towards excellence:
    • Jidoka (Autonomation)
    • Muda (Waste)
    • Overall Equipment Effectiveness (OEE)
  • We have automated machinery (Pocket Setters, Welt Pockets, Loop Setters, etc.) to ensure quality and productivity.

  • Coming towards WIP handling, we incorporated UPS model in sewing lines.

Lean Towards Improvement

  • Muda (Waste)
  • PDCA (Plan, Do, Check, Act)
  • Root Cause Analysis
  • Single-Minute Exchange of Dies (SMED)
  • Value Stream Mapping
  • Kaizen (Continuous Improvement)
  • We have Certified Lean Six Sigma Engineer, who with his team is always on his toes to implement Lean tools as mentioned above for elimination of waste, bottlenecks and apply improvements.

Lean Towards Improvement

  • Muda (Waste)
  • PDCA (Plan, Do, Check, Act)
  • Root Cause Analysis
  • Single-Minute Exchange of Dies (SMED)
  • Value Stream Mapping
  • Kaizen (Continuous Improvement)
  • We have Certified Lean Six Sigma Engineer, who with his team is always on his toes to implement Lean tools as mentioned above for elimination of waste, bottlenecks and apply improvements.