Tuesday 10 April 2018

Lean manufacturing tool series -14 (Workflow diagram)

Workflow diagram – An important lean tool

They say that a picture is worth a thousand words. In the case of business and process management, this couldn‟t be any more true. When it comes time to lean out a process, system, or business, the question of visualizing the process always comes up. Luckily a tool exists to bring everyone on the same page as well as visualize the processes involved, and this tool is a Workflow diagram. A workflow diagram is like the secret decoder ring that will result in the team‟s understanding and focused improvement.


Just as it sounds, a workflow diagram is a visual depiction of a workflow, using visual representations such as flowchart symbols and annotations to show the different steps and decision points in a workflow. A workflow is a sequence of operations or processes as defined by the work of a person, a machine, a group of machines, or a group of people, organization or staff. The work itself may actually be a virtual representation of actual work, such as a decision, processing of a document, or a procedure that is conducted. The flow part of the workflow is oftentimes depicting a transfer of a document or piece of a product from one step or workstation to another.
The workflow itself is not a great lean tool. While depicting the process helps to visualize what is happening inside of the company, it does not show the places for improvement. Like a roadmap, it maps out the different destinations and paths to get to and from a destination. Also like a map, it does not show where the roadblocks, bumpy roads, heavy traffic, or bad weather is. Just as a map can be used as an underlay for a weather map or traffic map, the workflow can be used as the building block on which other assessment tools are based.
The workflow can be used as a great learning tool, especially for newcomers to the organization, which is an ISO requirement.
In reality, it is often hard to trace the exact path of a task or document, especially when functional tasks and operational teams are not clearly defined. The workflow will often be better represented by a series of intertwined webs instead of clearly defined paths and flowing roadmaps. It is very common for a company to employ the use of software to help in defining and managing the workflows associated with a company.
After it is defined and improved, the end result is usually a better overall understanding of the company‟s processes as well as improved efficiency, less complicated processes, improved process control and better quality and standardization. If all of the members of a workflow and business understand where their place is in the workflow and how they are supposed to interact with other teams and organizations inside of the workflow, the results are sometimes amazing at the level of improvement that is possible. When a company first decides that it wants to employ lean processes, they usually start with a workflow diagram. Most managers and company executives are shocked to find out the inefficiencies that occur inside of their organizations. It is also a great way to make a big difference quickly by reminding, or informing all personnel that operate inside the workflow of what they should be doing with respect to processing the documents or materials that they handle.

Prepared by:Md. Tarikul Islam Jony
Mail:jonytex073@gmail.com
+8801912885383

Monday 2 April 2018

FABRIC INSPECTION PROCEDURE IN GARMENTS FACTORY



FABRIC INSPECTION: Fabric inspection will be done to assure the fabrics which are going to be used for the bulk production in garments are as per the acceptable QUALITY STANDARD.

SYSTEMS TO FOLLOW:

  1. Merchandising department must provide Fabric invoice with complete packing list, Approved color swatches to Q.A. Department.   
  2. Fabric inspection will be conducted for 4 point system.
  3. Must sort-out 10% out of the quantity received from each style/color/lot for the   inspection as SAMPLE quantity.
  4. Take 6” stripe cut from beginning of length of each roll to check the shade along length and width must mark the roll number in each cut piece for reference.
5. In case of different shade found then shade continuity card should be created   by taking a small swatch of each roll representing the shade and listing the continuity shade card by roll number to identify in the cutting.
6.      Fabric must be inspected in the lighting level of at least 800 – 1200 lux for over head lights. Have to use under bed lights which will highlight weaving faults, holes and yarn fault.
  1. If the 10% of fabric inspection is failed, have to go for another 15% fabric inspection.
  2. If 15% Fabric inspection also failed, have to go for 100% panel inspection.
  3. In fabric inspection acceptable points will be 28 per 100 square yards. If any roll or bale gets penalty points beyond 28 per 100 Sq.yds. Entire roll or bale also be   rejected. (for rolls and bales acceptable points per roll may varies from buyer to  buyer)
  4. Fabric width, length, weight, GSM matching should be checked for each roll/bale and record in the report.
  5. In the event of any fabric rejection, Q.A. Manager, Merchandising Manager, G.M., dying manager should be informed immediately with complete report for the decisions.
  6. Defect fabric rolls and bales must be marked by yellow color sticker and reject fabric will be marked by red color sticker.
  7. Fabric Inspection format must be duly filled completely with observation and findings in details.
  8. Inspection report must be submitted to the Q.A. Manger’s approval and then submit to G.M/Director.
  9. Fabric defect type display chart with all defect samples should be placed at the inspection table.
Follow the bellow given details to conduct the 4 point fabric inspection.

How to do 4 point fabric inspection?

1. Must have adequate lighting level of 800 to 1200 lux of good quality day light bulbs.

2. Vertical and Horizontal defects defined for the 4 point rating?

Vertical Defects (Along the length)
Horizontal Defects (Along the width)
                 Length
 Points
                  Width
Points
0.2 to 3.0 inch     (0.1 to 8.0 cm)
     1
0.2 to 3.0 inch (0.1 to 8.0 cm)
1
3.1 to 6.0 inch   (8.1 to 15.0  cm)
6.1 to 9.0 inch   (15.1 to 23.0 cm)
9.1 to 36.0inch  (23.1 to 92.0 cm)

     2           3 
     4
3.1 to 6.0 inch (8.1 to 15.0 cm)                            6.1 to 9.0 inch (15.1 to 23.0cm)                           9.1 to 36.0 inch(23.1 to 92.0cm)                                            
  2
  3
  4

   


















3.What is the calculation formula for 4 point system for 4 POINTS FABRIC INSPECTION?  
    

Total points            x           36 Inches    x 100(yds)    =   POINTS PER 100 SQUARE YDS.
No. of yds inspected               Fabric width


What is the acceptable level of quality in the fabrics inspection using the 4 point?
   System?    It is 28 POINTS per 100 SQUIRE YARDS.

                                                              Grades of fabric

             A+
01-05
C+
31-35
             A
06-10
C
36-40
             A-
11-15
C-
41-45
             B+
16-20
D+
46-50
             B
21-25
D
51-55
             B-
26-30
D-
56-60



Prepared by :
Tarikul Islam jony
+8801912885383
jonytex073@gmail.com

Lean manufacturing tool series -13 (Value Stream Mapping -VSM)

Value Stream Mapping (VSM) – Visualize the Value

It should be obvious that an ideal business and manufacturing process should run smoothly without any interruption between steps or departments. The quickest way from point A to point B is in a straight line, and the easiest way to achieve that straight line is by using Value Stream Mapping, or VSM.

VSM is used to identify the areas in which a large amount of waste exists. This gives the quality team a good idea where to focus their efforts and lean processes. By practicing VSM, a company can also streamline their business processes and achieve record levels of productivity. More commonly known as “Material and Information Flow Mapping”, VSM seeks to analyze and optimize the flow of materials and information necessary to bring a product or service to a consumer. As you might expect, the simpler, more straight-line, and clearly defined the processes or value stream is, the more efficiently the company will run. If used correctly, VSM can be used in many different industries and processes, from customer service, to consulting services, and from optimizing manufacturing lines to paperwork reduction. No matter what industry, effort, or process, there are a few steps which outline the processes necessary for mapping the different value streams.

When it comes time to implement the VSM techniques, it should be employed in four stages.

The first is to identify what it is that is to be mapped, or what the “target” will be. Second, using the helpful hints from above, the current state of the process should be drawn. The steps, information flows, and delays that are necessary to deliver the target product or service should be included in the preliminary map.

The next step is where the magic happens. Management should be brought in to assess the current state of the value stream map it possibly identify areas which need work in creating flow by eliminating waste. And lastly, taking into account what was found in the previous step, the future VSM should then be drawn and implemented.







While it is usually a management-lead initiative, in order to effectively create an accurate VSM, a company must employ the cooperation of its line workers to help the management create an
Collected & Edited by Md.Mallick. Nazrul Islam Page 23
effective VSM. Like a house without a strong foundation, without a good VSM to start with, the rest of the process will be useless.

Value Stream Mapping is one of the best ways for a company to understand its own processes and procedures. As most managers will be surprised at the inefficiencies, it is good to put them on paper so they can be addresses. Just as it can be used to identify the weak areas, it can also be used to project what the ideal VSM would look like, and use that as a reference when employing other Lean tactics to improve the performance of the company by eliminating waste. The end result is usually a stronger, leaner company that is streamlined to the point where it produces its maximum output with the least amount of defects.

Prepared by:Md. Tarikul Islam Jony
Mail:jonytex073@gmail.com
+8801912885383