Abstract:
Purpose – High Work In Progress (WIP) and its fluctuation are found to be common in
garment manufacturing lines in Sri Lanka. The purpose of this paper is to demonstrate a
lean cellular manufacturing model as a solution.
Design/Methodology/Approach – The application of group technology/ lean cellular
manufacturing techniques and its benefits are examined. The significance of the WIP and its fluctuation is investigated through the data obtained from several garment
manufacturing lines. Root cause analysis on the problem reveals the major factors
contributing to the problem. The sewing line is identified in few (more commonly four)
clusters and each cluster behaves as a separate manufacturing cell termed as a ‘sub cell’.
Findings – The hypothesis testing demonstrates that WIP fluctuation is significant in
garment manufacturing lines. Poor line balancing is one of the major reasons for WIP
fluctuation.
Practical Implication - The proposed sub cell concept leads to reduce the WIP level and
its fluctuation significantly and delivers many advantages. The validation of the model is
tested by implementing the concept into a garment manufacturing company with 20
production lines. The results are promising with a 12% increase in the production
efficiency, equivalent to US$ Million 1.23 annually.
Originality/ Value –The existing cellular systems are dedicated to work on parts of few
products. In garment manufacturing the lines are temporarily dedicated to manufacture
only one product. The existing cellular manufacturing systems do not suit for
manufacturing garments. Presently each garment manufacturing line behaves as one
entity, where empowerment, team work are difficult to be promoted. The new sub-cell
concept changes the organizational culture and makes the production lines more flexible through motivated, cohesive team. The operators are motivated with higher earning through higher productivity and dignity. .
