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Lean Manufacturing

Lean principles have evolved from the Lean Production Philosophy which has its origin in the set of business philosophies developed in post-war Japan known as T.P.S. (Toyota Production System).  Lean, as its core is a cost reduction philosophy through elimination of waste (muda – Japanese). The principles deployed in Lean made Toyota the pre-eminent auto-manufacturer in the world and by extension helped shape Japan into an economic power.

The concepts outlined in Lean Manufacturing evolved into a series of principles which in turn evolved into a business concept known simply as Lean which can be applied across several disciplines i.e Project Management, IT Deployment, etc.

The Organization known as APICS (American Production Inventory Control Society) has defined Lean as “A Philosophy of Manufacturing based on planned elimination of waste and continuous improvement of productivity.

How G.PRO Solutions and Lean Work Together

One of the ways in which G.PRO & Lean complement one another is in areas such as: Loss Time (machine breakdown/ setup time, SAM/labor costs, and material handling.

During machine setup (new MO/style/layout), time is lost due to the time the mechanics must setup or take down and change tooling. At other times the operator must spend valuable time looking for tools preparing for many delays related to machine setups as a result of constant changes to the production schedule at the same work station.

One of the core values of Lean Manufacturing is known as the “5S Method”.

  • Sort – Eliminate all unnecessary tools, parts, instructions
  • Simplify – A place for everything and everything in its place
  • Shine – Maintain a tidy and organized work environment
  • Standardize – Document the rules for maintaining the first 3S instructions
  • Sustain – Operations carried out in sequence, eliminating waste

Execution of the “5S Principles” meant that resources were planned in ahead, tools were in place and readily accessible, and (where possible) production jobs were scheduled to run in a sequence that minimized machine (or production line) set up. When the “5S Principles” were applied to a G.PRO environment they looked like this:

  • Sort – Use only components/ modules of the G.PRO system which benefit the factory
  • Simplify – Use G.PRO to enable integrated business processes i.e. IEES, PSM , QCM, Inventory Control etc.
  • Shine – Ensure the you work with accurate and timely data (real time)
  • Standardize – Reports and standardize, business processes and documentation, methodology and training.
  • Sustain – Business Processes executed by G.PRO executed on a consistent and timely basis.

Efficiency gain

The results achieved by G.PRO system deployments have resulted in cost reductions and improvements in efficiency so that work in process can be managed closely to ensure no bottlenecks in production occur.

The efficiencies you gain from a G.PRO implementation results in time reduction in set-ups, shop floor time management processes, means direct labor costs are also maximized. Through the use of data collection devices, you can account for time spent “on the clock” and non-productive time spent while a work-order is in unique. This way, non-productive time no longer figures as a basis for calculating direct labor.

Lean [R]evolution

Finally, as G.PRO itself evolves with the use of BI tools, along with lean techniques and philosophies such as lean pull-production principles, you will achieve business gains as you introduce JIT (just-in-time), resulting in greater capacity to monitor inventories, manage more efficiently, and align your suppliers to lean-pull production techniques. In the lean model, especially where cellular production techniques in manufacturing are introduced, there is going to be less handling of materials. Once, a production job begins on the shop floor, production raw materials flow through the plant rather than sit idle, waiting to be used in production.

When lean G.PRO is used in the organization, inventory moves from work station to work station in a continuous flow throughout the plant. As a result, you can expect to see return on investment which is accomplished by an improvement in efficiencies and reduction in your inventory investment.

Learn more

G.PRO SDT – RFID lean shopfloor data tracking
Track sewing operations in real time to gain insight on how to improve lean productivity and quality, shorten time to shipping and increase buyer satisfaction.
G.PRO PSM – Proactive production scheduling and monitoring
Create, view and monitor production schedules against actuals with customizable rules and alerts, better than a spreadsheet.
G.PRO IEES – Time, measure, analyze and improve work estimates
Benchmark shop floor sewing and work motions, set up operator best practices and get predictable, reliable estimates you can trust.
G.PRO QCM – Improve quality, cut defects and rejects
Gain insight into top sewing quality problems, identify sources of defects and rectify them at source, before your buyers do.