Lean Supply Chain Management in Fashion and Textile Industry

321 Pages·2022·5.639 MB·English

by  Rajkishore Nayak

Textile Science and Clothing Technology
Rajkishore Nayak   Editor
Lean Supply
Chain
Management
in Fashion and
Textile Industry
Textile Science and Clothing Technology
SeriesEditor
SubramanianSenthilkannanMuthu,SgTGroup&API,HongKong,Kowloon,
HongKong
This series aims to broadly cover all the aspects related to textiles science and
technologyandclothingscienceandtechnology.Belowaretheareasfallunderthe
aims and scope of this series, but not limited to: Production and properties of
various natural and synthetic fibres; Production and properties of different yarns,
fabricsandapparels;Manufacturingaspectsoftextilesandclothing;Modellingand
Simulation aspects related to textiles and clothing; Production and properties of
Nonwovens; Evaluation/testing of various properties of textiles and clothing
products; Supply chain management of textiles and clothing; Aspects related to
Clothing Science such as comfort; Functional aspects and evaluation of textiles;
Textile biomaterials and bioengineering; Nano, micro, smart, sport and intelligent
textiles; Various aspects of industrial and technical applications of textiles and
clothing; Apparel manufacturing and engineering; New developments and appli-
cations pertaining to textiles and clothing materials and their manufacturing
methods; Textile design aspects; Sustainable fashion and textiles; Green Textiles
and Eco-Fashion; Sustainability aspects of textiles and clothing; Environmental
assessments of textiles and clothing supply chain; Green Composites; Sustainable
Luxury and Sustainable Consumption; Waste Management in Textiles;
Sustainability Standards and Green labels; Social and Economic Sustainability of
TextilesandClothing.
Moreinformationaboutthisseriesathttps://link.springer.com/bookseries/13111
Rajkishore Nayak
Editor
Lean Supply Chain
Management in Fashion
and Textile Industry
Editor
RajkishoreNayak
SchoolofCommunicationandDesign
RMITUniversityVietnam
HoChiMinh,Vietnam
ISSN 2197-9863 ISSN 2197-9871 (electronic)
TextileScienceandClothingTechnology
ISBN 978-981-19-2107-0 ISBN 978-981-19-2108-7 (eBook)
https://doi.org/10.1007/978-981-19-2108-7
©TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerNature
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Preface
The concept of lean manufacturing was coined in Japanese manufacturing sector,
ToyotaProductionSystem(TPS)mainlydealingwithautomotivecomponents.The
majorfocusofleanmanufacturingwastoeliminatewastesfromtheoperationcycle.
Wastescanbedefinedastheprocessoroperation,whichdoesnotaddvaluetothe
product and the consumer is not willing to pay. The objectives of lean manufac-
turingwereto:(a)eliminatewastes(byavoidingwaiting,overproduction,reducing
inventory etc.) in the manufacturing process; (b) improve productivity and effi-
ciency; (c) optimize the utilization of space and equipment; and (d) reduce lead
time.Although,therehavebeensometechnologicaladvancementsthatareapplied
in lean manufacturing, the fundamentals of lean manufacturing have remained the
same.
In recent years, the manufacturing of fashion and textiles has completely been
shifted to developing countries such as Bangladesh, Vietnam, and Cambodia. The
developedcountries,duetohighlaborandutilitychargesarefocusingtomanufacture
high value added clothing or technical textiles. The manufacturing of fashion and
textilesislaborintensiveinmanydevelopingcountriesdespiteofthetechnological
developments and automation. Many of the fashion brands aim to buy the fashion
and textile products at cheaper prices, which lead to stiff competition among the
globalmanufactures.Further,thelaborcharges,rawmaterialspricesareincontin-
uousrise,whichmakesthemanufacturerstofacemanychallengesinmanufacturing
the garments in competitive prices. In the competitive global market, the fashion
and textile manufactures should improve product quality, improve efficiency, and
eliminate waste, which can be achieved by the implementation of lean manufac-
turing.Leanmanufacturingisanintegrativeapproach,whichcanbesuccessfulby
theinvolvementofthewholeorganizationasateam.
Thefashionandtextileindustriesarefacingahugecompetitionduetoglobaliza-
tion and challenges of sustainability. Fashion and textile industries are considered
to be the second largest polluters after the oil sector to due generation of a large
quantitiesofwastes,hence,theleanmanufacturingconceptcanbeutilizedtoreduce
waste. As the global focus is changing towards achieving or producing more with
limitedresources,theresource-basedfashionandtextilemanufacturingneedstobe
v
vi Preface
changed to a new manufacturing system. The new manufacturing system should
focusonthewastereduction,energysaving,useofadvancedtechnologiesandinfor-
mationsystems.Theseapproachescanhelptheorganizationstoachieveexcellence
and provide competitive advantage, which can be achieved by the implementation
ofleanmanufacturing.However,thetransitiontowardsanewmanufacturingsystem
requiresthehighestskillsetsandexcellentorganizationalleadership.
Theconceptofleanmanufacturingisgainingincreasedpopularityinmanyfashion
and textile industries due its ability to manage the process and material wastes.
The fundamental principle of lean manufacturing is based on continuously elimi-
nating waste from the manufacturing processes. Implementation of lean manufac-
turingfocusesonareassuchas:increaseproductivitybyreducingoverproduction,
waiting time, over processing, inventory, defects, unnecessary transportation, and
unnecessary movement, which are considered the seven wastes in lean manufac-
turing.Leanmanufacturingreducesthecycletime,leadtime,andchangeovertime,
hence,improvesproductivity,efficiencyandprofitability.Leancanhelptokeepthe
manufacturing costlowintherisinglaborandmaterialpriceintheglobalfashion
andtextilemanufacturingsector.
Various latest technologies such as Radio Frequency Identification (RFID),
Blockchain,InternetofThings(IoT),Industry4.0,ArtificialIntelligence(AI),and
Automationareessentialtoachievetheobjectivesofleanmanufacturing.Therefore,
many organizations are replacing the traditional technologies with the advanced
technologies to achieve the objectives. For example, several global retailers and
manufacturers are adopting the RFID technology in their supply chain to realize
the benefits, which includes accuracy of information, prevention of loss, product
visibility,easytraceability,reducedlaborcostandreducedleadtime.Hence,RFID
technology can be considered one of the leading technologies for successful oper-
ation of lean manufacturing. The useof other technologies has also been essential
partofleanmanufacturingasthesetechnologiesconverttheleanmanufacturingto
digitallean,whichimprovestheaccuracyandspeedinadditiontotimelyavailability
ofinformation.
This book will discuss the concepts of lean manufacturing, which have been
widely used recently in the fashion and textile supply chain to eliminate waste,
improveproductivityandefficiency.Leanmanufacturingtriestoapplyvariousfunda-
mentaltoolssuchasKaizen,Kanban,Jidoka,5SandSixSigma,toreducevarious
wastesforefficiencyandproductivity,whichwillbediscussedinthisbook.Inaddi-
tion, the technological changes such as RFID, IoT and Industry 4.0 that are used
in digital lean concepts will be also discussed in this book. The findings from the
researchontheuseofdigitaltechnologiessuchasRFIDthattheauthorandsomeof
thecontributorsperformedinVietnamesefashionandtextilesector,willbediscussed
inthisbook.Thebookconsistsofatotalof12chapters,contributedbythesubject
experts from various universities and academic institutes. The brief outline of the
chaptersofthebookhasbeengivenbelow.
“TraditionalFashionandTextileSupplyChain:ConcepttoConsumer”provides
anintroductionofthetraditionalprocessesusedinfashionandtextilesupplychain.
The process sequence and summary of each process has been discussed while
Preface vii
convertingrawmaterialsfromconcepttoconsumer.Variouscausesofmaterialand
process waste generated in these processes (in general) are also being discussed.
Therehasbeenabriefdiscussiononthehistoryofleanmanufacturinganditschrono-
logicaldevelopments.Further,thefundamentalprinciplesofleanmanufacturingand
varioustypesoftoolsusedinleanmanufacturinghasalsobeendiscussed.Various
toolsusedinleanmanufacturingarealsodiscussedinthischapter.Finally,theadvan-
tages,disadvantagesandfuturedirectionsofleanmanufacturingarecoveredinthis
chapter.
“Challenges in the Traditional Fashion and Textile Supply Chain” discusses
various challenges of traditional manufacturing methods. Various strategic chal-
lenges such as buyer driven supply chain, high SKU proliferation, sustainability
challengesandeducationalchallengesarediscussed.Variousoperationalchallenges
suchasleadtimeandsampling,limiteduseoftechnology,andlimiteduseoftech-
nologyhavebeendiscussedinthischapter.Someofthecausesoflowproductivity
and low efficiency from fashion and textile perspective has been included in this
chapter.
“FundamentalConceptsofLeanandAgileManufacturing”focussesontheevolu-
tion of lean manufacturing-definition, objectives, and principles of lean manufac-
turing.Thegoalofleanandagilemanufacturingtosatisfycustomerdemands,has
beendiscussedinthischapter.Thischapterfocussesonthefundamentalsofleanand
agile manufacturing concepts, in addition to the objectives, and principles. There
have been discussions on the history, chronological developments, applications in
themanufacturingsector,especiallyfashionandtextileindustry,andbenefitsoflean
andagilemanufacturing.Therehavebeendiscussionsabouttheimplementationof
lean concepts in fashion and textile manufacturing as well as how it can help to
improvetheproductivityandefficiency.Differentwastesandtheircontrolthrough
lean manufacturing. The chapter also discusses the differences between the two
concepts:leanandagilemanufacturing.
“LeanConceptinFashionandTextileManufacturing”coverstheoverviewoflean
manufacturing.HowtheleanmanufacturingwasdevelopedintheToyotaProduction
System(TPS)andHenryFordProductionSystemhasbeendiscussedinthischapter.
Furthermore, a conceptual framework for lean concepts has been provided in this
chapter.Thedevelopmentofleanforfashionandtextilemanufacturinghasalsobeen
discussedinthischapterwithafocusonthepastworksinleanmanufacturingwith
thechronologicaldevelopments.Variouswastesinfashionmanufacturinghavebeen
discussedwithemphasisontheircauseandeliminationprocesses.Leanapplications
ingarmentmanufacturinghavebeendiscussedindetailandabriefdescriptionhas
beengivenontheleanapplicationinthetextileindustries.Theleanapplicationto
achievesustainabilityisalsodiscussedinthischapter.
“StandardizedWorkinFashionIndustry”coverstheprocessessuchastimeand
motion study generally used in garment industries to establish standard time. The
fundamentalprinciplesandtheprocessofconductingtimeandmotionstudyhasbeen
coveredinthischapter.Thischapteralsodiscussesaboutthemaximumutilization
ofmachine,labor,cycletime,changeovertime,workbalancing,timemeasurement,
viii Preface
tools and jigs for time management, economy of motion and time management.
Variouscausesofidletimeandbottleneckingarealsocoveredinthischeaper.
“5SandItsImplicationsinFashionandTextileIndustry”,discussesthefivepillars
of 5S system (such as Sort, Set, Shine, Standardize & Sustain) in the context of
fashionandtextileleanmanufacturing. Thedetailedprocessesforimplementation
of 5S technology such as observation & preparation, planning, implementing and
assessmenthasalsobeendiscussed.Variousphasesandfacilitatingfactors(suchas
humanfactors,managementandleadership,staffcompliance,collaborativetools)of
5Stoolhavebeendiscussed.Enablersandbarriersintheimplementationof5Sare
covered.
“Kaizen Applications in Fashion and Textile Industries” focuses on the funda-
mentalconceptsofKaizen,inadditiontothesystematicdevelopments,andapplica-
tioninfashionandtextileindustries.AbriefhistoryofKaizenhasalsobeenincluded
todiscussthechronological developments. Various phasesofKaizenimplementa-
tion,startingfromplanningtoexecutionstages,forbusinessestobebenefittedfrom
wastereduction,increasedproductivity,andoptimizationofoperation,arediscussed
inthischapter.Indeed,theapplicationofKaizenconcepthasbeenaneffectivesolu-
tion for the fashion and textile industries with actual evidence from Bangladesh,
Peru,andIndia,whicharealsodiscussedinthechapter.Therehavebeendiscussions
howKaizenhasresolvedproblemsoffabricfault,maintainedergonomicstandards
andworkerscomforttoincreasetheproductivity.Further,thischapterhighlightsits
challengesfacedfortheimplementationofKaizen,advantagesanddisadvantagesin
thefashionandtextileindustry.
“Kanban Applications in Fashion and Textile Industries” provides a thorough
explanation of the Kanban concept. Various Kanban methods as well as its imple-
mentationinthefashionandtextileindustriesfromdifferentperspectivesarecovered
in this chapter. Kanban system was derived from a Japanese notion, which means
“visible sign”, originated with the efforts of the Toyota automotive company in
applyingtheconcepttothemanufacturingprocess.Kanbanhaseventuallybecomea
popularmethodologythatisusedwidelyusedintheautomobileindustryaswellas
inothersectorssuchasfashionandtextiles.IthasbeenasuccessfultoolintheLean
Manufacturing and Just-in-time concepts with the purpose of maximizing produc-
tivity and minimizing workplace waste, which has been discussed in this chapter.
TheuseofvarioussignalsintheKanbansystemhelptomaketheworkflowasagile
andefficientaspossible.Therehasbeendiscussionontheadvantagesanddisadvan-
tagesoftheimplementationofKanbansysteminthefashionandtextileindustries
toobtainhigherproductivityandefficiency.Thischapteralsohighlightssomecase
studies focusing on the fashion brands and manufacturers using Kanban. How the
implementationofKanbantoolinfashionandtextileindustriescanhelptoincrease
the productivity, control inventory, ensure supplier and employee participation are
alsodiscussedinthischapter.
“Other Lean Tools in Fashion and Textile Manufacturing”, explains how lean
manufacturing tools such as Muda, Six Sigma and statistical process control, and
ergonomics can help in waste reduction, process efficiency and safety in fashion
and textile industries. These tools focus on reducing the seven wastes as listed for
Preface ix
leanmanufacturingprocesstomaketheprocessmoreefficient.ThefourMudatech-
niques to perform waste identification which includes: building lean thinking and
cultures, hybrid approach of combining multiple decision-making methods, inte-
gratingleanandgreenmanagement,andvaluestreammappingtoprioritizeresponses
towastesarediscussedinthischapter.Theuseofstatisticalprocesscontrol(SPC)in
processcontrolinfashionandtextilemanufacturingandenhancethefutureproduc-
tionpredictabilityareelucidated.TheuseofSixSigmaasaprocess-basedstrategy
withfivestages(DMAIC)toeliminatedefectsinmanufacturingprocessarecovered.
Finally, the use of ergonomics to optimize human well-being and overall system
performance,inleanmanufacturingtoimprovequalityandwell-beingofworkersin
fashionandtextileindustriesalsodiscussed.
“DigitalTechnologies forLean Manufacturing” aims toofferthorough insights
into the digital technologies that are designed to complement the operation of
leanmanufacturing.Thischapteraimstohighlightthedigitaltechnologiesthatare
designed to complement the operation of lean manufacturing. Firstly, Industry 4.0
hasbeenexplainedthathelpstocomplementLeanManufacturingtogaincontinuous
improvement, better customer expectation and operational process. The results of
combiningdigitaltechnologieswithleanmanufacturingyieldtheconceptof“Lean
Industry 4.0”. Secondly, blockchain occurs as a disruptive innovation to resolve
the problems of lack of an integrated lean management system across the supply
chainnetwork,whichisalsodiscussed.Thirdly,theRadioFrequencyIdentification
(RFID)systemisanalyzed,anditsabilitytoofferhighlevelsofaccurate,real-time
information, decreased time-consuming activities and labor cost while increasing
productvisibilityandoperationspeediscovered.Fourth,ArtificialIntelligence(AI)
androboticsarealsodiscussedwiththeabilitytodealwithcomplexity,increasein
productivityandefficiencywiththeautomaticsystem,anddecreaseproductioncosts.
Finally,othernon-commonyetusefultoolsarementionedtogiveacomprehensive
view of the application of digital technologies on Lean Manufacturing, including
automatedguidedvehicles(AGVs),virtualstimulation(VS),andcybersecurity.To
consolidateourfindings,twocasestudiesarepresentedtogiverealisticviewpointsof
digitaltechnologyadoptionfromtwogiantfirmsinthetextileandapparelindustry,
namelyUniqloandH&M.ThefindingsofasurveybasedonVietnam’sfashionand
textile industries on the use of technology such as RFID is also included in this
chapter.
“LeanManufacturing:CaseStudiesfromFashionandTextileIndustries”focuses
onvariouscasestudiesfromglobalfashionandtextilebrands.Thischapterhighlights
thecausesrelatingtothefailureandsuccessofvariousglobalindustriesinthefashion
and textile manufacturing sector. The earlier chapters have clearly mentioned that
theimplementationofvariousleantoolssuchasKaizen,Muda,5SandKanbancan
helpthetraditionalfashionandtextileindustriestoimprovetheirproductivityand
efficiencybyreducingwaste.Thischapterwillhighlightthedirectcasesofhowthe
implementation of lean manufacturing improves the productivity and efficiency of
fashionandtextileindustries.Somecasestudiesfocusingonthefailureofsomeof
theindustriesfromAfricaandIndiaduetonotimplementationofleanmanufacturing
toolshasbeendiscussedinthefirstsection.Thecasestudiesfocusingonthesuccess