ebook img

Lean Supply Chain Management in Fashion and Textile Industry PDF

321 Pages·2022·5.639 MB·English
Save to my drive
Quick download
Download
Most books are stored in the elastic cloud where traffic is expensive. For this reason, we have a limit on daily download.

Preview Lean Supply Chain Management in Fashion and Textile Industry

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 SingaporePteLtd.2022 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuse ofillustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,and transmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar ordissimilarmethodologynowknownorhereafterdeveloped. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublication doesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevant protectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthors,andtheeditorsaresafetoassumethattheadviceandinformationinthisbook arebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublishernortheauthorsor theeditorsgiveawarranty,expressedorimplied,withrespecttothematerialcontainedhereinorforany errorsoromissionsthatmayhavebeenmade.Thepublisherremainsneutralwithregardtojurisdictional claimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSingaporePteLtd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore 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

See more

The list of books you might like

Most books are stored in the elastic cloud where traffic is expensive. For this reason, we have a limit on daily download.