Program Overview
This program, delivered by an industry expert, equips participants to transform garment production through practical lean manufacturing principles. The program helps participants move beyond theory to hands-on problem solving — learning to identify the eight wastes in apparel manufacturing, apply tools like 5S, SMV, line balancing, takt time, and Kaizen, and redesign production lines for speed, quality, and cost efficiency. Participants engage with global and Indian case studies, participate in simulation workshops, and build factory-specific action plans to embed lean as a continuous improvement culture.
Features
- Understand lean principles and their specific application in garment factories
- Identify waste patterns and bottlenecks across apparel production workflows
- Apply key lean tools (5S, SMV, line balancing) to real-world factory challenges
- Build a roadmap for sustaining continuous improvement and workflow excellence
Target audiences
- Factory Managers, Production Heads, Line Supervisors
- Industrial Engineers, Lean / CI / TPM Leads
- Quality Heads, Ops Excellence Teams
Curriculum
- 8 Sections
- 36 Lessons
- 2 Days
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- Apparel Manufacturing – Global & Indian Market Dynamics4
- Lean Thinking in Garment Manufacturing6
- 2.1Lean Thinking Core: Flow, Pull, Takt, Waste, Value
- 2.2The 8 Muda Types contextualized for garment factories
- 2.3Tools: 5S, Andon, SMED, Standard Work, Poka-Yoke
- 2.4Examples from top-tier factories (Turkey, Sri Lanka, Bangladesh)
- 2.5Lean vs Mass Production mindset
- 2.6Caselet: Vietnam Factory – How lean improved on-time delivery by 18%
- Identifying Wastes in Apparel Value Stream4
- Deep Dive – Industrial Engineering & Lean Metrics5
- 4.1Concepts: SMV, SAM, Line Balancing, Takt Time, Cycle Time
- 4.2KPI View: Efficiency %, RFT (Right First Time), OEE, Line Utilization
- 4.3Discussion: Role of IE team in lean-driven transformation
- 4.4International practices: IE-led layout optimization in Bangladesh & Sri Lanka
- 4.5SMV Calculation Sheet, Capacity Tracker
- Global Best Practices in Garment Lean Manufacturing5
- 5.1Case Study 1 – Bangladesh: Line discipline, social compliance with lean
- 5.2Case Study 2 – Vietnam: Modular lines and skill matrix integration
- 5.3Case Study 3 – Turkey: Fast Fashion compliance and flexibility
- 5.4Case Study 4 – China: Tech-integrated lean (IoT, RFID)
- 5.5Key Terms: Lean 4.0, Demand-Driven Manufacturing, Modular Cell, Lean Digitization
- Lean Tools Implementation4
- 6.1Implementation Stages: Diagnose → Redesign → Pilot → Sustain
- 6.2Roadblocks: Floor-level resistance, lack of buy-in, flawed KPI targets
- 6.3Solutions: Lean Leader System, DWM (Daily Work Management), Kaizen Routines
- 6.4Example: Tirupur factory Kaizen program that reduced DHU (Defect per Hundred Units) by 40%
- Simulation – Redesigning a Dysfunctional Line4
- Sustainability, Safety & Lean Culture4
Instructor
