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
Sustainable lean: Water, energy, waste (cutting-floor residue, dyehouse reusability)
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