Research Papers - Department of Mechanical Engineering

Permanent URI for this collectionhttps://rda.sliit.lk/handle/123456789/604

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Start date: 2010Subject: search.filters.subject.Apparel Industry

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Now showing 1 - 3 of 3
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    PublicationOpen Access
    An improved approach to line balancing for garment manufacturing
    (Faculty of Management Studies and Commerce, University of Sri Jayewardenepura, 2016-06-01) Wickramasekara, A. N; Perera, H. S. C
    Production managers in the apparel industry frequently face the issue of being unable to complete the orders at the scheduled time. One of the reasons for this issue is the unavailability of a Line Balancing procedure that could encompass the stochastic nature of the sewing process, which is manifested through the likes of variability of sewing times, machine breakdowns, correcting defective products, and operator breakings such as for changing bobbins and drinking water. The objective of this research is to introduce a diverse approach to Line Balancing through giving due consideration to the stochastic nature of the process. The improved approach was developed through case study approach. Having selected a sewing line in an apparel factory, the process times of operations, major random events and the times elapsed between random events were recorded. Then the whole production cycle was simulated using ARENA software. By attempting and analysing different scenarios, a different approach for line balancing was introduced. The initial steps of the algorithm developed includes: collecting processing times and necessary information on manufacturing process, fitting standard probability distributions to both value added and non-value added activities, developing the precedence diagram, developing an initial algorithm for balancing a production line and finally, making necessary adjustments to the algorithm analyzing different scenarios. In order to check the validity of the algorithm, a production line was balanced for two different daily production targets. Thus, the application of proposed algorithm to balance the production line reduces the gap between the expected production target and the real achievement.
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    PublicationEmbargo
    Viability of lean manufacturing tools and techniques in the apparel industry in Sri Lanka
    (Trans Tech Publications Ltd, 2012) Silva, S. K. P. N; Samarasinghe, G. D; Perera, H. S. C
    Lean Manufacturing can be considered as a business strategy which was originated and developed in Japan. It tries to identify waste and eliminate it. Thus it leads to improvement in productivity and quality and companies can achieve a competitive advantage over others. Sri Lankan industries, especially apparel sector have attempted to implement this, but a little research work is carried out in regarding its suitability. This research is an attempt to identify a suitable Lean model for the apparel industry in Sri Lanka. As the initial stage of this study, a literature review is carried out to study about the Lean Manufacturing. It starts by looking at how Lean Manufacturing first began. Then it seeks to identify the core principles, tools and techniques and how those tools and techniques are currently being used worldwide. After studying the global scenario the next step is to look at the Sri Lankan context using real world data. This was undertaken by means of structured surveys, observations, and on site interviews. Also the study will reveal period of Lean implementation, suitable implementation methods, order of implementation, tools which are avoided, sustainability of different tools, challenges faced, ways of overcoming challenges and benefits achieved after applying Lean Manufacturing concepts in the apparel sector of Sri Lanka. The findings state Lean Manufacturing can be applied to mass production apparel industries and has created a positive mindset on employees. As implementation of Lean concepts is still in developmental stage, the full benefit is not yet achieved. But current situation suggests that the industry can go forward with Lean and capitalize on its full potential. In this research the authors have proposed a model which can be used to implement Lean in a systematic manner and each manufacturer must develop their own Lean system through training, experiments, employee empowerment, right leadership and kaizen mindset. Originality of the research— The research builds up a Lean Model which is not yet developed for the apparel sector in Sri Lanka. It can be further modified to suit the global apparel industry and other industries as well.
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    PublicationEmbargo
    Developing a performance measurement system for apparel sector lean manufacturing organizations in Sri Lanka
    (Sage Publications, 2013-12) Perera, P. S. T; Perera, H. S. C
    Performance measurements systems were rarely adapted to changing manufacturing environments. Lean is one such practice aiming at productivity improvements. Non-cost performance improvements resulting from lean makes the inadequacy of traditional measurements for evaluating performance. Sri Lankan apparel manufacturers adapt lean manufacturing to meet global business challenges. However a study has not been done to develop an appropriate performance measurement system for lean environment in Sri Lankan apparel sector lean practicing companies. This study develops such a model from literature review and interview. Finally it is validated with the existing models.