When the era of industrial revolution 4.0 took the throne, the principle of lean production was further strengthened by the emergence of a series of new technologies. The combination of Lean – lean and Digital – digital technology is called digital lean production in the garment industry. One of the ways to help Lean overcome traditional limitations, help businesses bring the optimization of production processes to a new level.
>>>> Advise: digital transformation of the garment industry
Overview of lean manufacturing principles
What is Lean Manufacturing?
Lean Manufacturing (Lean Manufacturing) quickly became popular in textile manufacturing enterprises because of its superiority. Lean Manufacturing was considered as one of the core principles of the world’s leading factories like Toyota, and now it is considered as a rule that manufacturing enterprises must follow.
Lean manufacturing is the principle of organizing production with the goal of creating the right product that the market needs. Thereby, meeting the needs of customers, while still ensuring the highest quality, lowest cost and shortest implementation time.
Principles of lean production in the garment industry
- Defining value: Once a customer determines what is valuable to them, a business can create a product that contains only what is needed and eliminates unnecessary components.
- Value Stream Map: Allows managers to visualize each step in the manufacturing process to identify waste and opportunities for improvement.
- Create Flow: Process improvement is one of the goals of lean manufacturing. That’s because an improved step in the value stream, businesses can reduce their production time.
- Pulling system: The principle of the towing system is to do it right there, so that when it is needed, it will not be delayed even if it is new.
- Seeking perfection: To achieve perfection, businesses need to continuously improve and take preventive actions against the root causes of quality problems and production waste.
Digital lean production – Technology application in the textile industry
What is digital lean manufacturing?
Digital lean manufacturing – has become a new trend, an effective combination between traditional production principles and constantly changing digital technology, making the production process seamless. circuit than ever before.
However, Bill Gates said that: “…any automation applied to an inefficient operation will only intensify inefficiencies.” Therefore, for an efficient production process, it is necessary to combine Lean and 4.0 technology into textile production. Technology 4.0 will not replace Lean and vice versa, they will co-exist as technology implementation requires efficient and effective processes as a prerequisite for successful operation.
>>>> Learn more about 4.0 technology: Digital transformation of the textile and garment industry – A step forward
Combining technology to solve 7 waste groups in the production process
- Overproduction: Traditional lean manufacturing helps reduce overproduction by identifying supply and demand gaps. Using digital technology, managers can capture this information in real time and continuously update the right production quantities.
- Overprocessing: Digital lean manufacturing has many applications that help reduce the problem of redundancy. For example, Retex textile software helps manufacturers easily monitor and evaluate activities and avoid errors during operation.
- Excess inventory: Having excess inventory will lead to situations such as failure to identify defective products in time or increase lead time in the production process and a number of other risks. For technology software, allowing businesses to only import materials just enough for production, instead of hoarding them in advance.
- Defective Goods: Having defective products is a waste that must be minimized as much as possible. They can affect customer satisfaction and increase costs. With digital lean manufacturing, the process is further optimized by pinpointing the production stage as well as the cause of manufacturing defects.
- Waiting (Idle Worker or Idle Equipment): This type of waste occurs when employees cannot work because they are waiting for materials or equipment, or maybe the equipment is idle waiting for maintenance. . Digital lean manufacturing allows management to identify bottlenecks in the production process in real time. In addition, the mechanical repair time of the electromechanical parts can be controlled.
- Unnecessary transportation: The transportation of unnecessary personnel, tools, materials, or equipment. In this case, digital lean manufacturing can compute to minimize lead times and build production processes that are consistent with the status quo, as well as create financial value for the business.
- Redundant operations: Applying modern digital technology, digital lean production using sensors or AR / VR helps analyze and evaluate the steps taken by workers, thereby providing standard formulas for easy control the production process.
During these transformations, a number of factories such as Vinatex Dung Quat, Thien An Phuc, Phu Tuong … have quickly adapted 4.0 technology with Retex real-time production management software into business processes. From there, opening up the opportunity to make Lean even more lean in the digital world.
Contact Retex today to modernize your business.What is Lean Manufacturing?Digital Lean Manufacturing – Technology Applications in the Textile Industry
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