Implementing the Toyota Production System in the Manufacturing Process of Ready-Made Clothing A Case study Jacket production, VT Garment Co., Ltd.

Abstract

The objective of this research is to improve efficiency in the jacket production line of VT Garment Company Limited. We are applying the Toyota Production System (TPS) technique. The first step in the process is identifying the flaws that require improvement. After that, evaluate the organization's losses. Next, note the issues in the value stream map that require improvement. By selecting VSEW004 as the location to enhance the sewing manufacturing process, which employs 50 people. Lastly, the TPS system's 4 steps are implemented, consisting of, the first stage: Controlling the environment at work by setting up the workstation such that everything is practical, safe, and easily accessible, second stage: Modify the diagram to maintain the continuous workflow process, third stage: The standard task is to boost output effectiveness. Utilizing the Yamasumi Chart instrument to monitor the working hours of every employee, four stage: Scheduling every stage of manufacturing It is a system that lessens the quantity of ongoing work across departments. Depending on what the consumer needs, this stage will operate. It will be manufactured when there is a market for it. It suffices to use this action. The transfer of commodities from the sender's hand to the recipient's hand will likewise reduce as a result, as will the quantity of work in progress in each department. Results of the study revealed that, utilizing the jacket production line's Toyota Production System yielded a 92% gain in production efficiency, a 59% decrease in process backlog, an 82% decrease in repair work, an 81% increase in sewing production line productivity, and a 29% decrease in the amount of time needed to get items from the sender's hand to the recipient's hand. The Lead Time Door to Door, or Lead Time, in the jacket production process dropped by 39 days from the start of the job to its completion.