Research On E Company Garment Cutting Workshop Production Organization Optimization

E company is a vertical integrated cotton garment group and one of the world's leading producers of premium cotton shirts with 65,000 employees all over the world. Along with the rising of life standard level, people pursue more and more personalized fashion. Customer demand changes from large quantity of single order mode to small varieties of multi-order mode. In order to meet customer requirements, the garment companies have to change the mass production management mode to small orders with multi-varieties mode. For these large labor intensive companies, during the process transformation, there are many problem appearing such as, production flexibility, line balance, manpower, equipment utilization, WIP inventory which real bring great challenges to the management.This thesis integrated the basic lean manufacturing methods and management tools to make qualitative and quantitative analyses on clothing manufacturing company in the perspective of line balance and production optimization. For this kind of mass labor intensive enterprise, it is easily result in cost increasing because of building up of many WIP, lower line balance, too many non-value added movements, over needed workers and poor mobility. This finally decreases profit and market competitiveness of the company. So it is imperative to improve on-site management and enhance capacity. By the research of capacity enlarging, the none value added movement, work load, resource using can be reduce, and then improve efficiency, and make the company more humane, as well as increase satisfaction of customer, company and employees.The writer has 6 month's internship in the cutting shop floor of E Garment Company which is also the research target. By improving line balance, rationalizing the manpower and optimizing production management mode, this paper made research on optimization of cutting work shop production line based on lean manufacturing methodology with qualitative, quantitative analysis and instance application. First, there are different processes for different raw materials in the cutting work shop. These characters are thoroughly analyzed. Basing lean manufacturing and line balance, the cycle time of different processes was recalibrated, then human power was rationalized to reduce bottleneck process and improve process capacity. Secondly, in order to improve labor and equipment usage, the common processes were integrated, and the organization mode was also optimized. At the same time, preliminary study was done on managing front-line worker in terms of quality control.