Study On The Lean Management Implementation In Printing Workshop Of AD Company GZ

With the popularity of fast fashion in recent years,more and more apparel brands are asking for faster delivery from their suppliers.Meanwhile,the rising labor cost of China has been pushing more and more garment factories relocating to Southeast Asia countries for lower production cost.As the global label supplier of garment industry,AD Company also established printing factories in Southeast Asia to service customer better.Under these circumstances,AD Guangzhou factory is facing pressure not only from customers to reduce production lead-time but also challenge of increasing labor cost in China.The internal competition from factories in Southeast Asia has made it impossible to sustain profits by raising product prices.The only way out is to reduce lead-time without adding additional resource.Applying lean management will not only help AD Guangzhou factory to solve current problems,but also establish long-term competitive advantages with continuous improvement culture.This thesis takes the printed fabric label production line of Guangzhou factory as the research object.By drawing the value stream map,we found that WIP and waiting time are the key problems.This thesis applied capacity balance knowledge to solve the gap between unbalanced capacity and incoming order at prepress process.In order to improve the material preparation efficiency,this thesis applied visual management,7S management and standard operation procedure to redesign the new workstation and material rack.Meanwhile,the new order information system based on push and pull theory is proposed to realize JIT production.Besides,in order to reduce the WIP,this thesis analyzed the productivity difference between several types of cutting-type and printing and designed four different types of production cells,each small cell unit is supposed to be combined into a large production cell.Cell production will help the elimination of frequent WIP moving in the workshop and accelerate the production speed.In addition,in order to sustain improvement and drive long term implementation of lean production and continuous improvement,this thesis proposed some plans to develop lean environment like encouraging small group improvement activities,Kaizen projects management among employees and continues improvement mindset.At the same time,a performance appraisal system combined with PDCA improvement loop is also a guarantee for long-term application of lean management.From the literature research,we found that the study on lean management implementation in printing enterprises,especially label printing enterprises is rare,thus,this thesis not only has a strong reference value for the fabric label printing production line in AD Company internally,but also valuable for familiar production line in printing industry.