Apply Lean to increase productivity in the textile industry

At present, many textile and garment enterprises of Vietnam have applied Lean Manufacturing (Lean) as a solution to improve the quality of products and goods, increased value for businesses. At the Garment Corporation No.10, Lean Manufacturing (Lean), after the application of Lean Manufacturing, increased labor productivity by 52%
Lean is a group of tools and methods that are increasingly being applied in the industrial manufacturing sector, to eliminate waste and unreasonability in the production process, to have lower costs. and higher competitiveness for the manufacturer.

Lean’s principle is to help businesses reduce production time, delivery time from which cost savings bring added value to the business. Applying Lean technology the stages are connected through continuous flow; Strictly control the quality at each operation and stage. Lean will help you to plan, accurately calculate the stages in accordance with the production schedule, minimize the raw materials and inventory, thereby saving management costs, increase productivity and improve quality. Contact with suppliers and importers of garments.

Dr. Hoang Xuan Hiep – Rector of Hanoi Textile and Garment Industry University – Lean consultant for many garment enterprises exchanged with PV Newspaper said: “Lean after the application will bring business Many benefits such as: reducing waste, reducing waste; reduce process time and production cycle; minimizing inventory levels at all stages of production; Ensure that workers achieve the highest productivity during their work; make use of equipment and premises; capable of producing a wide variety of products in a more flexible manner with the lowest cost and conversion time; Enterprises can significantly increase production from existing facilities. Many garment enterprises, after consulting with us, successfully applied Lean in production such as Viet Tien Garment Corporation, Garment Corporation No.10, Duc Giang Corporation, Nam Dinh Garment Joint Stock Company. ”

Accordingly, at Garment Corporation 10, the productivity of labor increased by 52%, error rate decreased by 8%, reduced working hours per hour, increased income over 10%, decrease Production cost is from 5-10% / year.

Thanks to the application of Lean, the overall productivity of Nha Be Garment Corporation has increased by more than 20% and more importantly, to create emulation resonance in the production of units. The productivity and quality of each line has been stabilized and controlled through every hour of production. The income of the workers increased significantly. Especially since the application of lean, May Nha Be reduced the hours for workers to 1 hour / day, Saturday afternoon break and absolutely do not have to work shift.

Vietnam Textile and Garment Group (Vinatex), quality management at garment companies in the corporation have been invested many units in recent years. Many companies in the industry are aware of the improvement of product quality is the value added activities for the main business so there are many forms to be applied. Lean (Lean Manufacturing), in which two garment companies have demonstrated the effectiveness of this technology is Viet Tien and Hoa Tho Duy Xuyen Garment Joint Stock Company.

Viet Tien has been applying LEAN since 2007 and has failed to stop. In 2008, Viet Tien started applying LEAN 2 and started successfully. The result of applying LEAN is very positive for the unit: increasing labor cost, reducing errors, saving space to invest in new production lines without having to build factories …. Lean production technology from 2008 to now has the effect of making the productivity increase markedly, increasing on average by 20% compared to before.

Hoa Tho Garment Joint Stock Company (Duy Xuyen) is also a successful garment manufacturer. With Hoa Tho Duy Xuyen Garment Joint Stock Company, this is a solution to increase labor productivity effectively, helping businesses shorten the production time, delivery time from which cost savings bring maximum value increase for business.

After applying in 3 factories of Hoa Tho Textile Garment Corporation, Hoa Tho Garment Joint Stock Company (Duy Xuyen) has invested to convert all 8 lines under Lean model. With this model, together with the newly invested electronic system, the production process will be reduced. Setting up a U-shaped sewing line has helped the supervisors cover and supervise the production process, providing timely solutions to ensure an uninterrupted production line. Decrease the competition of labor with other units.