An Analysis on Minimization of Product Error (Poka-Yoke) and Excess Work in Progress (TPM & OEE) in Textile Industry

Abstract

The rapid change in textile styles, deviation of order quantities and increasing quality levels at the lowest possible cut-rate, demand the textile manufacturing industry to be focused on more effective and efficient manufacturing processes for survival in an immensely competitive market. To increase the productivity of the textile industries we need to reduce the manufacturing defects and time to manufacture the product. Lean is the tool to reduce the wastage in all process of textile manufacturing, reducing cost and value added to the product. This paper proposes the lean tool like POKA-YOKE, DPMO, cause and effect diagram &OEE to reduce the overall product error and work-in-progress. Analysis covers the area of c poka - yoke which is any effort to eliminate human errors in the system. In short, Error=mistakes = defects. Therefore, the removal and control of errors eliminates defects. And specific section of sewing line was OEE is applied to investigate the existing condition of machine and provide recommendation to improve present condition in Classic Polo Textile industry to reduce work-in-progress.