Implementation of Kaizen on a Basic Shorts Manufacturing to Reduce Cost and Accelerate Productivity

Abstract

The economy of Bangladesh is growing rapidly with the power of the Ready Made Garments industry which remains the highest exporting sector of the nation from the very beginning. With time being RMG sector has been facing many challenges and increasing production costs is always a bigger concern. Bangladesh is facing a higher production cost of manufacturing any garment compare to its previous ten years while the offering cost from the buyer remains approximately the same. Considering the challenges this sector is more focused on reducing production costs to maximize the profit margin. This paper aims to demonstrate comparative changes in terms of Cycle time, Standard Minute Value (SMV), Capacity, Hourly target, Manpower, and salary by implementing the Kaizen process on a basic shorts manufacturing process. Improving and implementing kaizen, work-study, and motion study in three separate processes of shorts result in a huge saving for the industry. Comparison of data is done by evaluating the process breakdown of the products considering before and after kaizen implementation. This comparison considers basic shorts manufacturing in a floor results in 4 minutes, 10 operators, and $11,520 yearly savings also ensures the increase in capacity, efficiency, and hourly target. So this paper can lead to a better output showing the guidelines for the manufacturers and also the expertise as well.