IMPLEMENTATION OF LEAN TOOL TO REDUCE STAINS AND DAMAGES IN GARMENT MANUFACTURING – A CASE STUDY IN AN EXPORT ORIENTED UNIT

In the present study, the visual control system was implemented in one of the leading export oriented garment manufacturing units in Bangalore to minimize stains and damages of garments. This study was conducted in the bitting and washing section from where more stains and damages occur. Seven garment styles were selected for the study, which included pale light and bright colors. Primary data was collected using the observational method. Interaction with supervisors was also helpful in understanding types of stains and damages and the root cause of their occurrence during the process to some extent. During the initial investigation, stain and damage percentage was recorded for all the styles. After successful implementation of visual controls such as dos and don'ts displays, information boards and story board postures, the data was collected, analyzed and compared with the initial recordings. There was a considerable reduction in the percentage of stains and damages. Among the results obtained, the stains section marked the highest reduction by 50 %, whereas damages were reduced by 26.57 % which may be rated as moderate. Therefore, changing dynamics of garment manufacturing need such practical approach to prove themselves as tough competitor in global market. However, to achieve more effective results, constant motivation of workers and time to time modification of visual control tools according to the requirement is a must.