Reducing Cost in RMG sector & IE as its importance Of Lithe Group

Abstract

This report provides that how to reduce cost in garments industry based on Industrial Engineering, like how IE department will reduce cost, what is the procedure of reducing cost, Capability of this factory and other departments in garments and their capacity. Methods of analysis of this report including practical research and data analysis with the help of department head in this organization, such as knitting capacity, Dyeing, and AOP capacity, cutting, sewing, finishing capacity, and their working procedures, and how to reduce the cost of that department with the help of IE. Results of the data analysis showed that this organization's knitting capacity is 40,000 Kgs where their used machine is Mayer & Cie and Matsuya and this knitting produced Single Jersey, Rib, Pique, Fleece, Terry, Mesh, Double Jersey, Interlock, Waffle/Thermal, etc. The dyeing section used machine is Sclavos, Thies, and Fongs and its capacity is 50 tones solid and 30 tones Yarn dyeing and 20 tones AOP production per day. This organization has also a print and embroidery section where the printing capacity is 70000 pcs, and embroidery capacity is 8,000 to 10,000 pieces. This organization CAD used updated GEMINI software and produced marker for 10 cutting table where Cutting capacity is 170000 where there have 3 updated auto spreader and 1 auto-cutter from FK France and FK Italy. and sewing capacity is 150000 pcs, and these 2 departments completely control IE department, where the manufacturing technology is being gradually transforming to adopting LEAN production after came IE for this department sewing efficiency increased by 8%, and cutting production increased minimum 10000 pcs. Also, an IE of cutting reduces sticker and ink by 30% of its total usage. This organization has worthy buyers such as M&S, Next, HRM, LPP, Zeeman, and Takko. The report has shown that how to decrease product cost and waste reduction of each department. The major area of viii weakness is the textile and dyeing section of this organization, they have capacity but they did not achieve the target as per capacity. Dyeing planning should be adjusted as per colorwise and fabrication wise so that process loss might be reduced ➢ Management should proper monitoring in dyeing and textile section. ➢ Need to sustain LEAN manufacturing system as per IE. The production was sometimes hampered due to accessories inhouse problem for merchandiser. The management of this organization are completely focused in sewing production but need to focused all the department of this organization as like sewing. sometimes department head was less focused on his job responsibility so that some internal problem was arisen.