Top 5 Most Effective Tools of Lean Manufacturing

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The lean manufacturing is the system undertaken by companies or organization to maximize their sale with less resource and with zero wastage. The ultimate goal is to adopt a good effective system for the development of the organization as well as its employees.

Lean manufacturing system was initially implemented by Japan. There was a significant change in the work ethics of the companies their resulting in increased in revenue generation. From there the idea was spread all over the world and now most of the companies have adopted this mechanism.

Lean manufacturing consultant doesn’t have fixed structure. It varies from organization to organization. But there are various tools which can be implemented in every organization for better result. Let us see.

  • 5S

The first and the basic tool is 5S tool. This tool helps the company to organize their workplace much efficiently. The main focus of the tool is to reduce waste and save time.

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As the name suggest that this tool comprises of 5 different steps. The first phase is ‘Sor’t. In this we sort the equipment and eliminate those machines or materials which aren’t necessary. The second step is ‘Set in Order’ in which we organize the equipment as per requirement. The third step is ‘Shine’ in which all the equipment and the workplace should be cleaned. The fourth step is ‘Standardize’; record the visual for future instances and the last step is ‘Sustain’ i.e. to maintain the process for ever.

  • Continuous flow

The next very important tool is the continuous flow or continuous improvement tool. This should be considered as an ethic rather than tool. However, this tool ensures continuous flow of raw materials to the production area and the final product to the market. It has various benefits such as it will reduce cost, time, and resources as well as decrease wastage.

  • Jidoka

Jidoka tool is very beneficial in manufacturing industries. Earlier the machines used to carry production process. Any defects or faults were only visible after the end product is quality checked. By this tool, we prepare machines to automatically stop production at time it detects fault and so the workers could immediately look the issue. This ensures no defected material in market.

  • Kaizen

One can say this tool is overall solution for every problem. Kaizen is system of continuous improvement in quality, quantity, work ethics and safety. It involves all the employees of the company to carry out each and every work. From manager to cleaning crew, everyone could come up with suggestions and all the tips are integrated to create a good process of eliminating waste and increase production.

  • TPM

Poor maintenance structure leads to several breakdowns of machine resulting decreased production, which is the biggest cause of loss to company. TPM emphasizes to create a proactive approach regarding maintenance work to maximize the operational time of equipment resulting in huge production. It creates a shared responsibility among the maintenance

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5 Rules to Follow Garment Labels

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In many different ways garment labels are used in the industry. They eventually play a specific part in all the clothes. Being as a form of advertisement, labels are used by almost every brand. They know the importance of labels and the impact it would create on the consumers. There are numerous other benefits of attaching a label to the garments. It works as a sample product of the quality offered by the brand. Beside all the pros, there is much more importance of using these labels to the garments.

Here are some important rules related to garment labels which should be followed by manufacturer.

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  • It is surely must for each and every manufacturer and brand to put garment labels on every piece of cloth they make. It is undoubtedly the best advertisement but besides the ethnic appearance of brand name it should also flaunt some important information like the fabric used in the garment, origin country of garments, its manufacturer details and also the guidelines of caring the clothes for optimum usage.
  • Whatever label it is, whether for eatable product or for garments, they are just meant to be visible. Don’t ever do a mistake of hiding these labels inside a cloth, it could cause to great extent to your product. The labels should be placed in an easy-to-find spot and must be visible to the consumer. Also, the durability matters, it is not enough to just only attach labels, you must ensure that they stick to clothes to the maximum. Either woven it, print it or stick it with powerful adhesive but it should last longer.
  • Cleaning instructions are very important to the garment. As a consumer we all want that our wardrobe maintains all its appearance and quality to the fullest and longest. We don’t want that clothes get ruin and our purchase gets wasted. For that clothing company should specify that the garment is best suited for washing or dry clean.
  • Most of the label gives benefit to the manufacturer, but care labels are more beneficial for consumers. Manufacturers should never miss attaching care labels on the clothes. These labels include instruction and tips to maintain the durability of the clothes. Basically there are five essential tips which are usually mentioned in care labels. The first is cleaning instruction whether it is requires machine or hand washing. Second is bleaching instruction, whether it is safe to use bleach or not. Third is drying tips as it should be dried in machine or through natural process. Fourth is ironing instructions and last is not-to-do instruction.
  • Usually labels are very necessary for all the products from cosmetics to garment but there are few objects which are pardon from labels. Leather products are one of them as using adhesive on them may ruin the material.

Demonetization in India

On November 8th, 2016 will be etched in Indian history as a landmark date. This was the day when Prime Minister Narendra Modi announced his demonetization move- scrapping of existing Rs 500 and Rs 1000 notes in a bid to end the vicious cycle of black money, curtail counterfeit currency, countering terrorism financing and mainly promote cashless economy. The announcement was like a bolt from the blue and it caught the entire country unaware. New notes of Rs 500 and a newer denomination of Rs 2000 were introduced. A very tight timeline was provided to the people for exchange of their old notes from the banks. Long queues outside ATMs and banks became the order of the day as cash shortage affected daily livelihood and drove down consumer spending. The government assured that the ordeal is only temporary and demonetization has its long term benefits. A thorough analysis of the events will help us to understand the rationale behind this sudden move.

Demonetization is not an entirely new concept in India. Already such moves had occurred in 1946 and 1978. The aim was always to demonetize high value currency in favour of new ones to curb black money. But the November 8th announcement was high on shock value-nobody had seen it coming. The entire country was sent into frenzy when Modi announced that Rs 500 notes and Rs 1000 notes will cease to be a legal tender. This was a very bold decision. Both the denominations formed 86% of the currency in circulation, by value. Scrapping them and replacing them would be a huge and challenging task. The logistical challenges in a vast country like India and the infrastructure required to carry out the entire process would be a real headache for the government.

Black money is definitely one of the reasons. It is a problem that has given sleepless nights to many in the Indian tax and legal administration. Illegal money, money on which no tax has been paid, undeclared money and disproportionate assets are some of the components of black money. With one stroke of bold decision making, the government rendered all black money, hidden as unaccounted cash in households, as mere pieces of paper. The demonetization move would ensure that a large part of the black money comes back to the banks and this would help the bank to lend more money and boost growth and employment. The prevalence of counterfeit money is another reason for scrapping the high value currencies. Fake money circulation is a huge problem and is detrimental to growth and prosperity. Not only this, the counterfeit currency was also used to fiancé terrorism and drug usage. The demonetization move would be a big blow to the counterfeit currency racket as their business would be badly hit with the government introducing new notes that their machines cannot produce a fake copy of. And one of the most progressive reasons that Modi had provided for demonetization is the aim to make the economy cashless. Digital economy would ensure that transactions become easier and there is more tax compliance. The cost of printing currency would substantially come down for RBI. This money saved can be used by the central bank to lend to other banks. Higher lending ability is always a strong indicator for growth in the country. All these reasons prompted the Modi government to take the demonetization step and that was done in ultimate secrecy to prevent knowledge of it being leaked to public.

However, due to demonetization the common public had to face a lot of ordeals. Daily wage labourers suffered the most as they were without both cash and jobs. Informal sectors that depend on cash transactions took a hit. Consumer spending spiraled down and growth was hit. People spent hours outside banks and ATMs. Reports of people dying while waiting in queues also surfaced. Productivity took a hit and day to day livelihood was hampered. Bank employees had to work overtime and their efforts must be lauded.  So this gives rise to questions if the move could have been better planned out and implemented in a better way. Since India is a vast country the logistics behind delivering cash to all parts of the country could have been better handled with micro ATMs and ATM vans deployed to all nooks and corners. The common man suffered once again which in all probability could have been prevented.

Three months later it is still for debate if the government was right to scrap high value currency or it was a poorly implemented plan. Crores of rupees have been deposited and this is a plus point. Also, black money hoarders are in constant fear.

However, the problem faced by the common people cannot be forgotten. In conclusion, being a well- intentioned move, demonetisation in India could have been a well-implemented move. It would have been a well-implemented move. It would have been a masterstroke. It still can be.