การเพิ่มผลิตภาพในแผนกเย็บกางเกงโดยใช้เทคนิคลีน

Abstract

This study applied lean techniques to the exported trouser sewing process at People’s Garment Public Company Limited, aiming to decrease production time and increase output. By observing and analyzing the current working conditions, including motion and working time, it was found that there were 50 stations with 50 employees. The lead time was 4,398.54 seconds per trouser, resulting in a production rate of only 130 trousers per day against a target of 240 trousers per day. Additionally, bottlenecks were identified in various production processes. The study assessed the production time at each step and compared it with the target Takt time. Waste in each process was reduced using the principles of the 7 wastes. Adjusting work motions reduced the lead time by 8.32 seconds per trouser. Further reduction in waste was achieved using the 5W1H and ECRs principles, employing simplicity (S) to design suitable tools, which resulted in an additional lead time reduction of 11.30 seconds per trouser. Excessive inventory and waiting time were addressed through the 7 wastes principle and line balancing, reducing the production cost by eliminating 7 employee positions. With the standard wage being 345 baht/day/employee, this led to a cost saving of 60,375 baht per month or 724,500 baht per year. Production increased by 120 trousers per day or 3,000 trousers per year. Considering the profit per exported trouser was 65 baht, the company gained an additional profit of 195,000 baht per month or 2,340,000 baht per year. Furthermore, lead time was reduced from 4,398.54 seconds per trouser to 4,378.93 seconds per trouser, and utilization increased from 36.93% to 39.12%.