30, June 2025

EFFICIENCY IMPROVEMENT OF TROUSER SEWING LINE BY IMPLEMENTING LEAN TOOLS

VOLUME-11; ISSUE-6; JUNE-2025

Author(s): 1. Sayantan Raha, 2. Priyabrata Mondal, 3. Saikat Sil

Authors Affiliations:

  1. Assistant Professor, Dept. of Fashion Technology, Amity University, Kolkata, India
  2. Assistant Professor, Dept. of Fashion Technology, Amity University, Kolkata, India
  3. Project Engineer, Shop Floor Control Support, CGS India Pvt. Ltd., Hyderabad, India

DOIs:10.2015/IJIRMF/202506049     |     Paper ID: IJIRMF202506049


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The Indian manufacturing industry must improve efficiency to meet changing buyer requirements and deliver quality products on time. Garment manufacturing companies rely on various production processes, but some activities are unnecessary and do not increase product value. Work-in-process inventory, lead time, and incorrect designs can hinder efficiency. Smooth, optimized processes were crucial to avoiding accidents and ensuring the production line was efficient and meets customer needs.

The project aims to improve production efficiency in the trouser sewing department by using lean manufacturing and mechanical design. Data was collected, capacity studies conducted, and mainly four bottlenecks identified from the pilot line. Lean tools such as kaizens & 5S techniques were applied to resolve these issues, resulting in an 8% improvement in production efficiency in 15 days observation also two machine operators were eliminated. The project also introduced autonomous maintenance recommendations for future work, reducing machine failure. This is essential for raising the clothing industry's profitability and productivity. The project showed how lean techniques, particularly for larger orders, can effectively reduce bottlenecks and improve quality.

Efficiency; Bottlenecks; Cycle Time; Pitch Diagram; Lean Manufacturing; 5S; Kaizen; Autonomous Maintenance;

Sayantan Raha,  Priyabrata Mondal,  Saikat Sil (2025); EFFICIENCY IMPROVEMENT OF TROUSER SEWING LINE BY IMPLEMENTING LEAN TOOLS, International Journal for Innovative Research in Multidisciplinary Field, ISSN(O): 2455-0620, Vol-11, Issue-6, Pp.394-412.          Available on –   https://www.ijirmf.com/

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