Analysis of the current state
| Process | Problems |
|---|---|
| Raw material inventory (Factory) | Purchasing excess raw materials increases inventory cost |
| Manually verification of stock level | |
| Delays of production due to lack of communication between different departments | |
| Fabric testing before cutting | Manual recording of fabric specification |
| Fabric waste occurred due to inaccurate identification of fabric rolls | |
| Cutting | Operators or machines remain idle while waiting for fabric delivery or preparation in the fabric-spreading process |
| Manual marker making and aligning patterns on fabric lead to material waste and slower production in the fabric-cutting process | |
| Delays in the production process due to disorganized workstation in pieces numbering and bundling process | |
| Sewing | Lack of proper organization of sewing equipment |
| Increased change over time due to the long-time waiting for maintenance personnel for machine adjustment | |
| Finishing and packaging | Lack of proper garment tracking leads to losses of garments and high WIP inventory |
| Manual documentation of packaging product | |
| Finished fabric inventory and shipment (Final Facility) | Manually counting finished fabric rolls without a real-time update |
| Miscommunication between departments hinders production planning and decision-making |
| Process | Problems |
|---|---|
| Raw material inventory (Factory) | Purchasing excess raw materials increases inventory cost |
| Manually verification of stock level | |
| Delays of production due to lack of communication between different departments | |
| Fabric testing before cutting | Manual recording of fabric specification |
| Fabric waste occurred due to inaccurate identification of fabric rolls | |
| Cutting | Operators or machines remain idle while waiting for fabric delivery or preparation in the fabric-spreading process |
| Manual marker making and aligning patterns on fabric lead to material waste and slower production in the fabric-cutting process | |
| Delays in the production process due to disorganized workstation in pieces numbering and bundling process | |
| Sewing | Lack of proper organization of sewing equipment |
| Increased change over time due to the long-time waiting for maintenance personnel for machine adjustment | |
| Finishing and packaging | Lack of proper garment tracking leads to losses of garments and high WIP inventory |
| Manual documentation of packaging product | |
| Finished fabric inventory and shipment (Final Facility) | Manually counting finished fabric rolls without a real-time update |
| Miscommunication between departments hinders production planning and decision-making |
Source(s): Authors’ own contributions
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