AREAS OF CONCERN REGARDING REDUCTION OF 8 WASTES OF LEAN

1. OVER PRODUCING: - Making the products which customers does not want e.g. Design errors or printing/embroidery at wrong place of the panels Producing earlier than required by the customer. Machine flaws resulting in errors in the garment which need reworks or a new garment as a replacement.

2. WAITING: - The fabric (cut pieces) kept in the super market are not feeded in the line for 2-3 days which is in a way waiting and thus is a waste. Packed and ready for shipment pieces kept in the shipment area for long period as it was produced earlier than required.

3. OVER PROCESSING: - Rework done on the production floor. Cutting is done more than required. This is the reason why the cut pieces are kept waiting for days to be feeded in the lines. Re-cutting after printing. Data duplicacy and thus same or common information in two or three reports is extra-processing in this unit.

4. INVENTORY: - Fabrics kept in the fabric stores are kept for long without being processed and some of the fabrics kept for relaxation for few days is a waste.

5. EXCESSIVE MOTION: - Improper line set-up develops the problems of excessive motion but since in this unit the cutting and sewing section are on the same floor, hence there is not much problem of excessive motion. 6. DEFECTS AND CORRECTIONS: - Design Errors which impacts in errors in silhouettes. Errors in data entry. Reworks.

7. TRANSPORTATION: - Transporting the fabric for relaxation to the cutting floor much before than required and then keeping it idle for days is a waste of excessive motion or transportation.

8. SKILLS (BEHAVIOUR AND UNDERUTILIZED PEOPLE): - Operators with higher efficiency or the operations in which they can perform even better dont get a chance and is a case of underutilized people and thus a waste of talent and efficiency which in turn if utilized properly will help the company itself.

Thus, we can observe that a single defect results in creating many more defects along with it.