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June 2, 2008




Continuous flow


Venue: Cinnamon Grand Colombo

77 Galle Road, Colombo 3, Sri Lanka


Part of

Lean Manufacturing & Engineering Series

Kanban One-Piece Flow From in-coming fabrics to shipping

Develop Operational Excellence

Cell Design for Transforming the Manufacturing Process

In the last 20 years, the largest single event having a positive impact on garment manufacturing improvement has been the introduction of flexible manufacturing cells (team-based cells). This seminar is about how to make cells work effectively, based on the speaker experience with over 300 actual installations around the world (Toyota Sewing System). Flexible manufacturing cells are effective tools for making products, whether they be high or low volume, or high or low variety. The true value of cells comes only from matching the cellular to the factorys manufacturing strategies, adequately planning the activities, using a team approach, fastidiously designing the team characteristics, organizing the implementation to include resource constraints, and employing tracking mechanisms to make sure it all happens and remains in place for the long term.

Circle of Operational Excellence

TPS is sometimes thought of as a set of techniques, like just-in-time, but in reality it represents deeply held beliefs about how to develop Customer Demand Just-In-Time Jidoka


Operational Excellence

Pull Production

The Core Pillars of TPS are:

Just In Time Jidoka

Built-in Quality

Continuous Flow Stability

Standardized Work

The production-side principles are well known: 1. Just in time 2. Pull System Production (Standardization & Continuous Flow) 3. Built-in Quality 4. Flexible workforce 5. Profit by Cost Control

Continuous Improvement

Development of Talented Workers

Modular Manufacturing Cells = Operational Excellence

Seminar Objectives
This seminar will cover the principles and methods used to convert to quick response manufacturing and how to evaluate and implement a variety of manufacturing systems into the plant for better productivity and results. Other topics include: advantages of the approach; expected results; how to determine the optimal number of employees per team; how to design operating procedures; laying out responsibilities and rules; developing a planning calendar. In addition, you learn why simulation is necessary, and how to do it are the allimportant components of this seminar designed for engineers and managers. Participants can evaluate real-life production systems in a variety of apparel plants and, in the process, learn steps that will enable them to create simulation and define differences in techniques and line set-ups. Insights will be shared to help garment manufacturers avoid new problems and solve old ones leading to improved utilization of labor and machinery.

People are the center of gravity of TPS


Developing Manufacturing Continuous Flow Maximizing Workers Value Stream Eliminating lack of line balancing Simulating manufacturing operations Formulating team structure Simplifying and Standardizing operations categories Improving product quality Meeting Takt Time as planned Reducing product cycle time Building self managed teams Integrating Problem Solving Techniques through workers Connecting workers to corporate objectives

Seminar Agenda
Who should attend?
Managing Director, General Manager, Factory managers and staffs, Engineers, lean champion & practitioner
Introduction Seminar Objectives and Expectations Corporate strategy meeting new set of challenges Learning about Market Requirements and Criteria Industry - Current State Identifying Waste of current manufacturing processes Identifying Waste related to large-lot production Disadvantages with head-to-head or face-to-face production lines One-Piece flow & team-based Concept Why one-piece flow is market-oriented production Basic Concept of One-Piece Production The five Rules and conditions of One-Piece Flow How to achieve One-Piece Flow (Abolish, Abandon, Stop & Develop) Characteristics and advantages of U-Shaped cells Role of team members and leader Case Study Redesign new production flow The Plan-Plan-Plan system Comparison between Garment factory & Motor Assembly Factory (Toyota) Fixed ideas in Sewing factory & Process-Razing Techniques The three ways to eliminate overstaffing waste Simulating the operations and Formulating the team Designing new cell & Steps to implement the new layout Improving U-shaped Cell operations after implementation Preventing Rework, Defects and Operation Errors Horizontal development of Zero changeover Establishing overall the manufacturing flow Future Issues to achieve Zero-defect production

Contact: Ms. Buddhika Tel. +94 11 462 2501 Fax +94 11 268 8439

Dagher Consulting Group PVT Ltd.

73/2 Ward Place, Colombo 7, Sri Lanka

Learning to See

Developing Manufacturing Cells Seminar

Complete the attached registration form. Forms may be submitted by e-mail or fax. Participants need to pay all registration fees in full 10 business days before the start date of the Seminar. Final date for submitting registration form: May 22, 2008. Note: Please contact DCG if you need assistance in hotel bookings and organizing airport pick-up.


Mr. Charles Dagher, CEO DCG (Canadian)

Registration Fees

Rs. 9,500/- (US$ 90) + VAT per person including lunch and refreshments, tea and coffee Discount of 10% per person for groups of 3 persons or more Two Payment Options 1. Send to our Project Office address given below by registered courier, either as USD bank draft or Sri Lankan rupees draft cheque for full amount in favor of Dagher Consulting Group and inform DCG by e-mail of the courier AWB, if applicable. Project Office Address: 73/2 Ward Place, Colombo 7, Sri Lanka

2. Wire transfer of the full amount (USD or Sri Lanka rupees) as per below details: Bank Details Beneficiary: Dagher Consulting Group Pvt Ltd Bank Name: DFCC Vardhana Bank Ltd. Account No.: 0010101430 Bank Address: No. 73, W.A.D. Ramanayake Mawatha, Colombo 2, Sri Lanka Swift Code: NMNJLKLX

Cancellation Policy

In case of cancellation, registration fees will be refunded for 80 percent if cancellation is received up to ten business days before the start date of the Seminar. Cancellations after that time are eligible for a 50 percent refund up to the start date. No fees will be refunded after the Seminar begins. Substitute participants are permitted; please notify us in advance by telephone or by e-mail up to 2 days before the start date of the Seminar.

Attendance Restrictions
Consulting firms are not eligible to attend this Seminar!

Presentation Language

Developing Manufacturing Cells Seminar REGISTRATION FORM

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Tel: Fax: Email: Website: Address: +94-11-462-2501/3 +94-11-269-8439 73/2 War Place Colombo 7, Sri Lanka

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