Lean & Six Sigma
5S, SMED, kaizen and problem solving applied to sewing lines.
Six Sigma for garment factories: DMAIC, DPMO and sigma level
What Six Sigma means, DMAIC vs DMADV, the main tools, and a worked example that turns 500 defective garments out of 50,000 into DPMO and a sigma level - with the conversion table.
Process mapping: SIPOC, swim lane and VA / NVA / delay analysis
Map any garment process - sample approval, size set or cutting - with SIPOC for the big picture, a swim lane for who does what, and activity analysis to measure how much time really adds value.
A3 report, visual management, 8-step problem solving and the 7 QC tools
How to solve a floor problem on one page: visual control vs visual display, the sections of an A3 report, the 8 problem-solving steps and when to use each of the 7 QC tools - with a planning-accuracy example.
25 Lean tools explained in one line each - with Lean interview Q&A
5S, Andon, Jidoka, JIT, Kaizen, Kanban, Poka-Yoke, SMED, OEE, takt time and more - one clear line each, plus the Lean and layout questions asked in IE interviews.
Lean basics: value-added work, ECRS and the 8 wastes (TIMWOODS)
What Lean really means on a garment floor: value-added vs non-value-added work, how ECRS shrinks necessary work, the 8 wastes, the Ohno circle, Gemba walks and a short history of Lean.
SMED: faster style changeovers
Separate internal and external work to cut the time lost when a line changes style.
5S on the sewing floor
Sort, Set in order, Shine, Standardise, Sustain - with practical examples for sewing lines.