Leveraging Kanban Lean Techniques to Improve Workforce Allocation and Production Efficiency in the Apparel Industry

This study delves into Lean manufacturing technologies, with a specific focus on the Kanban system—a pivotal tool for enhancing operational efficiency. The investigation centers on the swing line of a local Non-Kanban Ready-Made Garment (RMG) plant, scrutinizing current activities and workforce allocation. The goal is to demonstrate how implementing the Kanban system can efficiently divide the input workforce on the swing line, leading to heightened productivity, reduced idle time, and optimized working hours. The initial phase involves a comprehensive analysis of the existing non-Kanban assembly line, serving as a benchmark for evaluating the proposed Kanban paradigm. Utilizing cards or signals, the Kanban system is employed to visually optimize the process. The thesis visually represents the current non-Kanban swing line input process, highlighting operational efficiency and time utilization. Mathematical dimensions are explored to quantify the impact of the Kanban method on work efficiency. Through rigorous mathematical analysis, the thesis assesses the suggested Kanban model's potential to streamline input worker distribution, ultimately reducing working hours and elevating overall productivity. The key findings highlight the significant impact that installing the Kanban system might have on the local RMG facility's swing line.   Quantitative analysis offers quantifiable data on possible enhancements in efficiency, assisting decision-makers in the industry.   This thesis is a significant resource for field workers aiming to enhance their productivity, ensuring not just increased efficiency but also demonstrating the transformative impact of Lean manufacturing principles on industrial operations.