During earlier days garment manufacturing systems were developed to approach the mass quantity of garments in the product line, which means fully utilizing the capacity so that more products were produced by fewer workers and machines, however large queues of process inventory has been ignored. But workers and machines never had to wait for product, which minimized the production cost.

Over a period of time business could not be profitable with the conventional mass production system because of lower quantity value added products are expected to produce by the Industry. In today's scenario, customers are expecting different varieties of product which are also expected to be delivered to their end quickly, which ultimately minimizes the "order to delivery" cycle.

New challenges for apparel industry are to produce lesser quantity in minimum lead time. Mass production helps everyone to cut the cost while producing mass quantity. Whereas Japanese Lean system describes how to cut the cost while producing small quantity.

Before Apparel manufacturing activities are done is mass level

What is Lean manufacturing?

Lean Manufacturing is a systematic approach for eliminating the process waste through continuous improvement.

Waste: From the customers' point of view process waste is anything which does not contribute the product transformation that is all the non value added activities in the process line is known as waste.

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The authors; B. Senthil Kumar is working as a Consultant at ILFS CDI Ltd and Dr. V.R Sampath is Principal at NANDA Engineering College