1. Kwanglim Trading Co., Ltd
Kohl’s/Li & Fung Lean Conference
Singapore October 14th, 2014
Journey to
LEAN MANUFACTURING
Kwanglim Trading Co., Ltd

2. OCT. 2012 SINGAPORE LEAN CONFERENCE DEC.2012 1 LEAN PILOT LINE
Journey to Lean Manufacturing
OCT. 2012
SINGAPORE
LEAN
CONFERENCE
Kwanglim Trading Co., Ltd
Phase 0
DEC.2012
1 LEAN
PILOT LINE
INDONESIA
SEP. 2013
NO MORE
LEAN LINE
2014 LEAN CONFERENCE 2

3. Lack of Lean Specialists
Journey to Lean Manufacturing
Kwanglim Trading Co., Ltd
Phase 0: ANALYSIS OF THE STATE
Lack of Lean Specialists
Superficial Bench Marking
Lack of detailed plan & jumping to action
Little understanding & embracing by the members
Only change made: Sewing line layout
2014 LEAN CONFERENCE 3

4. Rolling out 5S & QCO in 2014 APPOINTED INTERNAL LEAN PROJECT LEADER
Journey to Lean Manufacturing
APPOINTED INTERNAL
LEAN PROJECT LEADER
Kwanglim Trading Co., Ltd
Phase 1
Rolling out
5S & QCO
in 2014
SORT
STORE
SHINE
STANDARDIZE
SUSTAIN
RECRUITED
OUTSIDE
LEAN EXPERT
TOOK LEAN
TRAINING
(TaF.tc in
Singapore) .
2014 LEAN CONFERENCE 4

5. Lean Schedule for 2014 - Indonesia
Journey to Lean Manufacturing
Kwanglim Trading Co., Ltd
Lean Schedule for Indonesia
TASKS
LEAN TRAINING FOR EMPLOYEES
VALUE STREAM MAPING(VSM)
5S IMPLEMENTATION
Fabric Warehouse
Cutting Room
Accessories Warehouse
Sewing
Mechanic
End Line QC
Ironing
Packing Accessories Warehouse
Packing
QA Inspection Room
C-TPAT Area
Office Area
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
TGT DATE TO START
TGT DATE TO FINISH
Target Date to Start
Target Date to Finish
2014 LEAN CONFERENCE 5

6. Lean Schedule for 2014 - Indonesia
Journey to Lean Manufacturing
Kwanglim Trading Co., Ltd
Lean Schedule for Indonesia
TASKS
QUICK CHANGE OVER (QCO)
LINE BALANCE PLAN LAYOUT
ONE-PIECE/CONTINUOUS FLOW
Pilot Line – line 18
CELLULAR MANUFACTURING LAYOUT & FLOW IMPROVEMENT
DEVELOP STANDARDIZED OPERATIONS
QCO
LINE BALANCE
FLOW LAYOUT
KAIZEN
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
TGT DATE TO START
TGT DATE TO FINISH
Target Date to Start
Target Date to Finish
2014 LEAN CONFERENCE 6

7. Lean Manufacturing – Challenges
Journey to Lean Manufacturing
Kwanglim Trading Co., Ltd
Lean Manufacturing – Challenges
Scarcity of lean experts within Korean textile/garment industry
Very few organization providing lean training for garment manufacturing
Language barrier (among lean trainers, management, and local employees)
Financial burden and communication issue to invite outside consultant
Difficulty of scheduling internal training at the production sites
Difficulty of changing the mindset of floor managers who are used to running the production line with their own method over long periods
of time
2014 LEAN CONFERENCE 7

8. Lean Manufacturing - Recommendations
Journey to Lean Manufacturing
Kwanglim Trading Co., Ltd
Lean Manufacturing - Recommendations
Consider to adopt lean production system based on your long
term management philosophy.
Do not get onto the Lean wagon pushed by your client without
top management’s understanding on entire lean system and
power behind true Toyota Production System(TPS)
Spend enough time and efforts to getting the floor managers
and leaders to understand the Lean system and
get their buy-in before actual rolling out .
Do not rush to achieve a great result in short time. Develop &
customize your own Lean System.
2014 LEAN CONFERENCE 8

9. 2% Senior Management Toolkits vs Philosophy
Journey to Lean Manufacturing
Kwanglim Trading Co., Ltd 2%
Senior Management
Toolkits vs Philosophy
2014 LEAN CONFERENCE 9

10. Thank you!
Kwanglim Trading Co., Ltd