Li & Fung Limited
Improve Competitiveness From Up the Supply Chain
Industry: Textile and Apparels
Service: LEAN 6 Sigma/ BPI
Li & Fung Limited (Li & Fung) is a leading global consumer good design, development, sourcing and logistics company serving major brands and retailers. It has an extensive network of suppliers for producing high-quality garment. In order to further improve quality and production efficiency, Li and Fung consulted TQM to implement LEAN/ improvement projects for dozens of its key suppliers.
Investigated the redesigning and reconstructing of the bag strip; launched DoE for automatically rivet loading and to reduce time needed for rivet alignment; streamlined to one-piece flow and further reduce the waiting time for next process.
Improved packaging process by implementing automation, tooling and fixture; reduced the time needed for this process; the production speed increased with less manpower.
Fabric and Sewing Factories
Verify the appropriate light source to suit customer requirement and ensure the perceived color is the anticipated color.
Establish a comprehensive process control plan; enhanced the IQC, IPQC and QA; reduced cost and eliminated waste in key processes.
TQM’s Unique Subtractive Quality Assurance
Introduced Ir. Dr. TONG's“Subtractive Quality Assurance”solution that resolved the problems without spending excessive money in upgrading machines, recruiting more quality control staffs, etc.
Adjusted the accelerating factor of aging test, which compressed the testing time from 1,000 hours to 2 hours.
Deploy customized instrument for dimension measurement, which allows workers to handle 20 pieces in a minute (3 pcs/min in the past) by eliminating repeated works and reducing the sample size and testing time.
Lowered suppliers’ defect rate;
Boosted competitiveness of Li & Fung and her suppliers;
Substantial improvement in suppliers’ quality and productivity performances and on-time delivery rate.