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. Li and Fung consulted TQM to assist in improving supplier quality control in terms of production planning and processes.
Develop supplier benchmarking assessment mechanism
Advised suppliers on improving quality in IQC, IPQC & QA operations and production flows
Establish KPIs and information management systems
Actively enforce 5S management
Trained staff on quality awareness and technical skill
Project Details – Common Problems in Factories
After reviewing 5 of Li & Fung Top-Notch factories, TQM has greatly improved the quality in in IQC, IPQC & QA operations and production flows. Some include…
Metal Parts in Strips Assembly Improvement
TQM has investigated the redesigning and reconstructing of the bag strip for better production. TQM has launched DoE for investigating the possibility of automation for automatically rivet loading and to reduce time needed for rivet alignment. The production has been streamlined to one-piece flow instead of batch production. It can further reduce the waiting time for next process.
Packaging Process Improvement
This process can be drastically improved by implementing automation, tooling and fixture. Once TQM determines the procedure occupied a large portion of the whole process, we started investigating the possible solution to reduce the time for this process. Through redesigning the workflow, the production speed increased with less manpower.
Fabric and Sewing Factories
Color Inspection Improvement
Have you even found the product’s color unmatched with the description?
Factory lighting is essential. The color you see for a product depends on the mix of light frequencies that reach your eye. TQM immediately verify the appropriate light source to suit customer requirement and ensure the perceived color is the anticipated color.
Natural versus artificial
Process and Quality Control & Control Plan
Most companies are looking for methods to reduce cost and eliminate waste in their processes. Maintained measurement and control in manufacturing processes helps facilitate a business’ overall success.
TQM helped to establish a comprehensive process control plan to ensure that the customer requirements will be met and the process variation will be reduced.
TQM’s Unique Subtractive Quality Assurance
TQM’s Director, Dr. Aaron TONG has introduced “Subtractive Quality Assurance”, whereas quality improvement does not always depend on cost. By analyzing the real cause, YTQM can be able to resolve the problem without spending excessive money in upgrading machines, recruiting more quality control staffs, etc.
Light Bulb Test Improvement
TQM successfully adjusted the accelerating factor of aging test by 60%. By initially accelerated the light bulbs aging test by 120%, which compressed the testing time from 1,000 hours to 94 hours, TQM further accelerated the test by 120% and compressed the testing time form 1,000 hours to 2 hours.
Safety Critical Component
Through process review, TQM is able to identify the opportunities to eliminate repeated works and reduce the sample size and testing time without affecting the customer risk. TQM also assists to deploy customized instrument for dimension measurement, which allows workers to handle 20 pieces in a minute (3 pcs/min in the past).
Safety Critical Component
Lowered suppliers’ defect rate
Substantial improvement in suppliers’ quality and productivity performances and on-time delivery rate
Boosted competitiveness of Li & Fung and her suppliers