The purpose of this paper is to implement lean in a sewing line, analyzing the layout, process flow and batch size, in order to improve Overall Equipment Effectiveness (OEE). To understand the overall performance and scope of improvement the existing layout and process flow are analyzed exquisitely. After that, the authors proposed a new layout reorganizing the process flow that eliminated backflows and reduced transportation time. The authors found that batch size has significant effect on waiting time and transportation time. Smaller batch size increases transportation time and decreases waiting time, and vice versa. For batch size optimization, summation of waiting time and transportation time for different batch size is calculated and the smallest one is selected as optimum. Through the application of reorganized process flow in proposed layout and optimum batch size, reduction in transportation time by 30.95% and increment in OEE by 3.75% have been achieved. Following the instruction of this paper, any organization can measure OEE and improve it by optimizing batch size, reorganizing process flows, redesigning layout and eliminating back flows. In this research the authors only redesigned layout, reorganized process flows and optimized batch size that lead to an improvement in OEE but it is still far behind as compared to world class OEE. Lean is enormous with its numerous tools and philosophies and it says that there is no ultimate destination on the improvement journey. There are many other tools and philosophies of lean which can be applied for further improvement.
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