Lean manufacturing model for productivity improvement: application in an apparel SME

Abstract

Purpose This study aims to propose a people-centered lean manufacturing model to improve productivity in apparel small and medium enterprises (SMEs) characterized by individualistic organizational culture, lack of long-term planning and null knowledge on lean manufacturing. Design/methodology/approach The proposed model adopts a people-centered perspective, acknowledging that production in many apparel SMEs still depends on workers’ experience and skills. Lean tools were selected based on successful case studies and implementation critical success factors. The model consists of three stages: pre-implementation, implementation and post-implementation. In the first stage, value stream mapping (VSM) identifies process deficiencies. During implementation, 5S is used to standardize workstations, while kaizen promotes continuous improvement. The final stage focuses on assessing lean objectives and comparing key performance indicators before and after the implementation of lean manufacturing. Findings Applying this model in a Mexican apparel SME led to a 40.23% increase in productivity. Practical implications The lean tools were adapted to fit the local organizational context. Social implications Replacing traditional production approaches with lean models can significantly enhance productivity in SMEs within the apparel sector. Originality/value A lean manufacturing model tailored for the apparel industry considering individualistic organizational culture, lack of long-term planning and null knowledge on lean manufacturing.