Barriers for Lean implementation in the textile industry

Abstract

Purpose The fundamentals of Lean are applicable and can be used in any industry, even non-profit and government organizations, however, there might be certain limitations due to the nature and the specifics of the industry. This study aims to explore what barriers of Lean implementation textile manufacturers might encounter. The authors consider the problem is worth to be explored for the potential to improve the effectiveness of Lean implementation in textile sector companies. Design/methodology/approach This research was conducted by using qualitative content analysis with open coding of the selected literature followed by empirical research in a Latvian textile manufacturing company. Findings The presented literature review shows Lean implementation barriers and critical success factors in various industries. The findings from the case study can be divided into two groups. The first confirmed the barriers already identified in the previous research. The second identified industry specific implementation barriers that were not recognized in the related literature. Research limitations/implications The original research was limited in scope to one Latvian textile manufacturer, therefore future studies on the subject to confirm the outcome of the research are required. Originality/value There is a limited number of studies on the application of Lean in the textile and apparel industry. The literature on Lean implementation in the Latvian manufacturing sector is also limited. The results of this research may have a practical application for textile manufactures considering implementing Lean in their processes.

Providing a model of LeAgile hybrid paradigm practices and its impact on supply chain performance

“…This required the education and development of all employees, the prospect of a supply chain driven by real customer demand, the creation of a self-learning organization and the introduction and implementation of standardized processes. Toyota has thus been able to produce products with fewer defects, in shorter production processes, with fewer suppliers, with lower inventory levels and with less investment (Robertsone, 2021).…”

Production Model to Increase the Rate of Order Fulfillment through the Implementation of Lean and MRP Tools in Dyeing in the Textile Sector

“…These problems presented by most textile companies can be reduced by using lean manufacturing tools. On the other hand, the high turnover of the sector causes learning to be tedious causing problems directly to production, so the company needs to be much more efficient [7]- [11].…”

“…On the other hand, a company with little experience in the use of techniques and tools of continuous improvement does not have evidence of formal mechanisms or dynamics, the lack of this organizational culture in textile companies is one of the barriers to the implementation of an improvement proposal. Textile manufacturers globally present the same challenges, so companies are forced to reduce costs and lead times by delivering quality products to attract customers [7], [8].…”

Production management model to reduce non-fulfillment of orders in Peruvian garment SMEs through 5S, SMED and standardization tools

“…It is essential to know the status of a system to process orders on time. [4]. This is based on the need of SMEs textiles and clothing, especially those that handle small batches of order, to improve their processes to meet their orders on time and achieve customer satisfaction.…”

“…The implementation of lean in the apparel industry has great potential, since lean can serve as the appropriate approach to successfully combat the challenges facing this industry. However, the adoption of lean in this type of company is not yet very popular [4]. Also, lack of awareness for lean implementation, company culture, lack of communication and employee resistance are the main barriers faced by companies in the industry during lean implementation [5].…”