Proposal for the Implementation of Lean Manufacturing in a Textile Apparel Company: A Case Study

Abstract

The apparel textile sector in El Salvador is an industrial field of great growth in recent years. However, not many companies properly take advantage of their available resources, restricting their competitiveness. The purpose of this case study is to generate proposals for the application of Lean Manufacturing at AYM Industrias, a medium-sized apparel manufacturing company. Specifically, the analysis is aimed at improving the value chain of screen-printed T-shirts. The data of times, distances, and plant resources were collected through technical visits and interviews with the personnel. A diagnosis was carried out with the mapping of the value stream (Value Stream Mapping, VSM) and the identification of the 7 types of waste to select the most adequate Lean Manufacturing tools. The proposals integrate the implementation of the 5S to improve organization and cleanliness, visual management and control to reduce waiting times due to lack of instructions, and the calculation of takt time to manufacture at the pace of demand. The screen-printing module was chosen for the pilot implementation of the proposals. The cycle time of printing and frame creation has a duration of 55,046 and 14,760 seconds, respectively. As a result, an improvement in productivity of 13% and 11%, respectively, is projected in garment production per hour. The future value stream map presents the reduction of delays, defects, and inventories, as well as the expected benefits of the proposals developed, preparing the company to apply higher levels of Lean Manufacturing in the near future.