757
Views
0
CrossRef citations to date
0
Altmetric
Production & Manufacturing

Lean waste prioritisation and reduction in the apparel industry: application of waste assessment model and value stream mapping

ORCID Icon &
Article: 2341538 | Received 06 Dec 2022, Accepted 06 Apr 2024, Published online: 20 Apr 2024

References

  • Abdulmalek, F. A., & Rajgopal, J. (2007). Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study. International Journal of Production Economics, 107(1), 223–236. https://doi.org/10.1016/j.ijpe.2006.09.009
  • Abtew, M. A., Kumari, A., Babu, A., & Hong, Y. (2020). Statistical analysis of standard allowed minute on sewing efficiency in apparel industry. Autex Research Journal, 20(4), 359–365. https://doi.org/10.2478/aut-2019-0045
  • Akçagün, E., Dal, V., & Yılmaz, A. (2012, October 7–10). Using value stream mapping at apparel industry: A case study [Paper presentation]. 6th International Textile, Clothing and Design Conference - Magic World of Textiles, Dubrovnik, Croatia.
  • Akter, M. M. K., Haq, U. N., Islam, M. M., & Uddin, M. A. (2022). Textile-apparel manufacturing and material waste management in the circular economy: A conceptual model to achieve sustainable development goal (SDG) 12 for Bangladesh. Cleaner Environmental Systems, 4, 100070. https://doi.org/10.1016/j.cesys.2022.100070
  • Amrina, E., & Andryan, R. (2019, April 26–29). Assessing wastes in rubber production using lean manufacturing: A case study [Paper presentation]. 2019 IEEE 6th International Conference on Industrial Engineering and Applications), Tokyo, Japan.
  • Barzola-Cisneros, V., Calderon-Tirado, J., Viacava-Campos, G., & Aderhold, D. (2021). Production model to increase productivity and delivery compliance in the Peruvian textile sector by applying value stream mapping, 5S and flexible production systems. In T. Ahram, R. Taiar, K. Langlois, & A. Choplin (Eds.), Human Interaction, Emerging Technologies and Future Applications III: Proceedings of the 3rd International Conference on Human Interaction and Emerging Technologies: Future Applications (pp. 599–605). Springer.
  • Bashar, A., & Hasin, M. A. A. (2018). Lean manufacturing awareness and its implementation status in the apparel industry in Bangladesh. International Journal of Lean Enterprise Research, 2(3), 202–217. https://doi.org/10.1504/IJLER.2018.093607
  • Bashar, A., & Hasin, A. A. (2016). The effect of continuous improvement on waste elimination for implementing lean manufacturing in the apparel industry of Bangladesh. Independent Business Review, 9(1-2), 132–146.
  • Bashar, A., Hasin, A. A., & Adnan, Z. H. (2021). Impact of lean manufacturing: Evidence from apparel industry in Bangladesh. International Journal of Lean Six Sigma, 12(5), 923–943. https://doi.org/10.1108/IJLSS-01-2020-0005
  • Behnam, D., Ayough, A., & Mirghaderi, S. H. (2018). Value stream mapping approach and analytical network process to identify and prioritize production system’s Mudas (case study: Natural fibre clothing manufacturing company). The Journal of the Textile Institute, 109(1), 64–72. https://doi.org/10.1080/00405000.2017.1322737
  • Carvalho, C., Carvalho, D., & Silva, M. (2019). Value stream mapping as a lean manufacturing tool: A new account approach for cost saving in a textile company. International Journal of Production Management and Engineering, 7(1), 1–12. https://doi.org/10.4995/ijpme.2019.8607
  • Cuellar-Valer, S., Gongora-Vilca, A., Altamirano-Flores, E., & Aderhold, D. (2020). Application of lean manufacturing in a Peruvian clothing company to reduce the amount of non-conforming products. In T. Ahram, R. Taiar, K. Langlois, & A. Choplin (Eds.), Advances in Intelligent Systems and Computing: Proceedings of the 3rd International Conference on Human Interaction and Emerging Technologies: Future Applications (pp. 481–488). Springer.
  • Dadashnejad, A. A., & Valmohammadi, C. (2019). Investigating the effect of value stream mapping on overall equipment effectiveness: A case study. Total Quality Management & Business Excellence, 30(3-4), 466–482. https://doi.org/10.1080/14783363.2017.1308821
  • Danese, P., Manfè, V., & Romano, P. (2018). A systematic literature review on recent lean research: State‐of‐the‐art and future directions. International Journal of Management Reviews, 20(2), 579–605. https://doi.org/10.1111/ijmr.12156
  • Deshkar, A., Kamle, S., Giri, J., & Korde, V. (2018). Design and evaluation of a lean manufacturing framework using value stream mapping (VSM) for a plastic bag manufacturing unit. Materials Today: Proceedings, 5(2), 7668–7677. https://doi.org/10.1016/j.matpr.2017.11.442
  • Erlach, K. (2013). Value stream design: The way towards a lean factory. Springer.
  • Ethiopian Textile Industry Development Institute. (2021). Ethiopian textile and apparel industry profile.
  • Ferdousi, F., & Ahmed, A. (2009). An investigation of manufacturing performance improvement through lean production: A study on Bangladeshi garment firms. International Journal of Business and Management, 4(9), 106–116. https://doi.org/10.5539/ijbm.v4n9p106
  • Gebeyehu, S. G., Abebe, M., & Gochel, A. (2022). Production lead time improvement through lean manufacturing. Cogent Engineering, 9(1), 1–14. https://doi.org/10.1080/23311916.2022.2034255
  • George, M., Ngoc, N. M., Nhi, L. K. Y., Tung, V. N. D., Truc, L. P. T., & Nayak, R. (2022). Lean manufacturing: Case studies from fashion and textile industries. In R. Nayak (Ed.), Lean supply chain management in fashion and textile industry (pp. 269–290). Springer.
  • Georgise, F. B., & Mindaye, A. T. (2020). Kaizen implementation in industries of Southern Ethiopia: Challenges and feasibility. Cogent Engineering, 7(1), 1823157. https://doi.org/10.1080/23311916.2020.1823157
  • Goshime, Y., Kitaw, D., & Jilcha, K. (2019). Lean manufacturing as a vehicle for improving productivity and customer satisfaction: A literature review on metals and engineering industries. International Journal of Lean Six Sigma, 10(2), 691–714. https://doi.org/10.1108/IJLSS-06-2017-0063
  • Hamja, A., Maalouf, M., & Hasle, P. (2019). The effect of lean on occupational health and safety and productivity in the garment industry – A literature review. Production & Manufacturing Research, 7(1), 316–334. https://doi.org/10.1080/21693277.2019.1620652
  • Hartini, S., Manurung, J., & Rumita, R. (2021). Sustainable-value stream mapping to improve manufacturing sustainability performance: Case study in a natural dye batik SME’s. IOP Conference Series: Materials Science and Engineering, 1072(1), 012066. https://doi.org/10.1088/1757-899X/1072/1/012066
  • Helleno, A., Pimentel, C., Ferro, R., Santos, P., Oliveira, M., & Simon, A. (2015). Integrating value stream mapping and discrete events simulation as decision making tools in operation management. The International Journal of Advanced Manufacturing Technology, 80(5-8), 1059–1066. https://doi.org/10.1007/s00170-015-7087-1
  • Henny, H., & Budiman, H. (2018). Implementation lean manufacturing using waste assessment model (WAM) in shoes company. IOP Conference Series: Materials Science and Engineering (Vol. 407, pp. 1–5). https://doi.org/10.1088/1757-899X/407/1/012077
  • Heravi, G., & Firoozi, M. (2017). Production process improvement of buildings’ prefabricated steel frames using value stream mapping. The International Journal of Advanced Manufacturing Technology, 89(9-12), 3307–3321. https://doi.org/10.1007/s00170-016-9306-9
  • Hines, P., & Rich, N. (1997). The seven value stream mapping tools. International Journal of Operations & Production Management, 17(1), 46–64. https://doi.org/10.1108/01443579710157989
  • Hodge, G. L., Ross, G. K., Joines, J. A., & Thoney, K. (2011). Adapting lean manufacturing principles to the textile industry. Production Planning & Control, 22(3), 237–247. https://doi.org/10.1080/09537287.2010.498577
  • Hussain, D., & Figueiredo, M. C. (2023). Improving the time-based performance of the preparatory stage in textile manufacturing process with value stream mapping. Business Process Management Journal, 29(3), 801–837. https://doi.org/10.1108/BPMJ-08-2022-0366
  • Jaca, C., Viles, E., Paipa-Galeano, L., Santos, J., & Mateo, R. (2014). Learning 5S principles from Japanese best practitioners: Case studies of five manufacturing companies. International Journal of Production Research, 52(15), 4574–4586. https://doi.org/10.1080/00207543.2013.878481
  • Jana, P., & Tiwari, M. (2021a). Lean management in apparel manufacturing. In P. Jana & M. Tiwari (Eds.), Lean tools in apparel manufacturing (pp. 1–16). Elsevier.
  • Jana, P., & Tiwari, M. (2021b). Lean terms in apparel manufacturing. In P. Jana & M. Tiwari (Eds.), Lean tools in apparel manufacturing (pp. 17–45). Elsevier.
  • Jasti, N. V. K., Kota, S., & Sangwan, K. S. (2020). An application of value stream mapping in auto-ancillary industry: A case study. The TQM Journal, 32(1), 162–182. https://doi.org/10.1108/TQM-11-2018-0165
  • Kanakana, G. M. (2013, July 9–11). Lean in service industry. Southern African Institute of Industrial Engineering.
  • Karunarathne, E., & Dhananjana, E. (2022). Layout planning with the style changeovers in development centers: A case study in apparel industry. Indian Journal of Commerce and Management Studies, 13(02), 01–07.
  • Kosasih, W., Sriwana, I. K., Sari, E., & Doaly, C. O. (2019). Applying value stream mapping tools and kanban system for waste identification and reduction (case study: A basic chemical company). IOP Conference Series: Materials Science and Engineering, 528, 1–8. https://doi.org/10.1088/1757-899X/528/1/012050
  • Kumar, B. S., & Sampath, V. (2012). Garment manufacturing through lean initiative - An empirical study on WIP fluctuation in T-shirt production unit. International Journal of Lean Thinking, 3(2), 102–116.
  • Kumar, R., & Kumar, V. (2012, October 19–20). Lean manufacturing: Elements and its benefits for manufacturing industry [Paper presentation]. National Conference on Trends and Advances in Mechanical Engineering, Faridabad, India.
  • Kumar, S., & Thavaraj, S. (2015). Impact of lean manufacturing practices on clothing industry performance. International Journal of Textile and Fashion Technology (IJTFT), 5(2), 1–14.
  • Lugert, A., Batz, A., & Winkler, H. (2018). Empirical assessment of the future adequacy of value stream mapping in manufacturing industries. Journal of Manufacturing Technology Management, 29(5), 886–906. https://doi.org/10.1108/JMTM-11-2017-0236
  • Makhija, A., Wickramasinghe, C., & Tiwari, M. (2021). Visual management. In P. Jana & M. Tiwari (Eds.), Lean tools in apparel manufacturing (pp. 131–208). Elsevier.
  • Manickam, B. K., & Rathinasamy, P. (2022). A fuzzy GRA-based decision-making approach on the selection of lean tools: A case study of Indian apparel industry. International Journal of Industrial Engineering, 29(1), 1–20.
  • Marudhamuthu, R., & Pillai, D. M. (2011). The development and implementation of lean manufacturing techniques in Indian garment industry. Jordan Journal of Mechanical and Industrial Engineering, 5(6), 527–532.
  • Masuti, P., & Dabade, U. (2019). Lean manufacturing implementation using value stream mapping at excavator manufacturing company. Materials Today: Proceedings, 19, 606–610. https://doi.org/10.1016/j.matpr.2019.07.740
  • Mishra, A. K., Sharma, A., Sachdeo, M., & K, J. (2020). Development of sustainable value stream mapping (SVSM) for unit part manufacturing: A simulation approach. International Journal of Lean Six Sigma, 11(3), 493–514. https://doi.org/10.1108/IJLSS-04-2018-0036
  • Mulugeta, L. (2021). Productivity improvement through lean manufacturing tools in Ethiopian garment manufacturing company. Materials Today: Proceedings, 37(2), 1432–1436. https://doi.org/10.1016/j.matpr.2020.06.599
  • Nihlah, Z., & Immawan, T. (2018). Lean manufacturing: Waste reduction using value stream mapping [Paper presentation]. E3S Web of Conferences 73, Semarang, Indonesia. https://doi.org/10.1051/e3sconf/2018730
  • Obeidat, M. S., Pei, Z., & Al-Aomar, R. (2012, May 19–23). Implementing lean manufacturing in the sewing industry [Paper presentation]. The 2012 Industrial and Systems Engineering Research Conference, Orlando, FL, USA.
  • Ohno, T. (1988). Toyota production system: Beyond large-scale production. Taylor & Francis.
  • Panizzolo, R., Garengo, P., Sharma, M. K., & Gore, A. (2012). Lean manufacturing in developing countries: Evidence from Indian SMEs. Production Planning & Control, 23(10-11), 769–788. https://doi.org/10.1080/09537287.2011.642155
  • Phuong, N. A., & Guidat, T. (2018). Sustainable value stream mapping and technologies of Industry 4.0 in manufacturing process reconfiguration: A case study in an apparel company [Paper presentation]. The 2018 IEEE International Conference on Service Operations and Logistics, and Informatics, Singapore. https://doi.org/10.1109/SOLI.2018.8476750
  • Prasad, M. M., Dhiyaneswari, J. M., Jamaan, J. R., Mythreyan, S., & Sutharsan, S. M. (2020). A framework for lean manufacturing implementation in Indian textile industry. Materials Today: Proceedings, 33, 2986–2995. https://doi.org/10.1016/j.matpr.2020.02.979
  • Prasad, S., & Panghal, M. (2022). Process-loss optimization through the implementation of Kanban & single-piece flow: A case study in an Ethiopian garment factory. Journal of Textile & Apparel Technology & Management (JTATM), 12(3), 1–14.
  • Rahmanasari, D., Sutopo, W., & Rohani, J. (2021). Implementation of lean manufacturing process to reduce waste: A case study. IOP Conference Series: Materials Science and Engineering, 1096, 1–9. https://doi.org/10.1088/1757-899X/1096/1/012006
  • Ratnayake, R., & Dinosha, V. (2018). Effectiveness of lean manufacturing layout of a firm within the apparel industry of Sri Lanka: A case study. http://dl.lib.uom.lk/handle/123/13016
  • Rawabdeh, I. A. (2005). A model for the assessment of waste in job shop environments. International Journal of Operations & Production Management, 25(8), 800–822. https://doi.org/10.1108/01443570510608619
  • Reda, H., & Dvivedi, A. (2021). Application of value stream mapping (VSM) in low-level technology organizations: A case study. International Journal of Productivity and Performance Management, 71(6), 2393–2409. https://doi.org/10.1108/IJPPM-03-2021-0118
  • Rimawan, E., Molle, T. D., & Putra, F. E. (2018). Lean production design with waste and method analysis of VALSAT for assembly process of four wheel vehicle components. International Journal of Innovative Science and Research Technology, 3(11), 449–455.
  • Rohani, J. M., & Zahraee, S. M. (2015). Production line analysis via value stream mapping: A lean manufacturing process of color industry. Procedia Manufacturing, 2, 6–10. https://doi.org/10.1016/j.promfg.2015.07.002
  • Romero, L., & Arce, A. (2017). Applying value stream mapping in manufacturing: A systematic literature review. IFAC-PapersOnLine, 50(1), 1075–1086. https://doi.org/10.1016/j.ifacol.2017.08.385
  • Rother, M., & Shook, J. (2003). Learning to see: Value stream mapping to add value and eliminate muda. The Lean Enterprise Institute.
  • Sangwa, N. R., & Sangwan, K. S. (2023). Leanness assessment of a complex assembly line using integrated value stream mapping: A case study. The TQM Journal, 35(4), 893–923. https://doi.org/10.1108/TQM-12-2021-0369
  • Santos, E., Lima, T. M., & Gaspar, P. D. (2023). Optimization of the production management of an upholstery manufacturing process using lean tools: A case study. Applied Sciences, 13(17), 9974. https://doi.org/10.3390/app13179974
  • Staritz, C., Plank, L., & Morris, M. (2019). A different path of industrial development? Ethiopia’s apparel export sector. In S. Scholvin, A. Black, J. R. Diez, & I. Turok (Eds.), Value chains in sub-Saharan Africa (pp. 79–93). Springer.
  • Scott, A. J. (2006). The changing global geography of low-technology, labor-intensive industry: Clothing, footwear, and furniture. World Development, 34(9), 1517–1536. https://doi.org/10.1016/j.worlddev.2006.01.003
  • Shah, R., & Ward, P. T. (2003). Lean manufacturing: Context, practice bundles, and performance. Journal of Operations Management, 21(2), 129–149. https://doi.org/10.1016/S0272-6963(02)00108-0
  • Silva, S. (2012). Applicability of value stream mapping (VSM) in the apparel industry in Sri Lanka. International Journal of Lean Thinking, 3(1), 36–41.
  • Silva, S., Perera, H., & Samarasinghe, G. (2011). Viability of lean manufacturing tools and techniques in the apparel industry in Sri Lanka. Applied Mechanics and Materials, 110–116, 4013–4022. https://doi.org/10.4028/www.scientific.net/AMM.110-116.4013
  • Singh, B., & Sharma, S. (2009). Value stream mapping as a versatile tool for lean implementation: An Indian case study of a manufacturing firm. Measuring Business Excellence, 13(3), 58–68. https://doi.org/10.1108/13683040910984338
  • Singh, C., Singh, D., & Khamba, J. (2021). Exploring an alignment of lean practices on the health and safety of workers in manufacturing industries. Materials Today: Proceedings, 47, 6696–6700. https://doi.org/10.1016/j.matpr.2021.05.116
  • Singh, J., Singh, H., & Singh, G. (2018). Productivity improvement using lean manufacturing in manufacturing industry of Northern India: A case study. International Journal of Productivity and Performance Management, 67(8), 1394–1415. https://doi.org/10.1108/IJPPM-02-2017-0037
  • Singh, J., Singh, H., Singh, A., & Singh, J. (2020). Managing industrial operations by lean thinking using value stream mapping and six sigma in manufacturing unit: Case studies. Management Decision, 58(6), 1118–1148. https://doi.org/10.1108/MD-04-2017-0332
  • Suárez‐Barraza, M. F., & Ramis‐Pujol, J. (2012). An exploratory study of 5S: A multiple case study of multinational organizations in Mexico. Asian Journal on Quality, 13(1), 77–99. https://doi.org/10.1108/15982681211237842
  • Suhardi, B., Putri, K. S., M. H., & Jauhari, W. A. (2020). Implementation of value stream mapping to reduce waste in a textile products industry. Cogent Engineering, 7(1), 1842148. https://doi.org/10.1080/23311916.2020.1842148
  • Sultana, M., & Islam, M. (2013). Scope of value stream mapping to initiate lean manufacturing: An analysis in the apparel industry of Bangladesh. International Journal of Lean Thinking, 4(1), 20–30.
  • Tapia-Leon, R., Vega-Neyra, X., Chavez-Soriano, P., & Ramos-Palomino, E. (2019). Improving the order fulfillment process in a textile company using lean tools [Paper presentation]. The 2019 Congreso Internacional de Innovación y Tendencias en Ingeniería (CONIITI), Bogota, Colombia. https://doi.org/10.1109/CONIITI48476.2019.8960698
  • Taplin, I. M., Winterton, J., & Winterton, R. (2003). Understanding labour turnover in a labour intensive industry: Evidence from the British clothing industry. Journal of Management Studies, 40(4), 1021–1046. https://doi.org/10.1111/1467-6486.00369
  • Tesfaye, S. A. (2019). Continuous improvement practices in the manufacturing industries of Ethiopia: An analytical view. Global Scientific Journals, 7(9), 466–477.
  • Ünal, C., & Bilget, S. (2021). Examination of lean manufacturing systems by simulation technique in apparel industry. The Journal of the Textile Institute, 112(3), 377–387. https://doi.org/10.1080/00405000.2020.1756104
  • Weldesilassie, A. B., Gebreeyesus, M., Abebe, G., & Aseffa, B. (2017). Study on industrial park development: Issues, practices and lessons for Ethiopia. Ethiopian Development Research Institute.
  • Wickramasinghe, G., & Perera, A. (2016). Effect of total productive maintenance practices on manufacturing performance: Investigation of textile and apparel manufacturing firms. Journal of Manufacturing Technology Management, 27(5), 713–729. https://doi.org/10.1108/JMTM-09-2015-0074
  • Wickramasinghe, G., & Wickramasinghe, V. (2017). Implementation of lean production practices and manufacturing performance: The role of lean duration. Journal of Manufacturing Technology Management, 28(4), 531–550. https://doi.org/10.1108/JMTM-08-2016-0112
  • Womack, J. P., & Jones, D. T. (2003). Lean thinking: Banish waste and create wealth in your corporation. Simon and Shuster.
  • Womack, J. P., Jones, D. T., & Roos, D. (2007). The machine that changed the world: The story of lean production–Toyota’s secret weapon in the global car wars that is now revolutionizing world industry. Simon and Schuster.
  • Wu, Y. C. (2003). Lean manufacturing: A perspective of lean suppliers. International Journal of Operations and Production Management, 23(11), 1349–1376.
  • Yadrifil, Y., Pratama, R. A., & Rus, A. M. M. (2020). Improvement recommendation to eliminate waste on the production process of line laminating door component with value stream mapping and waste assessment model method. AIP Conference Proceedings, 2227, 1–13. https://doi.org/10.1063/5.0004213
  • Yildiz, E. Z., & Güner, M. (2013). Applying value stream mapping technique in apparel industry. Tekstil Ve Konfeksiyon, 23(4), 393–400.
  • Yu, C. W., & Kuan, Y. W. (2011). Approaches and practices of lean manufacturing: The case of electrical and electronics companies. African Journal of Business Management, 5(6), 2164–2174.
  • Zahraee, S. M. (2016). A survey on lean manufacturing implementation in a selected manufacturing industry in Iran. International Journal of Lean Six Sigma, 7(2), 136–148. https://doi.org/10.1108/IJLSS-03-2015-0010
  • Zahraee, S. M., Esrafilian, R., Kardan, R., Shiwakoti, N., & Stasinopoulos, P. (2021). Lean construction analysis of concrete pouring process using value stream mapping and Arena based simulation model. Materials Today: Proceedings, 42, 1279–1286. https://doi.org/10.1016/j.matpr.2020.12.955
  • Zahraee, S. M., Hashemi, A., Abdi, A. A., Shahpanah, A., & Rohani, J. M. (2014). Lean manufacturing implementation through value stream mapping: A case study. Jurnal Teknologi, 68(3), 1–6. https://doi.org/10.11113/jt.v68.2957
  • Zahraee, S. M., Tolooie, A., Abrishami, S. J., Shiwakoti, N., & Stasinopoulos, P. (2020). Lean manufacturing analysis of a heater industry based on value stream mapping and computer simulation. Procedia Manufacturing, 51, 1379–1386. https://doi.org/10.1016/j.promfg.2020.10.192