Track: Lean

Abstract

This survey based study explored the implementation of lean manufacturing practices in textile industries of Pakistan. A total of 76 responses were received. The results of the study showed that the textile sector is at the beginning stage of lean implementation – more than half of the surveyed companies were in-transition to implement lean. The most important driver to implement lean was found to be organization’s continuous improvement program followed by the drive to focus on customers, and desire to use best practices. The respondents perceived cost reduction to be the biggest benefit that can be achieved by implementing lean, followed by customer satisfaction, and improved delivery time. Among tools and techniques 5S, quality control circles, kaizen and SMED were used extensively. Manufacturing planning and control was not formally implemented. Human resource related factors were perceived to be crucial to effectively implement lean. Level of implementation was found to have a significant relationship with the size and the type of company and not with the age of the company. Lack of awareness to implement lean, company culture, lack of communication, and employee resistance were the main barriers faced by the sample companies during the implementation of lean.