Abstract

The textile industry, particularly the SME segment, plays a crucial role in the global economy, contributing to employment, innovation, and economic growth. In Peru, the textile sector is vital for economic development, but SMEs face significant challenges, especially in the cutting process, leading to high defect rates. Addressing these challenges is critical for improving operational efficiency and product quality.

This study proposed a Lean Production Model integrating Poka Yoke, Andon, Standardized Work, and Total Productive Maintenance (TPM) to address these challenges. The model aimed to enhance the cutting process by implementing quality measures and preventive maintenance to reduce defects and improve efficiency.

The implementation of the model resulted in a significant reduction in defect rates from 12.70% to 6.71% and a decrease in rejection rates from 4.20% to 2.53%. Additionally, the rate of defects in raw materials dropped from 7.60% to 5.60%, demonstrating the model's effectiveness in improving production quality and operational efficiency.

The academic and socio-economic impact of this research is substantial, as it provides a comprehensive framework for addressing quality and efficiency issues in the textile industry. The model promotes continuous improvement, leading to enhanced competitiveness and sustainability for textile SMEs.

This study encourages further exploration of Lean principles in other areas of textile manufacturing and the integration of advanced technologies to enhance process performance and sustainability. Researchers and practitioners are urged to build on these findings to drive innovation and continuous improvement in the industry