Abstract
The textile industry, especially small and medium-sized enterprises (SMEs), plays a crucial role in the global economy, significantly contributing to trade, employment, and revenue. In Peru, the textile sector holds a prominent position, with a rich heritage and substantial impact on the country's GDP. Despite its importance, textile SMEs face numerous operational inefficiencies, particularly in their sewing lines, caused by delays in spare parts replacement, pneumatic and electrical system failures, and non-compliance with sewing standards. Addressing these inefficiencies is vital for improving productivity, reducing costs, and enhancing the competitiveness of textile SMEs.
This research aimed to develop a comprehensive Lean production model tailored to the specific needs of textile SMEs. The model incorporated process standardization, Total Productive Maintenance (TPM), and preventive maintenance to optimize operations. By streamlining production processes, minimizing waste, and enhancing equipment reliability, the proposed model sought to address the critical challenges faced by textile SMEs and improve overall operational efficiency.
Key results from the implementation of the Lean production model indicated significant improvements. The efficiency rate increased from 55% to 75%, the rate of reprocessed products decreased from 15% to 2%, and the on-time delivery rate improved from 90% to 97%. Additionally, the Mean Time Between Failures (MTBF) increased from 6.3 hours to 7.15 hours, while the Mean Time to Repair (MTTR) decreased from 1.3 hours to 0.75 hours. These results demonstrated the effectiveness of the proposed model in enhancing productivity and reliability.
The academic and socio-economic impacts of this research are profound. Academically, it bridges a notable gap in the literature by providing a systematic approach to implementing Lean Manufacturing and TPM in textile SMEs. Socio-economically, the improved operational efficiency can lead to increased competitiveness, job creation, and economic growth in the textile sector. This model can serve as a benchmark for other SMEs facing similar challenges, promoting broader application and adaptation of Lean principles.
In conclusion, this study highlights the urgent need for continuous improvement in the textile industry and calls for further research to explore innovative solutions. By fostering a culture of continuous improvement and leveraging Lean methodologies, textile SMEs can achieve sustainable growth and resilience in a dynamic market. Future research should focus on integrating advanced technologies to further enhance the effectiveness of Lean production models and address emerging challenges in the industry.