Abstract

This research explored the implementation of lean manufacturing practices in textile sector of Pakistan. Survey method was used to collect data from a sample of textile companies. The respondents comprised the managers of quality, production, and lean departments. The results of the study show that the textile sector is at the beginning stage of lean implementation. It lacks understanding of lean philosophy and concepts. More than half of the surveyed companies are in-transition to implement lean. The most important driver to implement lean practices 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 the cost reduction to be the biggest benefit that can be achieved by implementing lean, followed by customer satisfaction, and improved delivery time. Among process and equipment tools and techniques 5S, quality control circles, kaizen and SMED are used extensively. Manufacturing planning and control and related tools are still strangers. Human resource related factors like team effort and specialized and cross-functional training were perceived to be crucial to effectively implement lean. Lean production practices have a significant relationship with the size and the type of textile company and no relationship with the age of the company. Lack of awareness to implement lean, company culture, lack of communication, and employee resistance are the main barriers faced by the sample companies during the implementation of lean manufacturing.