Abstract

The textile and clothing sector remains the backbone of Bangladesh’s economy, with the ready-made garment (RMG) industry serving as its dominant export driver. Despite rapid global expansion and sustained competitiveness, RMG production continues to suffer from long changeover times, frequent style variations, and limited standardization—factors that constrain productivity and elevate operational costs. While lean tools such as 5S, Kaizen, and Just-in-Time are widely practiced, the Single-Minute Exchange of Dies (SMED) methodology remains underutilized in apparel manufacturing, despite its proven ability to minimize setup time and improve flexibility. This study develops and validates a structured SMED framework tailored to the dynamic conditions of the RMG industry. The framework integrates lean principles with strategies for handling fabric-specific setups, frequent style changes, and multi-machine operations. Furthermore, it explores the potential of aligning SMED with emerging Industry technologies, including monitoring and real-time analytics. Empirical validation demonstrates that the proposed framework significantly enhances key performance indicators (KPIs) such as setup-time reduction, overall equipment effectiveness, and production responsiveness. The findings highlight how adapting SMED to garments production not only reduces operational inefficiencies but also strengthens global competitiveness, offering a scalable pathway for digital-lean transformation in the RMG sector.

Keywords: SMED, Lean Manufacturing, Apparel Production, Setup Time Reduction, Key Performance Indicators (KPIs), Overall Equipment Effectiveness (OEE), Productivity Improvement, Operational Efficiency.