A Proposed Model for Productivity Improvement by Implementation of Lean Manufacturing Techniques in a Textile Industry

The development of the textile sector in India has experienced significant growth in recent years, becoming one of the main economic activities of the textile-industrial sector in south India. Many organisations face new competition and macroeconomic conditions in the current textile manufacturing scenario. Lean manufacturing system adoption is increasing due to the industry’s challenges in this swiftly changing world. Lean manufacturing makes an organisation more flexible and adaptable as change occurs. More than ten per cent of Non-Value-Added Activities (NVA) from the total production of an organisation direct to loss. The main task of lean manufacturing is to maximise resource utilisation by minimising unwanted waste. This research aims to reduce waste by executing different lean techniques after adequately studying the current process. The lean execution in the textile industry is minimal, and different existing studies identify the research gap in implementing a sequence of lean elements in a selected industry. Implementing the proposed layout reduces the cycle time from 472 seconds to 438 seconds, and operator movement for the industry is reduced from 153 feet to 117 feet. After the proper execution of various lean techniques, it was observed that the overall productivity increased by 4.84%.