The role of process monitoring devices and digital line balancing in achieving operational excellence in garment manufacturing

This study investigates the transformative potential of integrating digital technologies with lean manufacturing principles to address the evolving challenges in the garment industry. The industry demands high-quality products, rapid delivery, cost efficiency, and production flexibility to maintain competitiveness and sustainability. While traditional lean methods have focused on waste reduction and process optimization, the advent of digitalization offers unprecedented opportunities for enhancing operational excellence. This research specifically examines the role of Internet of Things-based Process Monitoring Devices (PMDs) and digital line balancing in achieving these goals. PMDs, integrated within a digital lean framework, facilitate continuous monitoring of machine performance and operator efficiency, providing real-time insights into operational processes. This real-time visibility enables data-driven decision-making and centralized analysis, fostering agility and responsiveness. Furthermore, this study presents a dynamic digital line balancing algorithm that optimizes sewing line configurations and workload distribution. This dynamic approach allows for real-time adaptations in production flows to mitigate bottlenecks and boost productivity. By exploring the synergistic relationship between PMDs, digital line balancing, and lean principles, this paper contributes to a comprehensive understanding of how digital solutions can revolutionize operational efficiency in the garment manufacturing sector.