Lean manufacturing and quality tools: the role of employee involvement in process improvement applied in a Brazilian clothing industry

Purpose Regardless of the company sector, if productivity tools are not implemented systematically and with employee involvement, management systems will not be sustainable. This study aims to evaluate the impact of employee involvement in the implementation of quality and lean manufacturing tools to improve production processes in the clothing industry. Design/methodology/approach The methodology began with a literature review of clothing industries that applied quality and lean manufacturing tools. Next, action research was conducted in a Brazilian company, mapping the production process with a flowchart and Pareto chart to identify defects in the t-shirt cutting sector. The light signal tool (andon) was then applied to visually expose quality problems, followed by brainstorming, kaizen and kata. Findings The results showed that integrating people into management systems reduced seams in the knitting process by 77% during January and February 2024. Additional improvements included the implementation of training programs. Practical implications Specific interventions, particularly training strategies, are crucial for performance improvement. Transfer of learning and feedback were strengthened by applying Japanese techniques such as kaizen, quality meetings and visual management practices. Originality/value Literature on the integrated application of lean and quality tools remains limited in the clothing industry. This study reinforces the importance of involving employees in process improvements. The diagnosis of quality problems in the knitting sector can serve as a benchmark for other companies seeking continuous productivity gains.