Evaluating 5S implementation and challenges in garment manufacturing units: a study in Tiruppur district

Purpose This paper aims to evaluate the current status of 5S implementation with special reference to garment manufacturing units in the Tiruppur district and helps manufacturers identify the primary challenges to successfully implementing 5S. Overcoming these challenges can significantly reduce wastage and enhance productivity through successful 5S implementation. Design/methodology/approach This research study was conducted in garment manufacturing units in the Tiruppur district that have partially or fully implemented 5S principles. A detailed questionnaire was designed to explore the levels of 5S implementation and the challenges faced during and after 5S implementation. Findings The empirical results of this study revealed that around 55% of the organizations had implemented the 5S principles in their manufacturing units, but the implementation was only partial. This study also revealed that financial constraints, insufficient training and lack of top-level management support are the major challenges that lead to partial implementation. This study highlights the need for enhanced resource allocation, cultural change and 5S training for successful and sustained implementation of 5S principles. Research limitations/implications The garment manufacturing units operate in a VUCA world. They need to compete with global giants in the export market and customer expectations have also increased in terms of cost, quality and lead times. Therefore, the successful implementation of 5S helps garment manufacturers to reduce waste which leads to reduced cost of production, lead time and increased efficiency. Originality/value To the best of the authors’ knowledge, this is the first quantitative examination of 5S implementation in Tiruppur which is India’s largest knitwear export cluster. Unlike previous research in Bangladesh and Pakistan, it statistically analyzes how training, familiarity with 5S and education influence 5S adoption across 102 garment units which offers new empirical evidence for the Indian Textile Industry.