Applications of lean manufacturing in the textile garments industry

The textile and garments industry (TGI) hold a vital position in the global economy, ranking as the third-largest manufacturing sector and contributing approximately 6.4% to global GDP, yet it is also recognized as the second-largest source of global pollution. Despite its economic importance, the industry faces persistent challenges such as intense competition, the rise of fast fashion, and various operational inefficiencies, including long production lead times (typically 90–120 days), high defect and rework rates, and excessive inventory. Moreover, slow returns on investment (ROI) and inadequate waste management systems continue to hinder the shift toward sustainable production practices. To address these challenges, Lean Manufacturing (LM) implementation in textile and garment operations and discusses how Lean tools are applied to reduce non–value-added activities and improve flow, quality, and responsiveness. Empirical evidence highlights the measurable benefits of Lean implementation in textile operations, where the application of tools such as Value Stream Mapping (VSM), 5S, and cellular manufacturing has increased production output by 17.8%, improved efficiency by 12.46%, reduced defect rates (e.g., from 12.7% to 6.71% in cutting processes), and shortened lead times by up to 80%. Furthermore, Lean Six Sigma (LSS) projects have achieved significant economic impacts, with documented annual cost savings of approximately $577,000 in some cases. Thus, the successful implementation of LM is essential for the competitiveness and long-term sustainability of textile and garment enterprises, requiring its integration with emerging digital technologies and the development of supportive financial and policy frameworks to overcome barriers such as slow ROI.