Enhancing operational efficiency in resource-constrained apparel SMEs through simulation-based process standardisation

This study examines Discrete Event Simulation as a strategic tool for operational optimisation in small and medium-sized textile enterprises, focusing on a women's boxer shorts production line. It addresses common inefficiencies in resource-constrained, high-variability environments: task fragmentation, unbalanced workloads, and excessive cycle-time variability. A validated simulation model was built in Arena® software using time and motion studies, probability distribution fitting, and field data. Two improvement scenarios were tested: (1) adding auxiliary labour at bottleneck stations, and (2) standardising operating procedures to reduce both mean processing time and cycle-time variability of critical operations. Scenario 1 yielded negligible throughput gains, whereas Scenario 2 increased average shift production by 31.7% over the simulated baseline of 398 pieces/shift (+26.5% versus the observed 414 pieces/shift), while reducing variability and improving stability. Statistical significance was confirmed via ANOVA (30 replications per scenario, p < 0.05) with Tukey's test, and model validity by deviation within ±4% of real performance. The standardisation strategy is also expected to yield sustainability benefits, raising good-quality output from existing capacity and reducing waste, though these effects are inferred, not directly measured, and left to future work. Overall, results highlight simulation's value for improving efficiency and competitiveness in modular textile manufacturing without major capital investment.