Factors Affecting Successful Implementation of Lean Manufacturing Tools and Techniques in the Apparel Industry in Sri Lanka

Abstract

Lean Manufacturing is a business strategy which was originated and developed in Toyota Motor Company, Japan. It is useful in identifying waste associated with processes. As a result companies can improve their productivity and quality and can achieve a competitive advantage over others. Lean Manufacturing was originated in automotive industry and then later on spread to many other industries in both developed and developing countries. In implementing this concept Toyota has introduced and developed many tools and techniques which can be used effectively.In Sri Lanka, apparel sector is the leader in implementing Lean Manufacturing. However a little research work is carried out in regarding its suitability. Therefore in order to fill this empirical gap, this research is an attempt to identify factors such as suitable methods of implementation, order of implementation, challenges, how to overcome those challenges and benefits of implementing Lean Manufacturing concepts in the apparel sector of Sri Lanka.The study first undertook literature review in the field of Lean Manufacturing. Then it developed broader research questions and administered them to fifteen apparel manufacturers in Sri Lanka using personal interviews and observations methods. The sample firms were selected judgmentally. In analyzing the data descriptive statistics and qualitative techniques were used. The result of the study revealed factors such as implementation strategies, order of implementation, challenges, how to overcome those challenges and benefits have influenced the successful implementation of Lean Manufacturing in mass production apparel industry. Since Lean is new to most of the Sri Lankan apparel manufacturers, the full benefit is not yet achieved. But current situation suggests that the industry can go forward with Lean.