Effectiveness of lean manufacturing layout of a firm within the apparel industry of sri lanka: a case study

Abstract

The study is based on Sri Lankan apparel manufacturer ABC and its SBU of Best Clothing to identify the effectiveness of a lean layout. Apparel export industry is the most important and dynamic contributor to Sri Lanka’s economy. The share of the world market clothes and its share of exports of Sri Lanka are steadily losing since 2000. The imports to US from Sri Lanka have reduced by 1 % in 2015. The time has come for Sri Lanka to look beyond the ordinary clothes and move from low -cost strategy. Retailers are demanding more on increasing for short lead times, to meet the customer demand. They prefer in maintaining a low inventory, material just in time at a low cost as to reduce the tax and increasing interest rates. Effective facility layout design reduces manufacturing lead time, increases the quantity and efficiency of the plant. In today’s society no style longs for more than a week. Four fashion seasons namely spring, summer, fall, winter is blending out 52 "micro-seasons" per year. For a style changeover, an effective layout is set to reduce the loss in efficiency because it will minimize the changeover time by developing multi skilled employees and easy changeover of machines with the size of the layout. Therefore, the findings of this research show that there are two aspects that must be fulfilled for a lean layout to be effective. They are better organizational performance and contented employees. The organizational performance was measured using quality, speed, flexibility, dependability and cost. The employee contentment was measured using safety and ergonomics, income generated, relationship and support received from superiors, peers and supporting department, opportunity for skill development and career growth.