Lean Manufacturing Implementation for Waste Reduction and Efficiency Improvement in Textile Production: A Case Study of Polanco Fashion International

Abstract

This project proposes a Lean Manufacturing implementation framework for Polanco Fashion International, a textile manufacturer in La Vega, Dominican Republic, facing challenges with production inefficiencies, high defect rates, and substantial waste. Currently, waste levels exceed 20%, with quality checks lacking standardized processes, resulting in inconsistent product quality and delivery delays. The proposed Lean Manufacturing approach integrates key tools such as Value Stream Mapping (VSM), 5S, and visual control, aiming to streamline production workflows and minimize waste. A Value Stream Map revealed a total lead time of 27.5 days and process efficiency issues, suggesting a 26% lead time reduction potential through targeted improvements. The 5S methodology addresses workspace organization and cleanliness in the cutting, sorting, and sewing areas, projecting a 15% productivity increase by reducing downtime due to disorganization. Visual control tools, such as pre-production checklists, are introduced to ensure material availability, reducing idle time and rework due to incomplete components. With an initial investment of $13,168, this Lean strategy is expected to reduce waste by 20%, enhance process flow, and cut rework costs, achieving a 12% overall reduction in operational expenses. Benefits are anticipated within six months of implementation, with a projected net gain of approximately $2,991,121 over a three-year horizon, establishing a feasible and replicable model for quality and efficiency in the Dominican Republic's textile sector.