Lean Manufacturing Implementation in Textile Dyeing: A Study of Process Optimization and Waste Reduction in a Peruvian SME
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International Journal of Recent Engineering Science (IJRES) |  |
| © 2025 by IJRES Journal | ||
| Volume-12 Issue-3 |
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| Year of Publication : 2025 | ||
| Authors : Casey Camila Aguilar-Landaeta, Jesicca Karla García-Saona, Richard Nicholas Meza-Ortiz |
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| DOI : 10.14445/23497157/IJRES-V12I3P105 |
How to Cite?
Casey Camila Aguilar-Landaeta, Jesicca Karla García-Saona, Richard Nicholas Meza-Ortiz, "Lean Manufacturing Implementation in Textile Dyeing: A Study of Process Optimization and Waste Reduction in a Peruvian SME," International Journal of Recent Engineering Science, vol. 12, no. 3, pp. 35-46, 2025. Crossref, https://doi.org/10.14445/23497157/IJRES-V12I3P105
Abstract
The textile dyeing industry in Peru faces persistent inefficiencies related to machine stoppages, rework, and inventory mismanagement, which impact productivity and competitiveness. Previous studies have demonstrated the potential of Lean Manufacturing tools, such as 5S, Kanban, and Just-In-Time (JIT), to optimize processes and reduce waste. This research addressed these challenges by designing and implementing a Lean-based production model in the dyeing section of a Peruvian textile company. The model focused on standardizing work processes, optimizing workspace layout, and enhancing material flow through Kanban and JIT. The results showed a 12% improvement in operational efficiency, a 39% reduction in rework hours for shade adjustments, and a 21% decrease in color deviation hours. Additionally, recipe delivery delays were reduced by 52%, minimizing machine stoppages and enhancing production continuity. These findings validate the effectiveness of Lean methodologies in textile dyeing, suggesting further exploration of Lean applications in other stages of textile production to achieve broader operational improvements.
Keywords
Lean Manufacturing, Textile Dyeing, Process Optimization, Waste Reduction, Kanban System, Operational Efficiency.
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