Research Papers - Department of Mechanical Engineering

Permanent URI for this collectionhttps://rda.sliit.lk/handle/123456789/604

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Author: search.filters.author.Perera, H. S. CSubject: search.filters.subject.Lean Manufacturing

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Now showing 1 - 3 of 3
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    PublicationOpen Access
    Factors affecting successful implementation of lean manufacturing tools and techniques in the apparel industry in Sri Lanka
    (SSRN, 2011-04-27) Silva, N; Perera, H. S. C; Samarasinghe, D
    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.
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    PublicationEmbargo
    Viability of lean manufacturing tools and techniques in the apparel industry in Sri Lanka
    (Trans Tech Publications Ltd, 2012) Silva, S. K. P. N; Samarasinghe, G. D; Perera, H. S. C
    Lean Manufacturing can be considered as a business strategy which was originated and developed in Japan. It tries to identify waste and eliminate it. Thus it leads to improvement in productivity and quality and companies can achieve a competitive advantage over others. Sri Lankan industries, especially apparel sector have attempted to implement this, but a little research work is carried out in regarding its suitability. This research is an attempt to identify a suitable Lean model for the apparel industry in Sri Lanka. As the initial stage of this study, a literature review is carried out to study about the Lean Manufacturing. It starts by looking at how Lean Manufacturing first began. Then it seeks to identify the core principles, tools and techniques and how those tools and techniques are currently being used worldwide. After studying the global scenario the next step is to look at the Sri Lankan context using real world data. This was undertaken by means of structured surveys, observations, and on site interviews. Also the study will reveal period of Lean implementation, suitable implementation methods, order of implementation, tools which are avoided, sustainability of different tools, challenges faced, ways of overcoming challenges and benefits achieved after applying Lean Manufacturing concepts in the apparel sector of Sri Lanka. The findings state Lean Manufacturing can be applied to mass production apparel industries and has created a positive mindset on employees. As implementation of Lean concepts is still in developmental stage, the full benefit is not yet achieved. But current situation suggests that the industry can go forward with Lean and capitalize on its full potential. In this research the authors have proposed a model which can be used to implement Lean in a systematic manner and each manufacturer must develop their own Lean system through training, experiments, employee empowerment, right leadership and kaizen mindset. Originality of the research— The research builds up a Lean Model which is not yet developed for the apparel sector in Sri Lanka. It can be further modified to suit the global apparel industry and other industries as well.
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    PublicationEmbargo
    Developing a performance measurement system for apparel sector lean manufacturing organizations in Sri Lanka
    (Sage Publications, 2013-12) Perera, P. S. T; Perera, H. S. C
    Performance measurements systems were rarely adapted to changing manufacturing environments. Lean is one such practice aiming at productivity improvements. Non-cost performance improvements resulting from lean makes the inadequacy of traditional measurements for evaluating performance. Sri Lankan apparel manufacturers adapt lean manufacturing to meet global business challenges. However a study has not been done to develop an appropriate performance measurement system for lean environment in Sri Lankan apparel sector lean practicing companies. This study develops such a model from literature review and interview. Finally it is validated with the existing models.