Research Papers - Department of Mechanical Engineering
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Publication Open Access Integration of industry 4.0 technologies to overcome lean manufacturing barriers in Sri Lanka’s apparel sector(Emerald Publishing, 2026-02-09) Silva, N; Hettiarachchi, D. I; Perera, P; Perera, CPurpose – This study aims to examine how Industry 4.0 (I4.0) technologies can enable Lean Manufacturing (LM) practices in Sri Lanka’s apparel industry. Although LM has been widely adopted to improve efficiency and reduce waste, persistent barriers such as frequent product changes, limited real-time visibility and infrastructural constraints have restricted its full potential. The purpose of this research is to explore how advanced digital solutions, including Internet of Things (IoT), real-time analytics and augmented/virtual reality (AR/VR), can address these barriers and enhance the competitiveness and sustainability of apparel manufacturing in a dynamic global market. Design/methodology/approach – A qualitative single-case study design was used to provide an in-depth understanding of digital–lean integration. The research was conducted in collaboration with a leading Sri Lankan apparel manufacturer. Data were collected through on-site factory observations, semi-structured interviews with managers and employees and examination of company records. Using Yin’s (2018) case study methodology as a guiding framework, the study analyzed how selected I4.0 technologies were implemented alongside lean tools and how these interventions addressed identified operational inefficiencies. Findings – The study found that I4.0-enabled solutions significantly enhanced lean practices by improving production workflow transparency, defect detection and downtime reduction. Tools such as IoT-linked dashboards, electronic Kanban systems and automated performance monitoring minimized non-value-adding activities and reduced bottlenecks. AR/VR applications demonstrated potential for training and machine setup, while predictive maintenance improved equipment reliability. However, the research also identified persistent shortcomings, including data confidentiality issues, workforce adaptability challenges and high capital investment requirements. The findings highlight both the opportunities and practical limitations of integrating digital technologies into lean environments. Research limitations/implications – The research was limited to a single case study of a large apparel manufacturer in Sri Lanka, which constrains the generalizability of findings. Data confidentiality policies restricted access to detailed financial information, preventing quantitative analysis of productivity gains and return on investment. Future studies could extend this research by including multiple firms across varying scales and geographies, enabling comparative insights. Broader empirical studies that quantify the financial outcomes of digital–lean integration would provide further validation and support for industry-wide adoption. Practical implications – For practitioners, the study offers a roadmap for integrating I4.0 technologies with lean practices in apparel manufacturing. The evidence suggests that digital lean tools can enhance transparency, improve workflow efficiency and support more accurate decision-making. Managers should prioritize investments in IoT-enabled monitoring, predictive maintenance and digital visual management systems while addressing workforce readiness through training programs. Attention must also be given to cybersecurity and change management to ensure sustainable implementation. These findings are particularly relevant for resource-constrained firms seeking to maximize operational efficiency while navigating global competitive pressures. Social implications – The integration of I4.0 and LM in Sri Lanka’s apparel sector holds broader social benefits by safeguarding employment in a critical export industry that provides livelihoods for over 300, 000 workers. Enhanced productivity and competitiveness contribute to economic stability and foreign exchange earnings. Moreover, digital lean practices can reduce waste, contributing to environmental sustainability and aligning with global sustainable development goals. By strengthening the resilience of the apparel sector, these advancements can help sustain jobs and improve working conditions, particularly in developing country contexts where apparel remains a cornerstone of industrial growth. Originality/value – This study provides one of the first in-depth examinations of how I4.0 technologies can act as enablers of LM in the Sri Lankan apparel industry. Unlike prior studies that treat lean and digital transformation as separate trajectories, this research highlights their synergies and tradeoffs in practice. By capturing both the benefits and shortcomings of digital lean tools, the paper contributes to theory by extending understanding of lean–I4.0 integration in emerging economy contexts. It also offers practical value by providing industry-specific insights that can inform managers’ strategic decisions on digital transformation.Publication Embargo Reviewing the Economics of Using LPG Vs. Electricity for Household Cooking in Sri Lanka(IEEE, 2020-11-16) Jayasekara, S; Fernando, Y. SCooking is an essential activity in the households in Sri Lanka. Sri Lankan households utilize several types of fuel to produce heat for their daily cooking needs. The most commonly used energy sources are Liquid Petroleum Gas (LPG) and Electricity. Therefore, it is essential to investigate the economic aspects of using each of these energy sources. This research aims to use existing data on several cooking appliances along with LPG and Electricity charges in Sri Lanka to calculate the costs of using each of the energy sources. With the total monthly cost of LPG at Rs.560/= and Electricity at Rs.1150/= as of March 2020, this study suggests that LPG is the most suitable energy source for cooking in Sri Lankan households.Publication Embargo The Potential Role of Carbon Tax in Achieving the Paris Agreement Targets for a Developing Country: A Case Study of Sri Lanka(IEEE, 2020-10-20) Fernando, G. L; Liyanage, M. HThis study assess the effect of carbon taxes on energy and emissions of the Sri Lankan energy sector during 2015-2050. Along with a Business As Usual (BAU) scenario, three alternative carbon price trajectories were considered. These scenarios have been proposed based on fifth Shared Socioeconomic Pathway (SSP5) to achieve the 2°C Paris target for Asia. The Carbon Price trajectories proposed by AIM/CGA, REMIND-MAgPIE and GCAM were considered. The energy-economic-environmental system was modelled using the AIM/Enduse model. It considered both energy supply and demand sectors. The results show that in the BAU scenario the GHG emissions are expected to increase from 19.8MtCO 2e in 2015to 106.2MtCO 2e in 2050. Out of three carbon tax scenarios the prices proposed by AIM/CGA has been the most efficient for reduction of GHG emissions as it could reduce final energy consumption by 26% and GHG emissions by 24% in 2050 as compared to BAU scenario.Publication Embargo Economic Viability of Solar PV for Domestic Applications in a Middle-Income Country: A case Study of Sri Lanka(IEEE, 2020-10-20) Wijesinghe, J. K; Najim, M. Y. M; Fernando, G. L; Liyanage, M. HThis study focuses on the economics of using solar Photovoltaics for residential in a middle-income country like Sri Lanka. It considers solar irradiance in the Colombo district to estimate the power generation potential by a selected 2.16kWp solar PV system throughout the year. It used solar irradiance data by NASA Surface Meteorology and Solar Energy (SSE), satellite solar insolation values for Sri Lanka and used the Liu and Jordan (LJ) method. Furthermore, it considered the economics of four different scenarios as model houses depending on appliance usage with net accounting. It was seen that without net accounting the Levelized cost of electricity could be as high as US0.69/kWh.However,withmechanismslikenetaccounting,itcouldbereducedtoUS 0.12 /kWh with full owners' contribution. Under the net accounting scheme houses that consume above 300 kWh/month will have the lowest payback period of 2 years and 9 months.Publication Open Access Readiness for" Social Learning Management System"(Social LMS) in Sri Lankan Universities: A case study research based on the students' perspectives.(International Journal of Advanced Studies in Computers, Science and Engineering, 2018-11-30) Gunawardhana, D. N. T; Perera, H. S. CPaper discusses the readiness for the Social Learning Management System in Sri Lankan Universities. The main objective of the study, was to identify the factors to be reconsidered in the existing Learning Management Systems. This is a multiple case study research based on two universities in Sri Lanka. Undergraduate students in the University of Colombo and the University of Moratuwa were included in the population and the sample method employed for the data collection in this research was Stratified Purposive Sampling. Learning Management System has become a support system of vital importance in higher education. Social Learning Management System is formed because of the Collaborative Learning methods in an online learning environment. The findings reveal that the willingness of undergraduate students to work in the social network environment for learning and grouping. The Social Learning Management System is a new concept and it has not yet been initiated in universities in Sri Lanka. The students’ responses have indirectly shown the importance of 'Social LMS'. That is, they have been explaining the features of 'Social LMS' in their responses. They have discussed the functionality of ‘Social LMS’ pointing out the lack of collaborative learning environment of existing LMS. The research has discovered that students already possess the mental and knowledge readiness towards the building of Social Learning Management System in Universities of Sri Lanka.Publication Open Access Technology Assessment of Herbal Products Industry in Sri Lanka(SSRN, 2021-06-29) Silva, N; Perera, H. S. C; Perera, L. C. D.TProduction of herbal product is not only a local business but also has global market opportunities. Therefore manufacturing with proven quality and consistency is an important aspect. The manufacturers should gain technological competence to ensure authenticity and efficacy, complying the quality and safety regulations, enhanced productivity and efficiency. In the competitive market environment technology assessment is a tool which can be used in projecting future trajectories of technology as well as current performance level of the organization. Out of the available models and frameworks for technological assessments, this study has used inputs from two models namely, the Technology Audit Model by Garcea – Areola and Outline of Innovation Management Audit by Tidd et al. these inputs have been used to develop a single model that can be effectively adaptable to herbal products industry. There are two main objectives of the study. Firstly, develop a model which includes guide lines for technology assessment of the herbal products industry in Sri Lanka. Secondly, assessment of the level of technology position of LNP Ltd using the model and presenting recommendations for future improvements. To accomplish the objectives, the study has identified five broad areas of technology, namely Technological Environment, Technological Strategy, Innovations and Technology Development, Technology Component and Technology Transfer, against which the LNP Ltd has been analyzed. A check sheet to cover these elements has been used to guide through the assessment process. The elements using a three of the point scale ranging from High to Low (High -3, Low-1). The score of 3 for each element will represent the industry standard practice against which the other practices are measured.Publication Open 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, DLean 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.Publication Embargo 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. CLean 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.Publication Open Access Passive techniques for residential buildings in low altitudes of Sri Lanka(Institution of engineers: Colombo, 1999) Jayasinghe, M.T.R; Attalage, R. AThe role of passive techniques, which utilises a certain number of passive elements to maintain the thermal comfort within the built environments of residential buildings at low atlitudes of Sri Lanka, has been highlighted. The possibility of defining a unique neutral temperature of 26°C for low altitutes of Sri Lanka has been utilised in a rational way in presenting simplified set of rules of thumb, that can be used by the designers at early stages. The effects of orientation, shading devices, window sizes, roofing materials, insulation, colour of the exterior and interior walls, use of courtyards to maximise natural ventilation, and arrangement of roof to minimise structural cooling are shown with suitable examples.Publication Embargo Analysis of household cooking energy demand and its environmental impact in Sri Lanka(Pergamon, 2002-11-01) Attalage, R. A; Wijayatunga, Priyantha DCThis paper presents the results and analysis of a study conducted with the objective of investigating the cooking energy requirements in the Sri Lanka domestic sector and the environmental emissions associated with it. The study was conducted out through a sample and showed that the main household energy supply sources were biomass, liquefied petroleum gas (LPG), electricity and kerosene with electricity being used largely for water boiling in all subsectors. It was observed that the urban sector cooking is largely dominated by LPG (95% of urban households) while the rural sector cooking is confined mainly to biomass (95% of rural households). The suburban sector consists of a mixture of all the sources (LPG-70% and biomass-85% of suburban households). Similarly, LPG dominates in electrified households (76.4% of electrified households), while biomass dominates in all non-electrified households. It was found in the analysis that the highest level of gaseous emissions due to cooking activity occurs in the rural areas, mainly due to the relatively large use of biomass, while the lowest level of emissions is recorded in a typical suburban household. Also, the analysis shows that fuel switching in domestic cooking activities from biomass to LPG and kerosene can be used as a measure to reduce emissions due to higher stove efficiencies and lower emission factors associated with these fuels. Substitution of 50% of biomass usage by kerosene in the rural households will result in 39–50% reduction in emissions within the rural sector. Further, substitution of 50% of biomass usage in urban and suburban sectors by LPG results in 4–49% reduction in emissions within these sectors.