Research Publications

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Subject: search.filters.subject.Apparel industry

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Now showing 1 - 4 of 4
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    PublicationOpen 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, C
    Purpose – 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.
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    ItemEmbargo
    Threading the digital needle: the influence of process and technical digitalisation on competitive performance in the apparel supply chain
    (Emerald Publishing, 2025) Susitha, E; Jayarathne, P.G.S. A; Herath, R
    Purpose – This study aims to examine the role of process and technical digitalisation in enhancing the apparel supply chain’s competitive performance. This study further explores how firm size moderates these relationships, offering operational-level insights into the strategic deployment of digital capabilities. Design/methodology/approach – A cross-sectional quantitative design was adopted, drawing on responses from 239 apparel industry practitioners. This study used structural equation modelling and multi-group analysis to validate the measurement model and test structural relationships, including moderation effects based on organisational size. Findings – Both process and technical digitalisation significantly enhance competitive performance, with technical digitalisation exhibiting a more potent effect. The findings indicate that process digitalisation benefits larger firms, while technical digitalisation influence remains consistent across different firm sizes. According to the findings, a differential effect of digitalisation types depends on the firm’s operational capacity and scale. Research limitations/implications – This study clarifies how digital technologies create value in supply chain performance. Technical digitalisation benefits all firms, but process digitalisation yields greater gains in larger, more resource-rich firms. Originality/value – This study integrates three perspectives to provide a refined lens for understanding the deployment of digital capabilities in supply chains. This study also contributes to the domain by investigating the effects of technical and process digitalisation on competitive performance in the apparel supply chain. The study offers a validated measurement framework and empirical evidence of how digital transformation drivers vary across organisations.
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    PublicationOpen Access
    Employee Happiness Heals the Turnover Intention: A Study of the Machine Operators of a Leading Apparel Company in Sri Lanka
    (researchgate.net, 2022-03-08) Weerarathna, R. S; Somawardana, W. S. D; Weerasinghe, W. A. P. D
    Happiness is a highly valued goal for most inhabitants as identified in most cultures. Feeling fulfilled is essential to social existence, and most people appear to be fairly content most of the time. A high rate of turnover among employees signals a major weakness in achieving organization's goals. This is because employees are the key players in determining organizational performance and survival. In ABC Apparel Company, it was identified that the employees who were machine operators' position have resigned frequently due to several reasons related to work. As a result of preliminary research, researchers identified several factors that make employees unhappy resulting in intention to leave their job. The main objective of the study was to find the impact of employee happiness on turnover intention. The research study was conducted in ninety (90) samples using simple random sampling among five hundred sixty (560) employees in the machine operator position. A selfadministered questionnaire was distributed randomly to a sample of ninety (90) employees who were in the machine operator position used in this study, and data was collected accordingly. Findings proved that employee happiness impact on turnover intention and a relationship exists between employee happiness and turnover intention. The importance of having employees happy within an organization was highlighted from this study
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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.