Synergy of Lean Tools to Optimize Operational Efficiency in Textile SMEs

Espinoza N.J.S.; Saboya K.N.C.; Tuesta F.M.; Pinzón-Hoyos F. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260686

Resumen

The Peruvian textile industry, which represents 7.3% of manufacturing GDP and generates 65 million jobs, faces critical competitiveness challenges due to operational inefficiencies. The jacket manufacturer analyzed generates losses of 8.10% of its annual revenue due to its efficiency of 69.72%, which is 5.48 percentage points below the sectoral benchmark of 75.20%. We present an integrated model that combines four Lean tools: Standardized Work, Poka-Yoke with elements of Industry 4.0, SMED, and Centerline. The model parameters are calibrated based on peer-reviewed empirical studies and validated through Monte Carlo simulation (10,000 replications) [6-8,12,18]. Contributions include the systemic integration of multiple root causes, accessible digitization via QR codes and tablets for SME environments with high employee turnover, and simulation-based validation. The results show that the investment of USD 24,760 will result in annual savings of USD 4,650 ± 420 over 246 days of implementation, while efficiency will increase to 74.3% ± 1.2% (95% CI: 72.1-76.5%), defects will decrease from 17.5% to 5.1% ± 0.8%, and setup time will decrease from 31 to 16.8 ± 1.3 minutes.

Instituciones: Universidad Peruana de Ciencias Aplicadas