Application of value stream mapping to increase productivity within the textile industry

Value-stream mapping (VSM) is a useful tool for identifying waste and areas for improvement. It has emerged as a preferred method of assisting and implementing the lean approach. While lean principles are well-established and have a wide range of applications in manufacturing, their application to the textile industry is limited. Based on a case study approach, this paper describes the implementation of VSM as a lean improvement initiative in a t-shirt manufacturing company. It entails mapping the firm's current activities and identifying areas for improvement. Following several interviews with current process participants, a current state map is created to describe the existing problem areas. A future state map has been created to depict the proposed improvement action plans. Value stream" to be "all the actions (both value added, and non-value added) currently required to bring a product through the main flows essential to every product: the production flow from raw material into the arms of the customer, and the design flow from concept to launch". Taking a value stream approach means focusing on the big picture rather than individual processes. VSM establishes a common foundation for the production process, allowing for more deliberate decisions to improve the value stream. VSM is a pencil-and-paper tool that uses a predefined set of standardized icons. VSM implementation results in reduced lead time, cycle time, and resource requirements. Our findings show that the new process change can reduce total lead time from 40 days to 19 days - a 52.5% reduction in overall lead time. Keywords: VSM, lean principle, textile industry