Evaluating the Role of Lean Manufacturing in Reducing Production Costs and Enhancing Efficiency in Textile Mills

Lean manufacturing has become a widely adopted strategy for improving operational efficiency and reducing waste in manufacturing sectors worldwide. However, its implementation within textile mills particularly in regions reliant on conventional and labor-intensive processes has been slower and less systematic. This study evaluates the role of lean manufacturing in reducing production costs and enhancing operational performance in textile mills, focusing on both large-scale and medium-sized facilities. The research applies a mixed-method approach combining case studies, field observations, employee interviews, and process data analysis from multiple textile production units. Key lean tools analyzed include 5S (workplace organization), Value Stream Mapping (VSM), Kaizen (continuous improvement), Kanban (visual workflow), and Just-in-Time (JIT) production. The findings indicate that when properly implemented, lean manufacturing contributes to significant cost savings, minimizes material waste, and improves machine utilization and labor productivity. Several mills recorded cycle time reductions of 15-30%, while defect rates declined by up to 40%, leading to measurable quality gains. Despite these benefits, the research also highlights critical challenges such as organizational resistance to change, lack of lean training, and difficulty sustaining continuous improvement initiatives over time. Based on these insights, the paper presents a structured lean implementation roadmap tailored for textile manufacturing, complete with KPIs and phased deployment strategies. This study contributes to the limited empirical literature on lean application in the textile sector and offers actionable strategies for mill managers, policymakers, and industry stakeholders seeking to modernize textile production through lean principles.