Advertisement

Implementing Lean Production to Promote Textile and Clothing Industry Sustainability

  • Laura Costa MaiaEmail author
  • Anabela Carvalho AlvesEmail author
  • Celina Pinto LeãoEmail author
Chapter

Abstract

Traditionally, Textile and Clothing industry (TCI) is an industry that naturally consumes large amounts of natural resources (e.g. natural fibers, natural dyes, water and energy) and release chemicals into the atmosphere, water and soil. Lean Production (LP) is an organizational methodology which main key idea is “doing more with less”. A fundamental difficulty faced by the TCI stakeholders has been in finding out how to implement this methodology efficiently in a sustainable way. Concerned about this problem, a methodology to support the implementation of LP in the TCI, named PESO was developed. This methodology is based on four dimensions: People, Ergonomics, Sustainability and Operational performance (PESO). By including sustainability as a dimension to be taken into account, it is expected to develop and create a natural awareness to consume less. Today in TCI there is a growing concern with sustainability, as shown by the increase in the number of research projects related with this issue. This chapter aims to highlight these developed and developing projects to the light of the Sustainability dimension of the PESO methodology. These were analyzed and discussed to illustrate that though these do not directly address Lean, allied with it could enable sustainability of their production system and processes. This is embedded in the synergy between LP and sustainability, also entitled Lean-Green. By doing this, TCI is on the road to achieve the sustainable development goals, directly, the goal 12, responsible consumption and production.

Notes

Acknowledgements

This work has been supported by COMPETE: POCI-01-0145-FEDER-007043 and FCT—Fundação para a Ciência e Tecnologia within the Project Scope: UID/CEC/00319/2013.

References

  1. Abreu, M. F., Alves, A. C., & Moreira, F. (2016). Comparing lean-green models for eco-efficient production. In Proceedings of 29th International Conference on Efficiency, Cost, Optimisation, Simulation and Environmental Impact on Energy Systems, Portoroz.Google Scholar
  2. Abreu, M. F., Alves, A. C., & Moreira, F. (2017). Lean-green models for eco-efficient and sustainable production. Energy. Retrieved from http://doi.org/10.1016/j.energy.2017.04.016.
  3. Abreu, M. F., Alves, A. C., & Moreira, F. (2018). Lean-green synergy awareness: A Portuguese survey. In C. Vilarinho, F. Castro, & M. L. Lopes (Eds.), WASTES—Solutions, Treatments and Opportunities II: Selected Papers from the 4th Edition of the International Conference on Wastes: Solutions, Treatments (pp. 125–131). London: CRC Press/Taylor & Francis.Google Scholar
  4. Altshuller, G. (1984). Creativity as an exact science: The theory of the solution of inventive problems. Journal of Development Economics. Gordon and Breach Publishers.Google Scholar
  5. Alves, A. C., & Colombo, C. R. (2017). Introducing sustainability in engineering education curricula: An achievable outcome or a utopia? In Proceedings of the 45th SEFI Annual Conference 2017— Education Excellence for Sustainability, SEFI 2017 (pp. 95–103).Google Scholar
  6. Alves, A. C., Dinis-Carvalho, J., & Sousa, R. M. (2012). Lean production as promoter of thinkers to achieve companies’ agility. The Learning Organization, 19(3), 219–237.  https://doi.org/10.1108/09696471211219930.CrossRefGoogle Scholar
  7. Alves, A. C., Abreu, M. F., Tereso, A. P., & Ferreira, P. V. (2017). Production system configuration selection in a lean environment using analytic hierarchy process. Cellular manufacturing systems: Recent developments, analysis and case studies.Google Scholar
  8. Alves, A. C., Kahlen, F.-J., Flumerfelt, S., & Siriban-Manalang, A. B. (2014). Fostering sustainable development thinking through lean engineering education. In Volume 5: Education and Globalization (Vol. 5, p. V005T05A013). ASME. http://doi.org/10.1115/IMECE2014-38192.
  9. Alves, A., Moreira, F., Abreu, F., & Colombo, C. (2016). Sustainability, lean and eco-efficiency symbioses. In M. Peris-Ortiz, J. J. Ferreira, L. Farinha, & N. O. Fernandes (Eds.), Multiple helix ecosystems for sustainable competitiveness—Innovation, technology, and knowledge management. Cham: Springer International Publishing. http://doi.org/10.1007/978-3-319-29677-7.
  10. Alves, A. C., Dinis-Carvalho, J., Sousa, R. M., Moreira, F., & Lima, R. M. (2011). Benefits of lean management: Results from some case studies in Portugal. In CLME 2011.Google Scholar
  11. Alves, A. C., Sousa, R. M., Dinis-Carvalho, J., Lima, R. M., Moreira, F., Leão, C. P., … Fernandes, S. (2014). Final year Lean projects: Advantages for companies, students and academia. Project Approaches in Engineering Education, 1–10. Retrieved from http://hdl.handle.net/1822/30172.
  12. Arezes, P. M., Dinis-Carvalho, J., & Alves, A. C. (2015). Workplace ergonomics in lean production environments: A literature review. Work, 52(1). http://doi.org/10.3233/WOR-141941.
  13. Bhamu, J., & Sangwan, K. S. (2014). Lean Manufacturing: Literature review and research issues. International Journal of Operations & Production Management, 34(7), 876–940.CrossRefGoogle Scholar
  14. Brundtland, G. H. (1987). Our common future: Report of the world commission on environment and development. United Nations Commission, 4(1), 300.  https://doi.org/10.1080/07488008808408783.CrossRefGoogle Scholar
  15. Chalmer, C., Eder-Hansen, J., Lehmann, M., Tochtermann, T., & Tarneberg, S. (2018). CEO Agenda 2018: Seven sustainability priorities for fashion industry leaders. Retrieved from http://www.globalfashionagenda.com/global-fashion-agenda/.
  16. Chen, Z., & Xing, M. (2015). Upgrading of textile manufacturing based on Industry 4.0. In 5th International Conference on Advanced Design and Manufacturing Engineering (ICADME2015) (pp. 2143–2146).Google Scholar
  17. Colombo, C. R. (2004). Princípios Teórico-Práticos para Formação de Engenheiros Civis: em Perspectiva de uma Construção Civil voltada à Sustentabilidade. Universidade Federal de Santa Catarina.Google Scholar
  18. Colombo, C. R., Caires, S., Alves, A. C. (2017). Universidade Cidadã: Entendendo e Construindo Conceitos rumo a um Novo Paradigma de Responsabilidade Social Universitária (N. Prelo, Ed.), Porto, PT.Google Scholar
  19. Cowger, G. (2016). Half measures gets less than half results. Mechanical Engineering the Magazine of ASME, 138(1), 30–35.Google Scholar
  20. EPA United States Environmental Protection Agency. (2014). What is sustainability? Retrieved August 3, 2018, from https://www.epa.gov/sustainability/learn-about-sustainability.
  21. Esty, D., & Winston, A. (2009). Green to gold: How smart companies use environmental strategy to innovate, create value, and build competitive advantage. New Jersey: John Wiley & Sons, Inc.Google Scholar
  22. European Commission. (2016). Buying green! A handbook on green public procurement [Comprando verde! Un manual de Compras Públicas Verdes] (3rd ed.). http://doi.org/10.2779/246106.
  23. European Commission. (2018). Sustainability and circular economy. Retrieved August 3, 2018, from https://ec.europa.eu/growth/industry/sustainability_en.
  24. Found, P. A. (2009). Lean and low environmental impact manufacturing. In POMS 20th Annual Conference (vol. 11, pp. 126–130). Orlando.Google Scholar
  25. Gupta, S., & Jain, S. K. (2013). A literature review of lean manufacturing. International Journal of Management Science and Engineering Management, 8(4). http://doi.org/10.1080/17509653.2013.825074.
  26. Hodge, G. L., Goforth, K. R., Joines, J. A., & Thoney, K. (2011). Adapting lean manufacturing principles to the textile industry. Production Planning & Control, 22(3), 237–247.CrossRefGoogle Scholar
  27. Hu, Q., Mason, R., Williams, S. J., & Found, P. (2015). Lean implementation within SMEs: A literature review. Journal of Manufacturing Technology Management, 26(7), 980–1012.  https://doi.org/10.1108/JMTM-02-2014-0013.CrossRefGoogle Scholar
  28. Hussain, T., & Wahab, A. (2018). A critical review of the current water conservation practices in textile wet processing. Journal of Cleaner Production. http://doi.org/10.1016/j.jclepro.2018.07.051.
  29. INE. (2018). Exportações de janeiro crescem nos têxteis e descem no vestuário. Retrieved March 12, 2018, from https://jornal-t.pt/noticia/exportacoes-de-janeiro-crescem-nos-texteis-e-descem-no-vestuario/.
  30. Jasti, N. V. K., & Kodali, R. (2015). Lean production: Literature review and trends. International Journal of Production Research, 53(3), 867–885.  https://doi.org/10.1080/00207543.2014.937508.CrossRefGoogle Scholar
  31. Krafcik, J. F. (1988). Triumph of the lean production system. Sloan Management Review, 30(1), 41–52.Google Scholar
  32. Lehmann, M., Tarneberg, S., Tochtermann, T., Chalmer, C., Eder-Hansen, J., Seara, J. F., … Deichmann, S. (2018). Pulse of the industry fashion 2018. Retrieved from http://www.globalfashionagenda.com/global-fashion-agenda/.
  33. Liker, J. K. (2004). The toyota way: 14 management principles from the world’s greatest manufacturer. New York: McGraw-Hill.Google Scholar
  34. Liker, J., & Meier, D. (2007). Toyota talent, developing your people the toyota way. American Media International. http://doi.org/10.1036/0071477454.
  35. Maia, L. C., Alves, A. C., & Leão, C. P. (2012). Design of a lean methodology for an ergonomic and sustainable work environment in textile and garment industry. In ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE) (Vol. 3). http://doi.org/10.1115/IMECE2012-89048.
  36. Maia, L. C., Alves, A. C., & Leão, C. P. (2013a). Preparation of a textile and clothing company to lean implementation by identifying ergonomic and environmental risks. In Integrity, Reliability and Failure of Mechanical Systems (IRF2013) (pp. 1–9).Google Scholar
  37. Maia, L. C., Alves, A. C., & Leão, C. P. (2013b). Sustainable work environment with lean production in textile and clothing industry. International Journal of Industrial Engineering and Management, 4(3), 183–190.Google Scholar
  38. Maia, L. C., Alves, A. C., & Leão, C. P. (2014). Implementar o modelo de produção Lean na ITV para promover sistemas eco-eficientes. Nova Têxtil, 101, 3–10. Retrieved from http://hdl.handle.net/1822/36861.
  39. Maia, L. C., Alves, A. C., & Leão, C. P. (2018). Lean production in the Portuguese textile and clothing industry: The extent of its implementation and role. In Lean Manufacturing: Implementation, Opportunities and Challanges. Nova Science.Google Scholar
  40. Maia, L. C., Alves, A. C., Leão, C. P., & Eira, R. (2017). Validation of a methodology to implement lean production in textile and clothing industry. In ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE) (Vol. 2). http://doi.org/10.1115/IMECE2017-71464.
  41. Maia, L. C., Eira, R., Alves, A. C., & Leão, C. P. (2015) The organizational improvement as trigger for better working conditions. RISTI - Revista Iberica de Sistemas e Tecnologias de Informação, spe4, 50–65. http://dx.doi.org/10.17013/risti.e4.50-65.
  42. Monden, Y. (1998). Toyota production system: An integrated approach to just-in-time (3rd ed.). Norcross: Engineering and Management Press.Google Scholar
  43. Moreira, F., Alves, A. C., & Sousa, R. M. (2010). Towards eco-efficient lean production systems. IFIP Advances in Information and Communication Technology, AICT (Vol. 322). http://doi.org/10.1007/978-3-642-14341-0_12.
  44. Negrão, L. L. L., Godinho Filho, M., & Marodin, G. (2016). Lean practices and their effect on performance: A literature review. Production Planning & Control, 28(1), 1–24.  https://doi.org/10.1080/09537287.2016.1231853.CrossRefGoogle Scholar
  45. Neves, R. (2018). Italianos e franceses dão brilho às exportações portuguesas de têxteis e vestuário. Retrieved June 8, 2018, from https://www.jornaldenegocios.pt/empresas/industria/detalhe/franceses-e-italianos-dao-brilho-as-exportacoes-portuguesas-de-texteis-e-vestuario.
  46. OECD. (2011). Sustainable manufacturing toolkit—Seven steps to environmental excellence. http://doi.org/10.1080/136627102200003447.
  47. Ohno, T. (1988). Toyota production system: Beyond large-scale production. Portland: Productivity Press.Google Scholar
  48. Panizzolo, R., Garengo, P., Sharma, M. K., & Gore, A. (2012). Lean manufacturing in developing countries: Evidence from Indian SMEs. Production Planning and Control: The Management of Operations, 23(10–11), 769–788.CrossRefGoogle Scholar
  49. Pappas, E. (2012). A new systems approach to sustainability: University responsibility for teaching sustainability in contexts. Journal of Sustainability Education, 3, 2–18.Google Scholar
  50. Resende, V., Alves, A. C., Batista, A., & Silva, Â. (2014). Financial and human benefits of lean production in the plastic injection industry: An action research study. International Journal of Industrial Engineering and Management, 5(2), 61–75. Retrieved from http://www.scopus.com/inward/record.url?eid=2-s2.0-84909986334&partnerID=tZOtx3y1.
  51. Rothenberg, S., Pil, F. K., & Maxwell, J. (2001). Lean, green, and the quest for superior environmental performance. Production and Operations Management, 10(3), 228–243.  https://doi.org/10.1111/j.1937-5956.2001.tb00372.x.CrossRefGoogle Scholar
  52. Rotmans, J. (2006). Tools for integrated sustainability assessment: A two-track approach. The Integrated Assessment Journal, 6(4), 35–57. Retrieved from https://core.ac.uk/download/pdf/18518367.pdf.
  53. Samuel, D., Found, P., & Williams, J. S. (2015). How did the publication of the book The Machine that changed the World change management thinking? Exploring 25 Years of Lean Literature, 35(10), 1386–1407. http://doi.org/10.1108/02683940010305270.
  54. Saunders, M., Lewis, P., & Thornhill, A. (2008). Research methods for business students. http://doi.org/10.1007/s13398-014-0173-7.2.
  55. Shingo, S. (1981). Study of the Toyota production system from an industrial engineering viewpoint. New York: Productivity Press.Google Scholar
  56. Silva, C., Tantardini, M., Staudacher, A. P., & Salviano, K. (2010). Lean production implementation: A survey in Portugal and a comparison of results with Italian, UK and USA companies. In R. Sousa, C. Portela, S. S. Pinto, & H. Correia (Eds.), Proceedings of 17th International Annual EurOMA Conference—Managing Operations in Service Economics, Universidade Católica Portuguesa, 6–9 June, Porto, Portugal (pp. 1–10).Google Scholar
  57. Stone, K. B. (2012). Four decades of lean: A systematic literature review. International Journal of Lean Six Sigma, 3(2), 112–132.  https://doi.org/10.1108/20401461211243702.CrossRefGoogle Scholar
  58. Sugimori, Y., Kusunoki, K., Cho, F., & Uchikawa, S. (1977). Toyota production system and Kanban system materialization of just-in- time and respect-for-human system. International Journal of Production Research, 15(6), 553–564.  https://doi.org/10.1080/00207547708943149.CrossRefGoogle Scholar
  59. Takeuchi, H., Osono, E., & Shimizu, N. (2008, June). The contradictions that drives Toyota’s success. Harvard Business Review, 98–104.Google Scholar
  60. Tasdemir, C., & Gazo, R. (2018). A systematic literature review for better understanding of lean driven sustainability. Sustainability, 10(7), 2544.  https://doi.org/10.3390/su10072544.CrossRefGoogle Scholar
  61. The Millennium Project. (2014). The 15 global challenges. Retrieved August 3, 2018, from http://www.millennium-project.org/projects/challenges/.
  62. UNEP. (1996). Cleaner production: A training resource package. United Nations Environment Programme, Industry and Environment.Google Scholar
  63. UNEP. (2007). Life cycle management: A business guide to sustainability. United Nations Environment Programme.Google Scholar
  64. UNEP. (2009). Towards sustainable production and use of resources. International Panel for Sustainable Resource Management, United Nations Environment Programme.Google Scholar
  65. UNEP. (2011). Decoupling natural resource use and environmental impacts. International Resource Panel, United Nations Environment Programme.Google Scholar
  66. UNEP. (2015). Annual Report 2015.Google Scholar
  67. U.S.-EPA. (2007). The lean and environment toolkit. United States Environmental Protection Agency. Retrieved from http://www.epa.gov/lean/environment/toolkits/environment/resources/LeanEnviroToolkit.pdf.
  68. Verrier, B., Rose, B., Caillaud, E., & Remita, H. (2014). Combining organizational performance with sustainable development issues: The Lean and Green project benchmarking repository. Journal of Cleaner Production, 85, 83–93.Google Scholar
  69. WBCSD. (1996). Eco-efficiency and cleaner production: Charting the course to sustainability. UNEP Environment Programme.Google Scholar
  70. WBCSD. (2000). Eco-efficiency: creating more value with less impact.Google Scholar
  71. WBCSD. (2010). Vision 2050—The new agenda for business. WBCSD. http://www.wbcsd.org/web/vision2050.htm.
  72. Weisenberger, S. (2017). Sewing digital transformation into the fabric of the textiles industry. Retrieved March 29, 2018, from http://www.industryweek.com/iot-and-digitization-manufacturing.
  73. Womack, J. P., & Jones, D. T. (1996). Lean thinking: Banish waste and create wealth in your corporation (F. Press, Ed.). New York: Free Press.Google Scholar
  74. Womack, J., & Jones, D. T. (2005a). Lean Solutions: How companies and Customers can create value and wealth together. New York, USA: Siman & Schuster.Google Scholar
  75. Womack, J. P., & Jones, D. T. (2005b). Lean consumption. Harvard Business Review. Retrieved from www.hbr.org.
  76. Womack, J., Jones, D. T., & Roos, D. (1990). The machine that changed the world: The story of lean production. New York: Rawson Associates.Google Scholar
  77. Wong, Y. C., Wong, K. Y., & Ali, A. (2009). A study on lean manufacturing implementation in the malaysian electrical and electronics industry. European Journal of Scientific Research, 38(4), 521–535.Google Scholar

Copyright information

© Springer Nature Switzerland AG 2019

Authors and Affiliations

  1. 1.Department of Production and Systems, School of Engineering, ALGORITMI R&D CenterUniversity of MinhoGuimarãesPortugal

Personalised recommendations