Lean Implementation in a Light Industry Factory

Initial Context:

The factory faced unique challenges:

• seasonal collections (autumn–winter, spring–summer) with extremely short product lifecycles – often only 2–3 weeks.
• high product variety (high mix) combined with low volumes per model (low volume).
• strict requirements for quality, finishing and traceability.

In this context, applying Lean principles became crucial to maintain efficiency, quality and profitability.

Identified Challenges:

• complex production preparation: technology and work instructions, equipment, lines, and operators all needed to be ready for frequent changes between different models.
• long setup and changeover times when switching from one product to another.
• large material inventories due to high supply risk and MOQ (minimum order quantity) constraints.
• repeated defects caused by the difficulty of applying standardization.
• lack of visibility over progress, as visual management had not been in the focus.

Activities Conducted

• gaining a detailed understanding of the situation and the action plan.
• discussions with Top Management and evaluation of factory processes.
• designing and implementing a Lean production system, adapted to the requirements:
• training personnel involved in implementing and maintaining the system.
• implementing a Lean-type production system in the manufacturing processes related to deliveries (performance measurement, staff involvement, process improvement activities, 5S, SMED, standardization, flow optimization through VSM, training and increasing flexibility of direct personnel).
• reducing quality issues, starting with customer complaints.
• creating visual work instructions and sample parts to allow operators to switch quickly from one model to another without major productivity losses.
• increasing workforce efficiency and equipment effectiveness (OEE) by accelerating the learning curve.
• reducing maintenance issues through optimized preventive maintenance.
• implementing the system in the agreed pilot area.

Tangible Benefits for the Client:

• production preparation time reduced by 30%.
• ramp-up time for new products has reduced by 70%.
• optimized material flows reduced unnecessary movements by approximately 7000 km per year.
• improved quality through standardization of core processes and error reduction – rejection rate decreased by 75%.
• on-time deliveries and compliant products, strengthening the brand’s reputation.