Sustainable Lean Approach in the Apparel Industry Validated through Discrete Event Simulation

Project Details

• Student(s): Gabriel Bared, Nour El Chaar, Amal Knaifati, Samer Nasr, Peter Younan
• Advisor(s): Dr. Marc Haddad
• Department: Industrial & Mechanical
• Academic Year(s): 2024-2025

Abstract

The Lebanese apparel industry faces challenges from an unsteady national economy, high production costs, and reliance on imported materials and goods. Lean manufacturing is highly effective in optimizing process efficiency and reducing waste. However, most lean validation studies in the apparel sector have lacked robust methodologies. This research addresses this gap by exploring the application of Discrete Event Simulation (DES) to assess lean interventions within a Lebanese apparel firm. The current production state was mapped using Value Stream Mapping (VSM) to identify inefficiencies, such as excess Work-In-Process (WIP) inventories, long lead times, and scheduling limitations. Proposed lean interventions, including batch size reduction, supermarket systems, Kanban scheduling, and the 6S methodology, were integrated into the DES model. These interventions demonstrated significant improvements in key performance indicators, such as reduced WIP levels, shorter cycle times, and enhanced production flow. This study highlights the synergy between lean principles and simulation, providing manufacturers with data-driven tools to implement sustainable, long-term solutions. By quantifying the impact of lean strategies in a simulated environment, this work advances sustainable practices in the apparel industry while addressing its unique operational complexities.