The research develops and applies an integrated methodology for creating a Lean
Manufacturing Environment in a traditional industry: the Portuguese Textile and
Clothing Industry. This is achieved by developing a modelling tool using quality as a
basis of performance assessment.
In the context of the textile industry specific research objectives were: to evaluate
current and potential application of Lean Manufacturing; to determine current
business performance assessment criteria; to determine current practice in formulation
of quality policy and metrics, and their impact on the effectiveness of new production
technologies and techniques; to develop an integrated methodology to link the
variables identified as important for the creation of a Lean Manufacturing
environment; to apply the methodology in selected industrial test sites; and to derive
quality system specifications which allow the realisation of Lean Manufacturing.
The idea proposed in this thesis uses a quality approach to facilitate the application of
Lean Manufacturing to the Textile and Clothing Industry. The author proposes a
model for this evolution. Ile model developed includes objective variables (quality,
productivity, delivery, cost, innovation, and time related elements), as well as
subjective variables (flexibility, technological, and anthropocentric elements). It
assesses the company performance from a Lean perspective, and not only from
traditional Financial or Quality Assurance perspectives. The model development
derived from applied research in 324 companies. A technique based on Data
Envelopment Analysis was developed to analyse data from those companies. It assisted
quantification of Lean Manufacturing assessment.
The research revealed that a particular set of companies, which have implemented
quality assurance systems, are closer to achieving Lean Manufacturing objectives. This
research project concludes with a proposal for new quality system requirements
specifically designed to facilitate the adoption of Lean Manufacturing