Citation :

Brian Jesus Alejandro-Torres, Jose Luis Yarma-Rivera, Wilson David Calderón-Gonzales, 2025. "Lean-TPM Strategies for Defect Reduction and Productivity Gains: Evidence from a Garment SME Case Study" ESP International Journal of Science, Humanities & Management Studies(ESP-IJSHMS)  Volume 3, Issue 2: 1-14.

Abstract :

The garment ma nufacturing sector in Peru faced persistent operational inefficiencies despite prior research highlighting the benefits of Lean Manufacturing and TPM principles. Previous studies, however, rarely addressed their combined adaptation for SMEs in developing economies. This research responded to urgent challenges such as production inconsistencies, high defect rates, and equipment neglect. A comprehensive production model was proposed, integrating 5S, standardized work, and autonomous maintenance. The model was validated through a four-month application in a Peruvian garment SME, resulting in a 60.52% reduction in overall defects and a 36.61% improvement in equipment effectiveness. These measurable improvements demonstrated that structured, low-cost interventions could significantly enhance SME competitiveness. Academically, the study contributed by adapting established operational frameworks to small-scale contexts, while socioeconomically, it strengthened SME resilience in volatile markets. Future research is encouraged to validate the model in broader settings and to explore digital enhancements that could further consolidate operational stability and drive sustainable development in the sector.

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Keywords :

Lean Manufacturing, Operational Efficiency, Textile Industry, SMEs, Process Improvement.