Abstract:
The apparel industry in Sri Lanka remains a cornerstone of the national economy,
contributing significantly to employment generation and export earnings; however, it
continues to face challenges due to inefficiencies in production processes and high
levels of material waste, particularly in the North Western Province, where many
factories operate. This study investigates the impact of lean manufacturing tools on
waste reduction focusing on Just-in-Time (JIT), Kanban, Kaizen, and Six Sigma. A
quantitative research design was employed using purposive sampling to include
individuals directly involved in production, such as production managers, quality
managers, lean executives, supervisors and other relevant parties. Data were collected
through a structured questionnaire and analyzed using descriptive statistics, reliability
testing, and regression analysis to ensure methodological rigor and validity. The
findings reveal that implementing lean manufacturing tools significantly reduces
waste, improves process efficiency, and enhances product quality. Regression
analysis confirmed that these lean practices account for a substantial portion of the
variation in waste reduction, while reliability testing verified the internal consistency
of the instrument. The study demonstrates that JIT, Kanban, Kaizen, and Six Sigma
collectively support more sustainable and competitive manufacturing operations.
Furthermore, it contributes to the theoretical understanding of lean manufacturing by
providing empirical evidence from a developing country context, which is often
underrepresented in literature. The results offer actionable insights for managers and
policymakers, highlighting that lean practices not only address inefficiencies and
waste but also promote cost-effective, efficient, and environmentally responsible
production strategies. Overall, this research emphasizes the critical role of lean tools
in fostering operational excellence, sustainability, workforce engagement, and global
competitiveness in the Sri Lankan apparel sector.
