Comparing the effectiveness of lean manufacturing principles between a small and a medium organisation in the apparel industry in KwaZulu-Natal (KZN)

Abstract

The South African apparel industry faces intense competition from both domestic and international markets, largely driven by low-cost imports and strong local rivalry prompting companies to seek operational efficiencies through the adoption of Lean Manufacturing Principles (LMPs). This study quantitatively examines the effectiveness of LMP implementation within small and medium-sized enterprises (SMEs) in the KwaZulu-Natal (KZN) apparel sector. A comparative analysis is conducted between a small-sized company (Company A) and a medium-sized company (Company B) to assess the degree of LMP adoption and its impact on operational performance, quality management, and competitiveness. A structured survey using a five-point Likert scale was administered to employees across various functional levels to collect data. The findings reveal significant differences in LMP adoption between the two companies, with Company B demonstrating more comprehensive implementation and greater improvements in efficiency and quality. Identified challenges include limited resources, insufficient managerial support, and knowledge gaps, particularly in smaller firms. This study uses a purposive sampling method to deliberately select two different apparel companies, one small and one medium, based on their level of Lean Manufacturing (LM) adoption. By comparing these two contrasting cases, the study provides a focused analysis of how lean principles are implemented in different organisational settings. This type of comparative case approach is rarely applied in studies focusing on small and medium enterprises in the South African apparel industry, making the research design a distinctive contribution. The study contributes to the understanding of LMP effectiveness in SMEs, proposing strategies to enhance lean adoption, reduce waste, and promote sustainable practices in the South African apparel sector. These strategies offer practical guidance for SMEs to implement lean practices more effectively, enabling real-world improvements in productivity, cost reduction, and sustainability.