Measuring Digital Lean Success: A Framework Using Core Process Metrics for Apparel Manufacturing

This study investigates the impact of digitalization on Lean manufacturing in the apparel industry, with a focus on the integration of key performance metrics enabled by technologies such as the Internet of Things (IoT), cloud computing, and data analytics. It highlights critical indicators including Lead Time, First Time Yield (FTY), Overall Equipment Effectiveness (OEE), On-Time Delivery Efficiency (OTDE), and Total Cost of Product (TCP), underscoring their growing relevance within digitally enhanced production environments. The research demonstrates that real-time data collection and analysis empower manufacturers to make informed, data-driven decisions, improve operational visibility, and support a culture of continuous improvement. The integration of digital tools with Lean practices is shown to yield measurable benefits, including a reduction in lead times of up to 20%, a 30% decrease in unit production costs, and a 35% improvement in OEE. Furthermore, significant progress has been observed in OTDE, with gains ranging from 10% to over 30%, and in FTY, which has increased by 20% to 50% in various implementations. Ultimately, the study argues that embedding these metrics within a Digital Lean framework not only facilitates waste reduction and improves product quality but also enhances organizational agility and responsiveness to market dynamics. These findings suggest that the convergence of Lean principles with digital technologies presents a strategic opportunity for apparel manufacturers to strengthen competitiveness within the evolving context of data-driven apparel manufacturing.