Achieving Sustainable Overall Equipment Effectiveness (OEE) in Apparel Industry With Lean and Digital Integration

The study explores how digitalization together with lean manufacturing techniques influences operational performance within the apparel sector while highlighting Overall Equipment Effectiveness (OEE) as a critical indicator of performance. The apparel industry usually achieves OEE values from 40% to 60% because its labor-intensive production and low levels of automation prevent it from reaching full productivity potential. Through targeted interventions, it is possible to increase these values to reach a sustainable benchmark of 75%. Achieving this target requires reducing downtime, addressing performance inefficiencies, and minimizing quality-related disruptions to enhance operational stability. Case studies conducted at Company X and Company Y have identified key bottlenecks hindering optimal OEE, including low automation levels and challenges arising from the inherent flexibility requirements of apparel production. Proposed solutions include the integration of advanced process monitoring devices (PMDs), digital line balancing algorithms, and lean manufacturing techniques. These strategies collectively reduce productivity losses and support the attainment of the 75% OEE target. However, reaching the world-class OEE benchmark of 85% is noted as a significantly challenging goal due to sector-specific constraints. This research presents a strategic framework highlighting the synergistic potential of digitalization and lean manufacturing tools in enhancing operational efficiency. By adopting these integrated approaches, apparel manufacturers can improve their OEE performance, achieve higher productivity, and secure long-term competitiveness in a rapidly evolving industry. Nevertheless, the study underscores that achieving 85% OEE remains a formidable challenge, given the unique limitations of the sector. Therefore, setting realistic and sustainable targets is crucial for the successful transformation of the apparel industry.