Synergy between Lean Manufacturing and Six Sigma methodologies as a continuous improvement strategy in the textile sector: Systematic Review

Abstract

In recent years, the textile sector has increasingly focused on adopting strategies centered around continuous improvement. Among the most relevant approaches are Lean Manufacturing and Six Sigma, which aim to enhance internal processes, eliminate unnecessary activities, and improve the overall quality of finished products. Despite their advantages, applying these methodologies involves certain difficulties, especially for small and medium enterprises, where limited technical capacity and resistance to change are common barriers to success. To explore this topic, a systematic review was carried out, guided by clearly defined inclusion and exclusion criteria. A total of sixty-two open-access scientific articles were examined, selected from widely recognized academic databases such as Scopus, Web of Science, ScienceDirect, and EBSCOhost. The analysis incorporated both qualitative and quantitative perspectives in order to understand the effects of implementing these methods in the textile industry. Results showed that combining Lean principles with the Six Sigma methodology helped reduce production defects by forty-four percent, increase productivity by twenty-seven percent, and enhance both delivery reliability and operational efficiency. These improvements were also associated with lower production costs. Furthermore, frequent challenges in the industry, such as inconsistent processes and poor inventory control, were addressed effectively, contributing to greater competitiveness and long-term sustainability. In summary, when organizations commit to overcoming cultural resistance and invest in proper training, the integration of Lean Manufacturing and Six Sigma becomes a valuable strategy for strengthening quality, increasing productivity, and supporting sustainable growth in the textile industry. This approach also enables better responsiveness to the evolving needs of global markets