Integration of human factors and ergonomics into lean implementation: ergonomic-value stream map approach in the textile industry

Industries started adopting lean concepts to provide better value to customers and to sustain themselves in a competitive world. Evidence revealed lean implementation worsens workers’ life quality due to the adopters’ consideration of lean’s technical practices alone and neglecting the vital role played by human factors and ergonomics (HFE). Hence, the study aims to integrate HFE and lean implementation to enhance workers’ life quality and operational performance in the textile industry. To achieve this, a value stream map (VSM) was modified by incorporating a human factors module. Ergonomic VSM (Ergo-VSM), was specifically enhanced to locate ergonomically critical activities in the system and evaluate human factors with lean parameters. Action research was conducted in the Sri Lankan textile industry with results revealing that Ergo-VSM was able to meet design objectives. The findings lead to the conclusion that an integrative approach enhances workers’ life quality and operational performance.