Simulation-Based Optimization and Lean Integration for Garment Production Efficiency: A Case Study from Ethiopian Apparel Manufacturing

Simulation-Based Optimization and Lean Integration for Garment Production Efficiency: A Case Study from Ethiopian Apparel Manufacturing | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Simulation-Based Optimization and Lean Integration for Garment Production Efficiency: A Case Study from Ethiopian Apparel Manufacturing Yared Hagos Gessesse, Leake Weleabzgi Gebrehiwot, Misgna Arefaine Gebreabzgi This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6570598/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 15 Apr, 2026 Read the published version in International Journal of System Assurance Engineering and Management → Version 1 posted 4 You are reading this latest preprint version Abstract Modeling and simulation are essential tools for understanding and optimizing production systems, particularly in the garment manufacturing industry. This study focuses on optimizing the production line at MAA Garment by applying discrete-event simulation (DES) combined with lean manufacturing tools. Excessive queuing at certain workstations significantly increased the overall cycle time. The study uses both primary and secondary data sources: primary data were gathered through interviews with key personnel and time studies, while secondary data were obtained from company records and related research. The simulation process included problem identification, data collection, model formulation, verification and validation, and experimentation. After identifying lean wastes through simulation, lean tools such as line balancing, layout redesign, and quality-at-the-source were implemented. The results show a reduction in cycle time from 6.99 minutes to 5.02 minutes, a substantial increase in line productivity from 31.57–70.58%, an improvement in line efficiency from 45.98–73.82%, and a doubling of the daily production target output from 600 to 1200 units. Furthermore, the number of operators was reduced from 19 to 17, enhancing operational efficiency. This study demonstrates how combining simulation with lean practices can significantly improve production performance and provides valuable insights for optimizing manufacturing processes in similar industries. Optimization System Modeling and Simulation Arena software Lean Wastes lean tools Full Text Cite Share Download PDF Status: Published Journal Publication published 15 Apr, 2026 Read the published version in International Journal of System Assurance Engineering and Management → Version 1 posted Reviewers agreed at journal 28 Aug, 2025 Reviewers invited by journal 28 Aug, 2025 Editor assigned by journal 03 May, 2025 First submitted to journal 02 May, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6570598","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":506963995,"identity":"6707f322-98cf-4899-956b-e8eb0bfe55c0","order_by":0,"name":"Yared Hagos Gessesse","email":"","orcid":"","institution":"Mekelle University - Endayesus Main Campus: Mekelle University","correspondingAuthor":false,"prefix":"","firstName":"Yared","middleName":"Hagos","lastName":"Gessesse","suffix":""},{"id":506963996,"identity":"abd25f7d-4227-4b38-a6db-a5028d8a7c9b","order_by":1,"name":"Leake Weleabzgi Gebrehiwot","email":"","orcid":"","institution":"Mekelle University - Endayesus Main Campus: Mekelle University","correspondingAuthor":false,"prefix":"","firstName":"Leake","middleName":"Weleabzgi","lastName":"Gebrehiwot","suffix":""},{"id":506963997,"identity":"0a9bf00a-6153-44d6-919e-7f8d43e46372","order_by":2,"name":"Misgna Arefaine Gebreabzgi","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAABFElEQVRIie3OsUoDMRjA8S8EkiXdI0LvCQSPQBQ87askHNhJdHISLBTSpThnqI/gWhxPDuxy6Fq3lgMXFQ4EUQQ1p3A4mNPRIf8pJPnlC0Ao9B/DzQotQAF0P9fsbwSv10Q0pJU1xKUHv5G1ES3vDo4g2hgNUbU8T/pnVqHFg4Fuz0NkzuSWvYR4UuSY62J3bzpXOD41IHxTHCGCEUCW72dcm7wmZLVjQI+9hN4K9gY9G5X4WZv3vpwr+urIsZ+AKOs3LcfETcmUIwS7HdXyMYk7Jzy1LCWb2qTxtFgOVyZXPB5nHnI9Kx/ZU7JtaY5vXsxOJGfpRXV/mER04BkDQDgA/76B6rv858tf4artNBQKhULwAcbvU5RomMiPAAAAAElFTkSuQmCC","orcid":"https://orcid.org/0009-0002-6222-386X","institution":"Mekelle University Ethiopian Institution of Technology","correspondingAuthor":true,"prefix":"","firstName":"Misgna","middleName":"Arefaine","lastName":"Gebreabzgi","suffix":""}],"badges":[],"createdAt":"2025-05-01 09:03:28","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6570598/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6570598/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s13198-026-03295-9","type":"published","date":"2026-04-15T15:57:04+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":107350939,"identity":"fcf4315d-0570-451e-b421-75f448838f90","added_by":"auto","created_at":"2026-04-20 16:07:20","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":755637,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscriptfile.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6570598/v1_covered_43ce5560-a44d-45db-8d52-b191585b11ec.pdf"}],"financialInterests":"","formattedTitle":"Simulation-Based Optimization and Lean Integration for Garment Production Efficiency: A Case Study from Ethiopian Apparel Manufacturing","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"international-journal-of-system-assurance-engineering-and-management","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"ijsa","sideBox":"Learn more about [International Journal of System Assurance Engineering and Management](http://link.springer.com/journal/13198)","snPcode":"13198","submissionUrl":"https://www.editorialmanager.com/ijsa/default2.aspx","title":"International Journal of System Assurance Engineering and Management","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Optimization, System Modeling and Simulation, Arena software, Lean Wastes, lean tools","lastPublishedDoi":"10.21203/rs.3.rs-6570598/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6570598/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eModeling and simulation are essential tools for understanding and optimizing production systems, particularly in the garment manufacturing industry. 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