Smart manufacturing model to improve sewing line efficiency using TPM, IoT, SMED, and Industry 4.0 Poka-Yoke: A Case Study

The high competitiveness of the textile industry poses multiple challenges for small and medium-sized enterprises (SMEs), driving the need to optimize processes and innovate continuously. In this context, the studied company faces difficulties in meeting customer orders due to factors that reduce efficiency, such as machine downtime and rework caused by garment defects. This study aims to increase sewing line efficiency by implementing Total Productive Maintenance (TPM) with IoT to reduce mean time between failures, Single Minute Exchange of Die (SMED) to decrease setup times, and IoT-enabled Poka-Yoke systems to minimize rework. The proposed model integrates a real-time monitoring system equipped with sensors and Internet of Things (IoT) services, linking Lean Manufacturing practices with Industry 4.0 technologies. As a result, the model improved efficiency in the sewing area from 72.65% to 81.93% (+9.28%)). Additionally, mean time between failures increased by 53%, setup time was reduced by 40%, and the rework rate decreased by 35%. These outcomes demonstrate that combining Lean methodologies with IoT-based solutions enables tangible operational improvements, directly enhancing productivity, profitability, and competitiveness in textile SMEs.