Lean Automation Strategies for Reshoring U.S. Apparel Manufacturing: A Sustainable Approach

The U.S. apparel industry has long been offshored in pursuit of lower labor costs, leading to significant challenges including supply chain vulnerabilities, environmental degradation, lack of transparency, and a sharp decline in domestic employment opportunities. However, global disruptions, shifting consumer preferences toward ethical production, and rising offshore costs are reshaping the business case for reshoring. This paper explores lean automation as a strategic pathway to bring apparel manufacturing back to the United States while maintaining economic viability and environmental responsibility. Lean automation integrates the waste-reducing principles of lean manufacturing with advanced technologies such as robotics, IoT, and AI to create flexible, efficient, and responsive production systems. These systems offer reduced labor dependency, improved quality control, and faster turnaround times critical for competing in fast fashion and on-demand segments. Our study examines the feasibility of this approach through a mixed-methods analysis including literature review, a custom-designed automation framework, simulation models, and real-world case studies of reshored apparel facilities.Findings suggest that lean automation significantly enhances productivity (by up to 30%), reduces carbon emissions, and enables scalable, small-batch production. Additionally, lean strategies foster adaptability in local supply chains and support green job creation. We also identify challenges such as initial capital costs and workforce retraining needs, proposing mitigation strategies supported by policy and educational partnerships. Ultimately, this research provides a roadmap for stakeholders aiming to transform the U.S. apparel industry into a resilient, sustainable, and globally competitive sector.