Abstract

Lean manufacturing is an applied methodology of scientific, objective techniques that cause work tasks in a process to be performed with a minimum of non-value adding activities resulting in greatly reduced wait time, queue time, move time, administrative time, and other delays. This work addresses the implementation of lean principles in a footwear manufacturing industry in order to evaluate present Process Cycle Efficiency (PCE) and lead time prior to developing an improved strategy to bring the improved PCE and to reduce the lead time. At the present state, the PCE was found 15.28% and after the implementation of lean tools, it would be 34.05% at the future state where lead time would also be reduced by 55.09% evaluated by Pareto analysis and value stream mapping tools. The production flow was optimized by minimizing several non-value added activities and time such as bottlenecking, machine breakdown, queue time, waiting time, material handling time, etc. Eventually, this study will be useful in developing a more generic approach to design lean environment in the management system of the studied reputed Footwear Industry in Bangladesh.

Keywords: Lean tools; VSM; Lead time; PCE; Technology assessment; Casual shoe

Abbreviations: PCE: Process Cycle Efficiency; D/T: Down Time; C/T: Cycle Time; U/T: Up Time; VD: Value Added Time; NVD: Non-Value Added Time; VSM: Value Stream Mapping; M/C: Machine; RPM: Rotation Per Minute