Abstract:
This study was a case analysis of lean tools and six sigma methodology implementation in shoe
production lines of “X” footwear industry in Bangladesh. This work addresses the implementation of
lean tools and six sigma methodology in the observed shoe production lines in order to evaluate
present Process Cycle Efficiency (PCE), Takt time, Value Added (VD) and Non Value Added
(NVD) activities, lead time, comparison of footwear industries various parameters in different
countries and finally to develop an improved strategy to bring the improved PCE, Takt time and to
reduce the lead time and NVD activities. Value Stream Map (VSM) and Pareto analysis were applied
to evaluate the present and future state PCE and to find out the NVD activities. By this study the
present state PCE of Derby, Casual, Court, Oxford, Boot and Moccasin shoe production lines were
found consequently as 11.32%, 15.28%, 8.32%, 8.01%, 10.68% and 12.20% that could be 25.60%,
34.05%, 19.46%, 18.84%, 24.45% and 26.91% after the implementation of lean tools and SS
methodologies within present production system. It is expected that after the implementation of lean
tools the existing lead time of Derby, Casual, Court, Oxford, Boot and Moccasin shoe production
lines could be reduced consequently by 55.78%, 55.09%, 57.23%, 57.44%, 56.28% and 54.64%. By
this study an economic benefit is also evaluated where it is expected that after the proper
implementation of lean tools and six sigma methodologies the total economic benefit would be
1206224160 Tk. or 1.2 billion USD per year. After all the production flow was optimized by
minimizing several NVD times such as bottlenecking time, waiting time, materials handling time,
etc. towards a lean environment establishment in management system of the studied “X” footwear
industry in Bangladesh.
