Abstract:
The footwear industry is one of the most promising and rapidly growing export sectors in Bangladesh. However, the manufacturing process is prone to defects and failures, which can lead to product rejections and customer complaints. With the rising demand for higher-quality products and the need to remain competitive in the global market, improving quality is essential for enhancing productivity and reducing costs associated with rejections and reworks. This study applies Pareto analysis and Cause-Effect diagrams to identify and address defects in footwear production, aiming to improve product quality. The research focuses on a leather footwear manufacturing company, specifically examining defects in the lasting and finishing processes of ladies' leather shoes. Data collected over six months were analyzed using Pareto analysis to identify the most significant defects. The analysis revealed that 82.20% of defects were concentrated in a few key areas. Additionally, Pareto analysis was used to pinpoint defects responsible for the majority of rejection and rework costs, accounting for 79.34% of the total expenses. These defects, including Leather Defects, Excess Roughing, Loose Leathers, Broken Stitch, Quarter Height Variation, Sole Damage, Poor Cementing, Vamp Length/Toe Depth Variation, Upper Damage, and Twisted Lasting, were identified as critical areas for improvement. To address these issues, hierarchies of causes for each defect type were organized, and Cause-Effect diagrams were constructed. Based on the analysis, specific recommendations were provided to mitigate the root causes of these defects, thereby reducing rejection losses and enhancing both productivity and product quality. The study concludes with actionable suggestions for further advancements in defect reduction and quality improvement in the footwear industry.
Keywords: Footwear Industry, Product Quality, Lasting and Finishing, Footwear Defects, Pareto Analysis, Root Cause Analysis, Productivity, Reduction of Costs.