Production
https://prod.org.br/article/doi/10.1590/0103-6513.20210072
Production
Research Article

Implementation of a Lean Manufacturing and SLP- based system for a footwear company

Sergio Enrique Munive Silvestre; Victor David Paucar Chaicha; Jose Carlos Alvarez Merino; S. Nallusamy

Downloads: 1
Views: 199

Abstract

Paper aims: This research article addresses an innovative solution to face one of the main problems in the footwear industry, namely the high order non-fulfillment rate.

Originality: This research offers companies in the footwear industry the possibility of implementing Andon through a structured and planned process that allows expediting problem solving. The advantage of this system is the ability to signal the status of workstations through rapid visual identification. Moreover, in this way social distancing is also secured, in line with World Health Organization guidelines to prevent the spread of COVID-19.

Research method: The article presents four phases through which the case study was addressed. Planning (determination of objectives), Restructuring of the Operations Area, Improvement of the Production Line and Continuous Improvement.

Main findings: An Arena simulation system was used to establish a new scenario where the defective product indicator decreases by 3.13% and productivity improves by about 38%. In turn, the resulting increase in the number of orders enhances company sales and profits, as well as the ability to meet the customer demand in a timely manner.

Implications for theory and practice: The case study suggests that the main causes of this issue (high order non-fulfillment rate) are the increasing rate of defective goods, delays in the production process, and excessive time consumption in the movement of staff and materials. This research serves as the basis for future lines of research, as well as for other organizations with similar characteristics to implement the proposal.

Keywords

Production, Layout, Andon, Kaizen, 5S

References

Abdul-Rashid, S. H., Sakundarini, N., Raja Ghazilla, R. A., & Thurasamy, R. (2017). The impact of sustainable manufacturing practices on sustainability performance: empirical evidence from Malaysia. International Journal of Operations & Production Management, 37(2), 182-204. http://dx.doi.org/10.1108/IJOPM-04-2015-0223.

Abu, F., Gholami, H., Saman, M. Z. M., Zakuan, N., Streimikiene, D., & Kyriakopoulos, G. L. (2021). An SEM approach for the barrier analysis in lean implementation in manufacturing industries. Sustainability, 13(4), 1-18. http://dx.doi.org/10.3390/su13041978.

Adesta, E., & Agung, H. (2018). The evaluation of lean manufacturing implementation and their impact to manufacturing performance. IOP Conference Series. Materials Science and Engineering, 453, 012031. http://dx.doi.org/10.1088/1757-899X/453/1/012031.

Aguilar, M. (2016). Estrategias de productividad para una empresa basadas en manufactura esbelta (Tesis de maestría). Instituto Politécnico Nacional, Ciudad de México.

Ali Naqvi, S. A., Fahad, M., Atir, M., Zubair, M., & Shehzad, M. M. (2016). Productivity improvement of a manufacturing facility using systematic layout planning. Cogent Engineering, 3(1), 1207296. http://dx.doi.org/10.1080/23311916.2016.1207296.

Andrade, Y., Cardenas, L., Viacava, G., Raymundo, C., & Dominguez, F. (2019). Lean manufacturing model for the reduction of production times and reduction of the returns of defective items in textile industry. In G. Di Bucchianico (Ed.), Advances in design for inclusion. AHFE 2019 (Advances in Intelligent Systems and Computing, Vol. 954). Cham: Springer. http://dx.doi.org/10.1007/978-3-030-20444-0_39.

Bhamu, J., & Singh Sangwan, K. (2014). Lean manufacturing: literature review and research issues. International Journal of Operations & Production Management, 34(7), 876-940. http://dx.doi.org/10.1108/IJOPM-08-2012-0315.

Everett, R. J., & Sohal, A. S. (1991). Individual Involvement and Intervention in Quality Improvement Programmes: Using the Andon System. International Journal of Quality & Reliability Management, 8(2). http://dx.doi.org/10.1108/EUM0000000001635.

Gisbert Soler, V., Pérez Bernabeu, E., & Sellés Cantó, M. A. (2012).Los gráficos de control por atributos(3rd ed.). Spain: 3C Empresa.

Andrade, A. M., Del Río, C. A., & Alvear, D. L. (2019). Estudio de Tiempos y Movimientos para Incrementar la Eficiencia en una Empresa de Producción de Calzado. Información Tecnológica, 30(3), 83-94, from https://www.scielo.cl/pdf/infotec/v30n3/0718-0764-infotec-30-03-00083.pdf. http://dx.doi.org/10.4067/S0718-07642019000300083.

Goyal, G., & Verma, D. S. (2019). Optimization of plant layout in manufacturing industry. International Journal of Recent Technology and Engineering, 8(2), 3115-3118. http://dx.doi.org/10.35940/ijrte.B2679.078219.

Innovate Peru. (2020). Retrieved in 2020, August 25, from https://www.innovateperu.gob.pe/quienes-somos/nuestros- fondos/mipyme

Jiamruangjarus, P., Naenna, T., & Zhou, Z. (2016). An integrated multi-criteria decision making methodology for conveyor system selection. Cogent Engineering, 3, 1158515. http://dx.doi.org/10.1080/23311916.2016.1158515.

Kłodawski, M., Jacyna, M., Lewczuk, K., & Wasiak, M. (2017). The issues of selection warehouse process strategies. Procedia Engineering, 187, 451-457. http://dx.doi.org/10.1016/j.proeng.2017.04.399.

Lopez-Leyva, J. A., Molina-Inzunza, A., Navarro-Paz, P., Verduzco-Unzón, S., & Yáñez, M. (2020). Customized smart andon system to improve the efficiency of industrial departments. Journal of Scientific and Industrial Research, 79(1), 35-37.

Nasution, A. A., Siregar, I., Anizar, Nasution, T. H., Syahputri, K., & Tarigan, I. R. (2018). Lean manufacturing applications in the manufacturing industry. MATEC Web of Conferences, 220, 02005. http://dx.doi.org/10.1051/matecconf/201822002005.

Perú, CITEccal. (2018). Retrieved in 2018, March 27, from http://citeccal.itp.gob.pe/citeccal-lima-implemento-programa-de- 5s-y-kaizen-en-empresa-de-calzado/

Rabanal, Mariela & Zamami, Sonia & Quiroze, Juan & Alvarez, José. (2020). Systematic layout planning: a research on the third party logistics of a Peruvian Company. In T. Ahram, R. Taiar, S. Colson & A. Choplin (Eds.), Human Interaction and Emerging Technologies. IHIET 2019 (Advances in Intelligent Systems and Computing, Vol. 1018). Cham: Springer. http://dx.doi.org/10.1007/978-3-030-25629-6_153.

Randhawa, J. S., & Ahuja, I. S. (2017a). 5S - a quality improvement tool for sustainable performance: literature review and directions. International Journal of Quality & Reliability Management, 34(3), 334-361. http://dx.doi.org/10.1108/IJQRM-03-2015-0045.

Randhawa, J. S., & Ahuja, I. S. (2017b). Evaluating impact of 5S implementation on business performance. International Journal of Productivity and Performance Management, 66(7), 948-978. http://dx.doi.org/10.1108/IJPPM-08-2016-0154.

Retail, P. (2017). Retrieved in 2017, June 12, from https://www.peru-retail.com/peru-cuarto-mayor-productor- calzado-america-del-sur/

Reyes, J., Morales, L., Aldas, D., Reyes, R., & Toasa, R. (2019). Real time automatic andon alerts for android platforms applied in footwear manufacturing. In Proceedings of the First International Conference, ICCCE 2018. Cham: Springer. http://dx.doi.org/10.1007/978-3-030-12018-4_4.

Sarria Yépez, M. P., Fonseca Villamarín, G. A., & Bocanegra-Herrera, C. C. (2017). Modelo metodológico de implementación de lean manufacturing. Revista EAN, 83(83), 51-71. http://dx.doi.org/10.21158/01208160.n83.2017.1825.

Sayid Mia, M. A., Nur-E-Alam, M., & Uddin, M. K. (2017a). Court shoe production line: improvement of process cycle efficiency by using lean tools. Leather and Footwear Journal, 17(3), 135-146. http://dx.doi.org/10.24264/lfj.17.3.3.

Sayid Mia, M. A., Nur-E-Alam, M., Rahman, M. L., & Uddin, M. K. (2017b). Footwear industry in bangladesh: reduction of lead time by using lean tools. Journal of Environmental Science, Computer Science and Engineering & Technology, 6(3), 251-259. http://dx.doi.org/10.24214/jecet.C.6.3.25159.

Sierra, V. P., & Beltrá, L. C. (2017). Metodología dinámica para la implementación de 5’s en el área de producción de las organizaciones. Revista Ciencias Estratégicas, 25(38), 411-423.

Singh, J., & Singh, H. (2018). Enigma of KAIZEN approach in manufacturing industry of Northern India: a case study. International Journal of Quality & Reliability Management, 35(1), 187-207. http://dx.doi.org/10.1108/IJQRM-12-2016-0220.

Suhardini, D., Septiani, W., & Fauziah, S. (2017). Design and simulation plant layout using systematic layout planning. IOP Conference Series. Materials Science and Engineering, 277, 012051. http://dx.doi.org/10.1088/1757-899X/277/1/012051.

Tanco, F., Kalemkerian, F., & Santos, J. (2021). Main challenges involved in the adoption of sustainable manufacturing in Uruguayan small and medium sized companies. Journal of Cleaner Production, 293, 126139. http://dx.doi.org/10.1016/j.jclepro.2021.126139.

Tarigan, U., Ishak, A., Hutauruk, Y. O., Siregar, K., Sari, R. M., & Tarigan, U. P. P. (2020). Implementation of lean services and facility layout to improve health clinical service processes. IOP Conference Series. Materials Science and Engineering, 1003(1), 012031. http://dx.doi.org/10.1088/1757-899X/1003/1/012031.

Vanichchinchai, A. (2020). Exploring organizational contexts on lean manufacturing and supply chain relationship. Journal of Manufacturing Technology Management, 31(2), 236-259. http://dx.doi.org/10.1108/JMTM-01-2019-0017.

Yang, T., Su, C.-T., & Hsu, Y.-R. (2000). Systematic layout planning: A study on semiconductor wafer fabrication facilities. International Journal of Operations & Production Management, 20(11), 1359-1371. http://dx.doi.org/10.1108/01443570010348299.

Yenni, E. (2007). Perancangan ulang tata letak gedung di RSUD dr Soeroto Ngawi dengan menggunakan pendekatan Systematic Layout Planning. Surakarta: UNS.

Yuik, C. J., Perumal, P. A., & Feng, C. J. (2020). Exploring critical success factors for the implementation of lean manufacturing in machinery and equipment SMEs. Engineering Management in Production and Services, 12(4), 77-91. http://dx.doi.org/10.2478/emj-2020-0029.
 


Submitted date:
06/07/2021

Accepted date:
04/07/2022

627bf60ba953951645420294 production Articles
Links & Downloads

Production

Share this page
Page Sections