Application of Lean Tools for the Improvement of Process Cycle Efficiency of Moccasin Shoe Production Line Mia Md. Abu Sayid1,2,*, Nur-E-Alam Md.3,4, Ahmad Farid2, Wahid Murad A.B.M.1, Uddin M. Kamal2 1Institute of Leather Engineering and Technology, University of Dhaka, Dhaka-1209, Bangladesh 2Institute of Appropriate Technology, Bangladesh University of Engineering and Technology, Dhaka, Bangladesh 3Leather Research Institute (LRI), Bangladesh 4Council of Scientific and Industrial Research, Savar, Dhaka, Bangladesh *Corresponding Author: Md. Abu Sayid Mia, E-mail: emsayid@gmail.com, Contact: +8801674772545
Online published on 23 January, 2018. 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 found12.20% and after the implementation of lean tools, it would be 26.91% at the future state where lead time would also be reduced by 54.64% 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 “X” Footwear Industry in Bangladesh. Top Keywords Lean Tools, VSM, Lead Time, PCE, Technology Assessment, Moccasin Shoe, Bangladesh. Top |