8 OCTOBER 2023OPINIONBy Ari Wibowo, Lean & Advanced Manufacturing Manager, New BalanceThe footwear industry has been growing rapidly over the past few years, with an increasing demand for footwear from consumers all around the world. In order to meet this demand, many footwear manufacturers are turning to lean manufacturing and automation to improve their production processes and reduce costs. Here are some ways that these concepts can be implemented in the footwear industry:1. Lean manufacturing: Lean manufacturing is a philosophy that focuses on minimizing waste and maximizing efficiency in production processes. Some ways that this can be applied in the footwear industry include:· Streamlining the production process: This involves identifying and eliminating any unnecessary steps in the production process to reduce lead times and increase efficiency.· Mini-Line-Conversion (80% by volume as a target), which is suitable for their high-complex model mixed with small POs.· Applying 5S principles (Sort, Set in Order, Shine, Standardize, Sustain) to organize the workplace, maintain cleanliness, and enhance safety.· Implementing visual management: Visual management techniques, such as using color-coded materials and kanban cards, can help to improve communication and reduce errors in the production process.· Adopting a pull-based production system that produces only what is needed, when it is needed, and in the quantity required.· Implementing a just-in-time (JIT) inventory system that minimizes inventory holding costs, reduces stockouts, and improves cash flow.· Continuous improvement: This involves constantly reviewing and refining the production process to identify areas for improvement and implement changes to make the process more efficient.2. Automation / Advanced Manufacturing: Automation involves using technology to automate repetitive tasks and improve efficiency. Some ways that this can be applied in the footwear industry include:· Automated cutting, traveling head, and at least one auto nesting/cutting system: it can help to reduce waste and increase accuracy.· Automated stitching: which enables us to place materials on a pallet and deliver them to sewing machines along a digital path. It can help to reduce labor costs and increase productivity.· Robotic assembly: Robots can be used to perform repetitive assembly tasks, such as attaching soles to upper shoes, which can improve efficiency and reduce the risk of injury to workers.· Implementing automated material handling systems (AGV ­ Auto Guided Vehicle) to transport materials and products between workstations.· Using 3D printing technology: to create prototypes and customized products.· Adopting robotic systems (Low-Cost automation): to perform repetitive and dangerous tasks such as cutting, stitching, gluing, and stamping.LEAN MANUFACTURING AND AUTOMATION IN FOOTWEAR INDUSTRY
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