9OCTOBER 2023· Incorporating sensors and monitoring control systems: to track production performance at the end of each manufacturing section (Offline/Treatment, Stockfitting, Stitching, Assembly) for synchronization and productivities control (output versus manhours), identify bottlenecks, and optimize production processes. · Automated packaging: Using machines to package shoes can help to reduce errors and increase efficiency.· Automated warehouse systems, such as conveyor belts and automated guided vehicles, can be used to increase efficiency and reduce the need for manual labor.· Digital system for daily production scheduling (Advanced Planning and Scheduling (APS). Can help with daily planning and tracking the matching components/uppers & soles supporting an hourly size run plan with visibility of the sizes run, measuring the BTS (Build to Schedule), and avoiding unplanned changes.Overall, the implementation of lean manufacturing and automation can help to improve efficiency and productivity in the footwear industry, leading to higher-quality products, increased flexibility of production lines, enhanced safety, and increased profitability. Implementing lean manufacturing and automation in the footwear industry can be challenging due to several reasons, including:1. High degree of customization: The footwear industry has a high degree of customization, with many different styles, sizes, and colors of shoes produced. This can make it difficult to implement lean principles, which typically rely on standardization and simplification of processes.2. Complex supply chain: The footwear industry has a complex supply chain, with raw materials sourced from different countries and multiple suppliers involved in the manufacturing process. This can make it challenging to implement just-in-time (JIT) production, which requires close coordination between suppliers and manufacturers.3. Resistance to change: Implementing lean manufacturing and automation requires a significant change in the way work is done. Employees may be resistant to these changes, especially if they perceive that their jobs are at risk due to automation.4. High initial investment: Implementing automation requires a significant initial investment in equipment and software, which can be a barrier for smaller companies in the footwear industry.5. Limited technology options: The footwear industry is not as technologically advanced as some other industries, such as electronics or automotive. This means that there may be limited technology options available for automation, which can make it more difficult to implement.6. Intellectual property protection: Footwear companies may be reluctant to share their production processes and techniques, which can make it difficult to implement lean principles and automation across the industry.Despite these challenges, many footwear companies are starting to implement lean manufacturing and automation to improve efficiency and quality. By working closely with suppliers and investing in technology, footwear companies can overcome these challenges and remain competitive in the global market. LEAN MANUFACTURING AND AUTOMATION IN FOOTWEAR INDUSTRYImplementing automation requires a significant initial investment in equipment and software, which can be a barrier for smaller companies in the footwear Ari Wibowo
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