Lean Manufacturing at Tier 1 vendors to a Large Footwear company

July 31, 2017

Project Brief:  Lean Manufacturing implementation at 27 stitching units of one of India’s largest footwear manufacturers located in and around Kottayam, Kerala.

Project Details: Initially, the units were manufacturing in batches. This led to a huge WIP, confusions at the end of the day on the sizes and product mix leading to poor delivery. We implemented continuous flow production, reduced WIP and focused on increasing through-put and reducing change-over time during article changes. Already most of the units have reported more than 30% increase in the output. We are completing this engagement in
Aug-2016.

Results: More than 50% increase in output

 

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