New Balance

The 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 PO’s.

• 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, travelling head and at least 1 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.

• Incorporating sensors and monitoring control systems : to track production performance in 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 on daily planning and tracking the matching components/uppers & soles supporting an hourly size run plan with visibility of the sizes run, measure the BTS (Build to Schedule) and avoid unplanned changes over.

“Lean manufacturing is a philosophy that focuses on minimizing waste and maximizing efficiency in production processes.”

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.