Assignment on Synthetic Footwear Industry

 Material Storing System/Procedure:

The storage system in a synthetic footwear industry is an essential aspect to ensure that the production
runs smoothly. The materials used in the production of synthetic footwear, such as synthetic leather,
foam, rubber, etc. should be stored in a controlled environment to prevent damage and deterioration.

The procedure for material storage in a synthetic footwear industry typically involves the following
steps:

a. Receiving and inspection: Upon receipt of the materials, they should be inspected for any
defects or damages. The materials that fail the inspection should be returned to the supplier.

b. Labeling: All the materials should be labeled with the type, quantity, and date of receipt.

c. Storing: The materials should be stored in a dry, clean, and secure area that is protected from
sunlight and moisture. The materials should be stored in a manner that prevents damage, such
as stacking them on pallets.

d. Inventory control: The industry should maintain an accurate record of the materials in storage,
including the type, quantity, and location of the materials.

 Material Supply Procedure to Different Departments

The material supply procedure in a synthetic footwear industry involves the following steps:

a. Requisition: The various departments in the industry, such as the cutting department, sewing
department, finishing department, etc., send a requisition for the materials they require for
production.

b. Issuance: The materials are issued from the store to the various departments based on the
requisition received.
 c. Receiving: The departments receiving the materials should inspect them to ensure that the
correct type and quantity of materials have been received.

d. Recording: The issuance and receipt of the materials should be recorded in the industry’s records.

 Documentation Procedure

Documentation is an important aspect of the synthetic footwear industry, as it helps to maintain an

accurate record of the materials and production processes. The documentation procedure typically
involves the following steps:

A. Record-keeping: The industry should maintain an accurate record of the materials received,
issued, and used in production.

b. Documentation of production processes: The industry should document the various production
processes, including the type of materials used, the quantity used, and the date of production.

d. Quality control documentation: The industry should maintain a record of the quality control
measures taken, such as inspection of the materials and the final product.

 Quality Assurance System

Quality assurance is an important aspect of the synthetic footwear industry, as it ensures that the final
product meets the required standards. The quality assurance system typically involves the following
steps:

a. Inspection of materials: The materials should be inspected before they are used in
production to ensure that they meet the required standards.

b. Inspection of the final product: The final product should be inspected to ensure that it
meets the required standards, including size, color, texture, and durability.
 c. Testing: The final product should be tested to ensure that it meets the required
standards, such as waterproofing, breathability, and abrasion resistance.

d. Record-keeping: The industry should maintain a record of the quality control measures taken,
including the results of the inspections and tests.

 Introduction to Material FIFO System:

The First-In, First-Out (FIFO) system is a method of managing inventory in which the first items received
are the first items to be used. This system is commonly used in the synthetic footwear industry to
manage materials used in shoe making. By using the FIFO system, manufacturers can ensure that they
are using the oldest materials first, reducing the risk of materials becoming outdated or damaged.

 Bin Card:

A bin card is a record-keeping tool used to track the movement of materials in a warehouse or storage
area. It typically includes information such as the quantity of materials in the bin, the date they were
received, the date they were used, and any other relevant information.

The bin card is an important tool for managing inventory in the synthetic footwear industry because it
allows manufacturers to track the movement of materials used in shoe making, ensuring that they have
the necessary supplies on hand to meet production needs. To use a bin card, manufacturers should
regularly update it with information about the movement of materials, including the addition of new
materials, the removal of materials used in production, and any other changes in the inventory.

 Types of Synthetic Materials Used in Footwear:

Synthetic leather:

Synthetic leather is a material that is made from polymer materials like PU and is designed to look and
feel like natural leather. It is a popular alternative to natural leather because it is more affordable and it
is also more environmentally friendly. Synthetic leather is also easier to clean and maintain than natural
leather.

Mesh:

Mesh is a lightweight and breathable material that is commonly used in athletic shoes. It is made from a
variety of synthetic materials, including polyester and nylon. The breathable nature of mesh makes it
ideal for athletic shoes, as it allows air to circulate around the feet, keeping them cool and comfortable
during physical activity.
Rubber:

Rubber is a durable and flexible material that is widely used in the shoe industry. It is commonly used in
the soles of shoes as it provides excellent grip and traction. Rubber soles are also resistant to water and
abrasion, making them ideal for outdoor activities.

Canvas:

Canvas is a sturdy and durable material that is commonly used in casual shoes. It is made from cotton or
linen and is often used in the upper part of shoes. Canvas shoes are lightweight and comfortable,
making them a popular choice for casual wear.

Polyester:

Polyester is a popular synthetic material used in the footwear industry due to its durability and low cost.
It is a synthetic fiber that is used in the production of many different types of shoes, including running
shoes, sneakers, and sandals. Polyester is known for its strength and resistance to damage, which makes
it an ideal material for use in the sole and upper of shoes. It is also lightweight, breathable, and easy to
care for, making it a popular choice for many consumers.

Polyurethane:

Polyurethane is a versatile material that is used in the production of a variety of different types of shoes,
including sneakers, dress shoes, and athletic shoes. This material is known for its durability, flexibility,
and resistance to abrasion. Polyurethane is also lightweight and easy to care for, making it an attractive
option for many consumers. In addition, this material is environmentally friendly and can be recycled,
making it a popular choice for those who are concerned about sustainability.

PVC:

PVC, or polyvinyl chloride, is a synthetic material that is used in the production of a variety of different
types of shoes, including sandals, rain boots, and clogs. This material is known for its durability,
flexibility, and resistance to moisture. PVC is also easy to clean and maintain, making it an attractive
option for many consumers.

Nylon:

Nylon is a synthetic material that is used in the production of a variety of different types of shoes,
including athletic shoes, hiking boots, and backpacking shoes. Nylon is known for its strength and
durability, as well as its resistance to abrasion and moisture. This material is also lightweight and easy to
care for, making it an attractive option for many consumers.

Ethylene-vinyl acetate (EVA):

Ethylene-vinyl acetate (EVA) is a lightweight, flexible, and durable synthetic material that is often used in
the footwear industry. It is known for its good shock-absorbing properties, making it ideal for use in
athletic shoes and other performance footwear.

Thermoplastic elastomers (TPE):

Thermoplastic elastomers (TPE) are a class of synthetic materials that are known for their elasticity and
resistance to abrasion and tear. They are often used in the production of shoes, as they provide a
comfortable and flexible fit.

Lishine Cloth:

Lishine cloth is a type of synthetic material that is commonly used in the production of footwear. It is
made from a blend of polyester and polyurethane and is known for its durability, comfort, and moisture-
wicking properties. Lishine cloth is often used as a lining material in footwear to provide additional
cushioning and support.

Furombo:

Furombo is a type of synthetic material that is commonly used in the production of footwear. It is made
from a blend of polyester and polyurethane and is known for its soft, fluffy texture and insulation
properties. Furombo is often used as a lining material in footwear to provide additional warmth and
comfort.

Glass Wool:

Glass wool is a type of insulation material that is made from recycled glass. It is commonly used in the
production of footwear to provide insulation and prevent heat loss. Glass wool is known for its high
thermal resistance, low thermal conductivity, and ability to reduce heat transfer.

 Lamination Process:

Lamination is a process that involves bonding two or more materials together to form a single, more
durable material. In the synthetic footwear industry, lamination is used to improve the strength and
durability of the shoes. The process involves the application of heat and pressure to bond the materials
together. The materials used in the lamination process can vary greatly depending on the desired end
product

The lamination process of synthetic footwear materials involves several steps, which include:
Preparation of the Material: The first step in the lamination process is to prepare the material. This
involves cutting the material into the desired size and shape, cleaning it to remove any dirt, and
preparing it for bonding.

Application of Adhesive: The next step is to apply the adhesive to one of the surfaces of the material.
The adhesive used in the lamination process is typically a thermoplastic polymer or a glue that is heated
to activate the bonding process.

Laminating the Material: Once the adhesive has been applied, the two pieces of material are placed
together and subjected to heat and pressure. This heat and pressure activates the adhesive and bonds
the two pieces of material together.

Cooling and Hardening: After the laminating process, the material is cooled and allowed to harden. This
step is crucial as it ensures that the bond between the two pieces of material is strong and permanent.

Quality Control: The final step in the lamination process is quality control. The laminated material is
inspected for defects, and any defective pieces are removed.

 OPERATION SPECIFICATION:

Metarial specification Temperature Rpm Drying Lamination

time chemicals
LINING MESH 200-230° C 250- 60 WATERBASE
(D-MESH/K-MESH/LYCRA/SPANDEX/SP 300 minutes LAMINATION
ANGO/JIAGI MESH) +2-4MM FOAM GLU
(TC/MERCERIZED CLOTH) +2-4MM 250-280° C 500- 30 WATERBASE
FOAM 550 minutes LAMINATION
GLU