Sip Report... Sakshi

STUDY ON PLANT LAYOUT DESIGN IN LGPL
SUMMER INTERNSHIP PROJECT
REPORT
Submitted by
Sakshi
III Semester
2211310700082
Under the guidance of
Ms. Nishtha Bhagwani
(Assistant Professor)
in partial fulfilment of the requirements for award of the degree of
MASTER OF BUSINESS ADMINISTRATION
of
Dr. A.P.J Abdul Kalam Technical University
Allenhouse Institute of Management
January, 2024
DECLARATION
I undersigned, hereby declare that the summer internship project titled “Study on Plant
layout Design” submitted in partial fulfilment for the award of Degree of Master of Business
Administration of A.P.J Abdul Kalam Technical University is a bonafide record of work
done by me under the guidance of Ms. Nishtha Bhagwani, Allenhouse Institute of
Management. This report has not previously formed the basis for the award of any degree,
diploma, or similar title of any University.
Signature Sakshi
Date
ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been possible without the kind
support and help of many individuals. I would like to extend my sincere thanks to all of them.
It has been great honor and privilege to undergo this project.
I am highly indebted to Ms. Nishtha Bhagwani for his guidance and constant supervision as
well as for providing necessary information regarding the project and also for the support in
completing the project. His constant guidance and willingness to share his vast knowledge
made us understand this project and his manifestations in great depths has helped us to
complete the assigned tasks on time.
I would like to express my gratitude towards my parents for their kind cooperation and
encouragement which helped me a lot.
My thanks and appreciation also go to my colleagues who have willingly helped me in

developing the project.
Sakshi Dr. Shivani

Kapoor
Director
CERTIFICATE
This is to certify that the report titled “Study on Plant Layout Design” being submitted by
Sakshi, 2211310700082, in partial fulfilment of requirements for the award of the Degree of
Master of Business Administration is a bonafide record of the project work done by Sakshi
of Allenhouse Institute of Management during the period of September 01, 2023 to
September 30, 2023.
Mr. Sabyasachi Das Dr. Shivani

Kapoor
Operations Executive
Director
CONTENTS
I. INTRODUCTION
 A. Background of FURO Shoes

 Shoe Anatomy
 Contribution (Sales, Top Article)
 B. Purpose of the Plant Layout Document
 II. PLANT LAYOUT OVERVIEW
 Facility Size and Location

 Key Production Areas
 Flow of Materials and Products
 Safety and Compliance Measures
 III. DESIGN CONSIDERATIONS
 Factors Influencing Plant Layout

 Layout Objectives (e.g., Efficiency, Safety, Cost-Effectiveness)
 Ergonomics and Workstation Design
 Technology and Automation Integration
 IV. PRODUCTION PROCESS
 Shoe Manufacturing Steps
 Machinery and Equipment
 Sole Production Flowcharts or Diagram
 V. QUALITY CONTROL AND ASSURANCE
 Quality Inspection Stations
 Quality Control Measures
 Compliance with Industry Standards
 VI. LOGISTICS AND SUPPLY CHAIN
 Inventory Management
 Supply Chain Integration
 Shipping and Distribution
 VII. SUSTAINABILITY INITIATIVES
 Environmental Considerations
 Sustainable Practices in Plant Layout
 VIII. SAFETY AND EMPLOYEE WELL-BEING
 Safety Protocols
 Employee Facilities (e.g., Breakrooms, Restrooms)
 Health and Safety Measures
 IX. FUTURE IMPROVEMENTS
 Continuous Improvement Strategies

 5S Methodology
 Kaizen Technology
 Future Expansion Plans
 X. RESEARCH METHODOLOGY
 Research Objective
 Research Design
 Sampling Size
 Sampling Area
 XI. DATA ANALYSIS
 XII. CONCLUSION
 XIII. RECOMMENDATIONS
 XIV. BIBLIOGRAPHY
 XV. ANNEXURE
INTRODUCTION
A. BACKGROUND OF LEAYAN GLOBAL PRIVATE LTD
Leayan Global Private Ltd incorporated its business under parent company RSPL Limited. In
the year 1995, company started its leather & footwear business journey to make India fit
started from 2017 when we launched a sports shoes brand called Furo sports from the house
of Red Chief Shoes (estd.1997), we set out on a mission to introduce the world of sports with
a common ground where style meets grip. We believe that if you have a grip on your pursuit
of adventures, you are an athlete.
The company is known for its commitment to innovation, sustainability and customer
satisfaction.
LGPL is one of the biggest footwear manufacturers based in North India having a large
infrastructure including its own tannery. The tannery is completely integrated tanning unit
and is capable of tanning from raw materials to finished leather.
Quality Assurance Cell makes certain that the finished product adheres all its QA norms &
undergoes a stringent & comprehensive testing process for its physical and chemical
properties in order to meet all specification of the esteemed buyers with precision and
accuracy.
They believe in a grip so strong that it lets us take that leap of faith. A grip so ground-
breaking that it leads us to paths unwritten. A grip that has the potential to bounce back from
setbacks. A grip unlike any other – FURO Sports. Because when its GRIP you want, it’s
FURO you need!
The company has its own R&D department exclusively dedicated to monitor latest styling,
new constructions for personal & customer specific developments.
To give people an experience of this unparalleled performance, we introduced the world’s
first tyre- inspired ‘Hi-grip technology’ achieved through the use of specially compounded
rubber, in adherence to international quality standards.
We always ensure to put our best foot forward when it comes to sports shoes. Be it for
running, walking, basketball, tennis or hiking, we have everything available for all your
gripping adventures. We believe that anybody and everybody has some form talent hidden
inside them. And that's why we have created shoes with this unbeatable grip at an affordable
price, so everyone has the chance to stand their ground and make their mark.
Ready to take on the world with a simple motto “Got FURO Got Grip”, our products are
now available in more than 16 states across various multi brand outlets, including 10+
company-owned brand- exclusive stores along with major online platforms like Amazon,
Flipkart and Myntra etc.
CONTRIBUTION
SHOE ANATOMY
Eyelets
Counter loop
Tongue
Lace
Collar
Eye stay
Padding
Vamp
Counter
Logo
Mid sole
Rubber sole
Outer sole Quartor Winsel

PURPOSE OF THE PLANT LAYOUT
DOCUMENT
The purpose of this document is to provide a comprehensive overview of FURO Shoes’

manufacturing facility plant layout. It aims to describe the design, organization, and flow of
the production facility to ensure the efficiency, safety and cost-effectiveness.
A plant layout document serves several important purposes in the design and operation of a
manufacturing or industrial facility. These purposes include:
1. Optimal Space Utilization: One of the primary purposes of a plant layout document
is to ensure efficient use of available space within the facility. Proper layout planning
can help minimize wasted space, reduce congestion, and ensure that all resources are
utilized effectively.
2. Workflow Optimization: A well-designed plant layout helps streamline the

production process by organizing equipment, workstations, and materials in a logical
sequence. This optimization reduces the time and effort required for materials
handling and production, leading to increased productivity.
3. Safety and Compliance: Safety is a crucial consideration in any industrial setting. A

plant layout document helps identify potential safety hazards, such as high-risk areas
or equipment, and ensures compliance with safety regulations and standards. This
includes providing clear pathways for emergency exits and safety equipment
placement.
4. Cost Efficiency: Efficient plant layouts can lead to cost savings by minimizing
unnecessary movements, reducing material handling, and improving process flow.
This, in turn, can reduce operational costs and increase profitability.
5. Expansion Planning: Plant layout documents are valuable for long-term planning, as
they provide a visual representation of the existing facility. This can aid in decision-
making when it comes to expansion, renovation, or reconfiguration of the plant.
6. Communication and Collaboration: A well-documented plant layout serves as a

clear and visual reference for employees, contractors, and stakeholders. It helps in
communicating the design and operational requirements and facilitates collaboration
among various teams, including engineering, production, maintenance, and
management.
7. Equipment and Resource Allocation: The layout document helps in determining the
allocation of equipment, machinery, and resources to specific areas within the plant. It
ensures that the right equipment is placed in the right location to support production
goals.
8. Maintenance and Repairs: Maintenance teams can benefit from a plant layout
document as it provides a clear overview of equipment locations and access points.
This aids in planning and executing maintenance tasks efficiently.
9. Continuous Improvement: As processes and technology evolve, a plant layout

document can be a valuable tool for continuous improvement efforts. It helps identify
bottlenecks, inefficiencies, and opportunities for optimization.
10. Documentation and Record-Keeping: Plant layout documents serve as an official

record of the facility's design and organization. They can be used for regulatory
compliance, insurance purposes, and historical reference.
In summary, a plant layout document plays a crucial role in ensuring the efficient and safe
operation of a manufacturing or industrial facility. It helps optimize space, workflows, and
resource allocation while supporting long-term planning and ongoing improvement
initiatives.
PLANT LAYOUT OVERVIEW
A.Facility size and location

Designing the size and location of a plant facility is a critical decision that can significantly
impact the efficiency, cost-effectiveness, and long-term success of a manufacturing or
industrial operation. Here are key considerations for facility size and location in plant design:
Facility Size:
1. Production Capacity: Determine the required production capacity to meet current

and future demand. Consider factors such as market growth, sales forecasts, and
scalability. The facility size should accommodate production needs without being too
large or too small.
2. Space for Equipment and Processes: Allocate space for machinery, production
lines, workstations, and storage. Ensure that there's sufficient room for equipment
installation, maintenance, and safe operation.
3. Material Handling: Plan for efficient material flow within the facility, minimizing
unnecessary transportation and storage. Design layouts that reduce travel distances for
materials and products.
4. Future Expansion: Consider the potential for future expansion. Allow for flexibility
in layout and construction to accommodate growth in production or changes in
product lines.
5. Storage: Include space for raw material storage, work-in-progress (WIP) storage, and
finished goods storage, based on inventory requirements and turnover rates.
6. Support Facilities: Don't forget about support areas like offices, break rooms,
restrooms, maintenance shops, and quality control labs. Allocate space for these
essential functions.
7. Regulatory Compliance: Ensure compliance with local building codes, safety
regulations, environmental standards, and zoning laws. Consult with relevant
authorities to understand any restrictions or requirements.
Facility Location:
1. Proximity to Suppliers: Consider the proximity of your facility to suppliers of raw

materials, components, and parts. Being closer to suppliers can reduce transportation
costs and lead times.
2. Market Access: Evaluate the location's accessibility to target markets. Proximity to

customers can reduce distribution costs and delivery times.
3. Transportation Infrastructure: Assess the availability of highways, railways, ports,

and airports for shipping and receiving goods. A well-connected location can improve
logistics efficiency.
4. Labor Force: Consider the availability and skill level of the local labour force.
Ensure that you can find and retain the necessary talent for your operations.
5. Cost of Land and Labor: Compare the costs of land, utilities, and labour in different
potential locations. Choose a location that aligns with your budget and cost
expectations.
6. Environmental Factors: Evaluate environmental factors, such as climate, weather,

and environmental risks (e.g., flooding, earthquakes) that could impact operations and
safety.
7. Market Conditions: Research the economic and business conditions of the region.
Consider factors like taxation, incentives, and the overall business environment.
8. Competition: Assess the competitive landscape in the chosen location. Determine if

there are advantages or disadvantages related to competition.
9. Risk Management: Identify potential risks and vulnerabilities associated with the
location, such as political stability, natural disasters, and supply chain disruptions.
10. Regulatory Environment: Understand local, regional, and national regulations that
may affect your business, including taxes, permits, and import/export regulations.
In summary, the size and location of a plant facility are critical aspects of plant design.
Careful consideration of these factors is essential to ensure that the facility is efficient, cost-
effective, compliant with regulations, and strategically positioned to support the business's
goals and growth. It often involves a comprehensive analysis that considers both short-term
and long-term factors.
Regenerate
KEY PRODUCTION AREAS

The shoe industry is a multifaceted sector with various key production areas that encompass
the entire manufacturing process, from design and materials sourcing to distribution. Here are
the key production areas of the shoe industry:
1. Design and Development:

 Shoe designers create the initial concepts and designs for new shoe models.
 They work on sketches, prototypes, and 3D models to visualize the final
product.
2. Materials Sourcing:
 Raw materials are sourced, including leather, synthetic materials, textiles,
rubber, foam, and various components like eyelets, laces, and adhesives.
 Sustainability and ethical sourcing practices are becoming increasingly
important in this area.
3. Pattern Making:
 Patterns for shoe components, such as the upper, insole, and outsole, are
created. These patterns serve as templates for cutting materials.
4. Cutting and Preparation:

 Materials are cut according to the patterns.
 Components like soles, uppers, linings, and insoles are prepared for assembly.
5. Assembly and Stitching:

 Shoe components are stitched or bonded together using specialized machinery.
 Skilled workers assemble the different parts to create the shoe's upper.
6. Lasting and Bottoming:

 The shoe upper is pulled over a foot-shaped form called a "last."
 The bottoming process involves attaching the sole to the upper using
adhesives or stitching.
7. Finishing:
 This stage involves cleaning, polishing, and adding final details to the shoe,
such as branding, logos, and decorative elements.
8. Quality Control (QC):
 Shoes go through rigorous quality control checks to ensure they meet industry
standards and customer expectations.
 QC inspectors examine each pair for defects and consistency.
9. Packaging:
 Finished shoes are prepared for shipping by packaging them in boxes and adding
labels, tags, and other packaging materials.
10. Warehousing and Distribution:

 Shoes are stored in warehouses before distribution.
 Distribution networks and logistics ensure products reach retailers and
consumers efficiently.
11. Retail Sales:

 Shoes are sold through various channels, including brick-and-mortar stores,
online retailers, and brand-owned stores.
 Retail staff assist customers in selecting and trying on shoes.
12. Customer Service and Support:

 Brands provide customer support for inquiries, returns, and repairs.
 Warranty and after-sales service may be offered.
13. Marketing and Branding:

 Shoe companies invest in marketing campaigns to promote their products.
 This includes advertising, influencer partnerships, and social media marketing.
14. Research and Development (R&D):

 Continuous R&D efforts focus on developing new materials, technologies, and
manufacturing processes to improve shoe
quality, comfort, and sustainability.

15. Sustainability and Eco-Friendly Initiatives:
 Many companies are increasingly focusing on sustainable practices, including
using eco-friendly materials, reducing waste, and adopting sustainable
production processes.
16. E-commerce and Online Sales:

 The growth of e-commerce has become a significant production area, with
companies managing online sales, website development, and digital marketing.
17. Customization and Personalization:

 Some companies offer customization options, allowing customers to choose
colors, materials, and designs to create unique shoes.
18. Innovation and Technology:

 Technology is playing an increasing role in the industry, with developments
like 3D printing, automation, and augmented reality used for design,
production, and customer engagement.
These key production areas collectively represent the complex and multifaceted nature of the
shoe industry, which involves a combination of craftsmanship, design, technology, and
logistics to deliver footwear products to consumers.
FLOW OF MATERIALS AND PRODUCTS
The flow of materials and products in the shoe industry involves a series of interconnected
processes, from the sourcing of raw materials to the distribution of finished shoes to
consumers. Here's an overview of the typical flow:
 The process begins with the procurement of raw materials, including leather,
synthetic materials, textiles, rubber, foam, and various components (eyelets,
laces, adhesives) from suppliers.
 Sustainability and ethical sourcing practices are increasingly important
considerations in materials sourcing.
2. Material Inspection and Quality Control:

 Incoming materials are inspected and undergo quality control checks to ensure
they meet the required standards and specifications.
3. Pattern Making:
 Patterns are created for various shoe components, such as the upper, insole,
and outsole.
 Patterns serve as templates for cutting materials.
4. Cutting and Preparation:

 Materials are cut according to the patterns, optimizing material utilization.
 Components like soles, uppers, linings, and insoles are prepared for assembly.
5. Assembly and Stitching:

 Skilled workers assemble the different components of the shoe, including the
upper and sole.
 Assembly may involve stitching, bonding, or other joining methods.
 The shoe upper is pulled over a foot-shaped form called a "last."
 The bottoming process involves attaching the sole to the upper using
adhesives or stitching.
7. Finishing:
 Shoes go through a finishing process that includes cleaning, polishing, and
adding final details, such as branding, logos, and decorative elements.
8. Quality Control (QC):
 Finished shoes undergo rigorous quality control checks to ensure they meet
industry standards and customer expectations.
 QC inspectors examine each pair for defects and consistency.
9. Packaging:
 Finished shoes are packaged in boxes and prepared for distribution.
 Labels, tags, and other packaging materials are added.

 Finished shoes are stored in warehouses before distribution.
 Distribution networks and logistics ensure products reach retailers and
consumers efficiently.
11. Retail Sales:

 Shoes are sold through various channels, including brick-and-mortar stores,
online retailers, and brand-owned stores.
 Retail staff assist customers in selecting and trying on shoes.
SAFETY AND COMPLIANCE
MEASURES
The shoe industry, like any manufacturing sector, places a strong emphasis on safety and
compliance measures to ensure the well-being of workers, protect consumers, and adhere to
regulatory requirements. Here are some of the key safety and compliance measures in the
shoe industry:
1. Occupational Health and Safety (OHS):

 Provide a safe and healthy work environment for employees. This includes
proper ventilation, ergonomic workstations, and safety equipment.
 Conduct regular safety training for workers to minimize accidents and injuries.
 Implement safety protocols for the use of machinery and equipment, such as
press machines and stitching equipment.
2. Chemical Management:
 Ensure the safe handling and disposal of chemicals used in the manufacturing
process, such as adhesives, dyes, and solvents.
 Comply with regulations such as the Registration, Evaluation, Authorization,
and Restriction of Chemicals (REACH) in the European Union and similar
regulations in other regions.
3. Fire Safety:
 Install fire detection and suppression systems in manufacturing facilities and
warehouses.
 Conduct fire drills and provide training on fire safety procedures for
employees.
 Ensure compliance with local building and fire codes.
4. Machine Safety:
 Regularly inspect and maintain machinery to prevent accidents.
 Implement safety guards and interlocks on equipment to protect workers from
moving parts.
 Train operators on safe machine operation and maintenance.
5. Worker Protection:
 Provide personal protective equipment (PPE) such as gloves, safety goggles,
and hearing protection as needed.
 Develop protocols for handling hazardous materials and situations.
 Promote proper ergonomics to reduce musculoskeletal disorders.
6. Environmental Compliance:
 Adhere to environmental regulations related to waste disposal, emissions, and
hazardous materials.
 Implement eco-friendly practices, including recycling and waste reduction.
 Consider sustainable material choices and production processes.
7. Supply Chain Transparency:

 Ensure transparency in the supply chain by verifying the ethical and safe
working conditions of suppliers and subcontractors.
 Monitor and audit suppliers to confirm compliance with safety and labor
standards.
8. Product Safety:
 Conduct product testing to ensure shoes meet safety and quality standards,
including chemical safety and durability.
 Comply with product safety regulations, such as the Consumer Product Safety
Improvement Act (CPSIA) in the United States.
9. Labelling and Documentation:

 Properly label products with essential information, such as material
composition, country of origin, and care instructions.
 Maintain documentation to track product safety and compliance.
10. International Standards:

 Adhere to international standards, such as ISO 9001 for quality management
and ISO 14001 for environmental management, when applicable.
11. Ethical and Labor Standards:

 Uphold ethical labour practices, including fair wages and working hours, and
respect for human rights.
 Monitor and address any instances of child labour or forced labour within the
supply chain.
12. Regulatory Compliance:

 Stay informed about industry-specific regulations in different regions and
countries, such as safety and labelling requirements.
 Collaborate with legal and compliance teams to ensure adherence to all
applicable laws.
13. Continuous Improvement:

 Encourage a culture of continuous improvement regarding safety and
compliance.
 Regularly review and update safety procedures and compliance protocols as
needed.
Compliance with safety and regulatory measures is not only a legal obligation but also crucial
for maintaining a positive brand reputation and ensuring the well-being of employees and
consumers. The shoe industry, like other manufacturing sectors, is continuously evolving to
meet higher standards of safety, sustainability, and ethical.
DESIGN CONSIDERATIONS
A. FACTORS INFLUENCING PLANT LAYOUT

Plant layout is a critical aspect of manufacturing and facility design, as it significantly
impacts efficiency, productivity, safety, and overall operational effectiveness. Various factors
influence plant layout decisions. Here are some of the key factors:
1. Nature of the Product: The type of product being manufactured plays a significant
role in determining plant layout. Different products may require distinct production
processes, equipment, and spatial arrangements. For example, the layout for an
automobile manufacturing plant will be vastly different from that of a food processing
facility.
2. Production Process: The specific production processes involved in manufacturing

the product dictate the arrangement of equipment and workstations. Sequential
processes may require a linear layout, while batch processes may need more flexible
layouts.
3. Volume and Variety of Production: The production volume and product variety
influence layout decisions. High-volume, repetitive manufacturing may benefit from a
product-oriented layout, whereas low-volume, high-variety production may require a
process-oriented layout.
4. Material Flow: Efficient material handling is essential for minimizing production

costs. The flow of raw materials, work-in-progress (WIP), and finished products
should be carefully planned to reduce transportation time and costs.SH
5. Available Space: The size and shape of the available space have a direct impact on
plant layout. It's essential to make the best use of the available area while considering
expansion possibilities.
6. Safety Requirements: Safety is a top priority in plant design. The layout should
minimize the risk of accidents, facilitate emergency exits, and ensure compliance with
safety regulations.
7. Regulatory Compliance: Plant layouts must adhere to local, regional, and national
regulations and building codes, including safety, environmental, and zoning
regulations.
8. Utility and Service Requirements: Access to utilities such as water, electricity, gas,
and compressed air is critical for plant operations. Layout should consider the
placement of utility connections and services.
9. Cost Constraints: Budget limitations and cost considerations play a significant role
in determining the layout. Balancing cost-effectiveness with operational efficiency is
essential.
10. Flexibility and Scalability: The ability to adapt to changing production requirements
and accommodate future growth is crucial. Flexible layouts can be reconfigured as
needed.
11. Workforce and Labor Requirements: The number of employees and their skill
levels influence the layout. It's important to create ergonomic workstations and
optimize the use of labour.
12. Aesthetics and Image: Some industries, such as retail or high-end manufacturing,
place importance on aesthetics and the company's image. The layout should reflect the
desired brand image.
13. Environmental Considerations: Sustainability and environmental factors are

increasingly important. The layout should support eco-friendly practices, waste
reduction, and energy efficiency.
14. Supplier and Customer Proximity: The proximity to suppliers and customers can
impact transportation costs and lead times. Being closer to key stakeholders can be
advantageous.
15. Market and Competitive Factors: Market demands and competition can influence
production strategies. Quick response to market changes may require a more flexible
layout.
16. Technology and Automation: Advances in technology and automation may

influence the layout, allowing for more efficient use of space and resources.
17. Health and Sanitation Requirements: Industries like food processing and
pharmaceuticals have strict health and sanitation standards that need to be integrated
into the layout.
18. Noise and Environmental Impact: Consideration of noise pollution and other
environmental impacts on neighbouring areas is important, especially in densely
populated regions.
Effective plant layout design involves a careful balance of these factors to create a
productive, safe, and cost-efficient manufacturing environment. It often requires
collaboration among engineers, architects, production managers, and other stakeholders to
arrive at the best solution for a specific facility.
B. LAYOUT OBJECTIVES
Plant layout is a critical aspect of manufacturing and facility design, as it significantly
impacts efficiency, productivity, safety, and overall operational effectiveness. Various factors
influence plant layout decisions. Here are some of the key factors:
1. Nature of the Product: The type of product being manufactured plays a significant
role in determining plant layout. Different products may require distinct production
processes, equipment, and spatial arrangements. For example, the layout for an
automobile manufacturing plant will be vastly different from that of a food processing
facility.
2. Production Process: The specific production processes involved in manufacturing

the product dictate the arrangement of equipment and workstations. Sequential
processes may require a linear layout, while batch processes may need more flexible
layouts.
3. Volume and Variety of Production: The production volume and product variety
influence layout decisions. High-volume, repetitive manufacturing may benefit from a
product-oriented layout, whereas low-volume, high-variety production may require a
process-oriented layout.
4. Material Flow: Efficient material handling is essential for minimizing production

costs. The flow of raw materials, work-in-progress (WIP), and finished products
should be carefully planned to reduce transportation time and costs.
5. Available Space: The size and shape of the available space have a direct impact on
plant layout. It's essential to make the best use of the available area while considering
expansion possibilities.
6. Safety Requirements: Safety is a top priority in plant design. The layout should
minimize the risk of accidents, facilitate emergency exits, and ensure compliance with
safety regulations.
7. Regulatory Compliance: Plant layouts must adhere to local, regional, and national
regulations and building codes, including safety, environmental, and zoning
regulations
8. Utility and Service Requirements: Access to utilities such as water, electricity, gas,
and compressed air is critical for plant operations. Layout should consider the
placement of utility connections and services.
9. Cost Constraints: Budget limitations and cost considerations play a significant role
in determining the layout. Balancing cost-effectiveness with operational efficiency is
essential.
10. Flexibility and Scalability: The ability to adapt to changing production requirements
and accommodate future growth is crucial. Flexible layouts can be reconfigured as
needed.
11. Workforce and Labor Requirements: The number of employees and their skill
levels influence the layout. It's important to create ergonomic workstations and
optimize the use of labour.
12. Aesthetics and Image: Some industries, such as retail or high-end manufacturing,
place importance on aesthetics and the company's image. The layout should reflect the
desired brand image.
13. Environmental Considerations: Sustainability and environmental factors are

increasingly important. The layout should support eco-friendly practices, waste
reduction, and energy efficiency.
14. Supplier and Customer Proximity: The proximity to suppliers and customers can
impact transportation costs and lead times. Being closer to key stakeholders can be
advantageous.
15. Market and Competitive Factors: Market demands and competition can influence
production strategies. Quick response to market changes may require a more flexible
layout.
16. Technology and Automation: Advances in technology and automation may

influence the layout, allowing for more efficient use of space and resources.
17. Health and Sanitation Requirements: Industries like food processing and
pharmaceuticals have strict health and sanitation standards that need to be integrated
into the layout.
18. Noise and Environmental Impact: Consideration of noise pollution and other
environmental impacts on neighbouring areas is important, especially in densely
populated regions.
Effective plant layout design involves a careful balance of these factors to create a
productive, safe, and cost-efficient manufacturing environment. It often requires
collaboration among engineers, architects, production managers, and other stakeholders to
arrive at the best solution for a specific facility.
C. ERGONOMICS AND
WORKSTATION DESIGN
Ergonomics plays a crucial role in the shoe industry, as it directly affects the comfort, safety,
and efficiency of workers involved in the manufacturing process. Proper workstation design
and ergonomic considerations are essential to prevent injuries, enhance productivity, and
improve the overall work experience. Here are key ergonomic principles and considerations
for the shoe industry:
1. Workstation Layout:
 Ensure that workstations are arranged to minimize excessive reaching, bending, and
twisting. Work processes should flow logically and reduce unnecessary movements.
 Maintain adequate clearance around workstations for easy access and movement of
materials and workers.
2. Work Surface Height:
 The height of work surfaces, such as cutting tables and assembly benches, should be
adjustable to accommodate different workers' heights and tasks.
 Workers should be able to maintain a neutral posture with their wrists straight when
performing tasks.
3. Seating:
 Provide ergonomic seating options, such as adjustable chairs with proper lumbar
support, for tasks that require prolonged sitting, like design and administrative work.
 Ensure that chairs are correctly adjusted to fit each worker's body.
4. Flooring:
 Choose anti-fatigue mats or flooring materials that reduce strain on workers' legs
and lower back, especially in areas where workers stand for extended periods.
5. Lighting:
 Ensure adequate, adjustable lighting to reduce eye strain and facilitate accurate work.
Proper lighting is essential for quality control tasks, such as inspection and finishing.
 Consider natural lighting and adjustable task lighting for specific workstations.
6. Tool and Equipment Design:
 Select ergonomic tools and equipment with handles that fit comfortably in workers'
hands.
 Tools should require minimal force and repetitive movements to operate.
 Equip machinery with safety features to prevent accidents.
7. Materials Handling:
 Use mechanical aids, such as carts, conveyors, and lift-assist devices, to reduce
manual handling of heavy materials and products.
 Ensure that materials are stored at appropriate heights to minimize bending and
reaching.
8. Footwear and Personal Protective Equipment (PPE):
 Encourage workers to wear appropriate footwear with proper arch support and
cushioning.
 Provide and enforce the use of PPE, such as safety glasses, gloves, and hearing
protection, where necessary.
9. Training and Education:
 Train workers on proper lifting techniques, posture, and ergonomics awareness.

 Encourage workers to report discomfort, pain, or signs of musculoskeletal issues early
to prevent more severe injuries.
11. Breaks and Rotation:

 Implement scheduled breaks and job rotation to allow workers to change tasks and
postures, reducing the risk of repetitive strain injuries.
 Break areas should include seating and facilities for resting and eating.
12. Noise Control:
 Control noise levels in the workplace to protect workers' hearing and reduce
stress.
 Provide hearing protection where necessary, and consider sound-absorbing
materials in areas with high noise levels.
13. Feedback and Continuous Improvement:

 Encourage workers to provide feedback on workstation design and ergonomic
issues.
 Regularly evaluate and update workstation design and processes to address
ergonomic concerns and improve worker comfort.
By incorporating these ergonomic principles and considerations into workstation design and
manufacturing processes, the shoe industry can create a safer, more comfortable, and more
productive work environment, ultimately leading to higher product quality and employee
satisfaction.
D.TECHNOLOGY AND AUTOMATION
Technology and automation have significantly impacted the shoe industry, transforming
various aspects of the manufacturing process, from design and production to distribution and
retail. Here are some key ways in which technology and automation are applied in the shoe
industry:
1. Design and Prototyping:

 Graphic Design software allows designers to create intricate shoe designs and
make rapid design iterations.
 This printing technology enables the creation of prototypes and sample shoes
quickly and with precision.
2. Digital Foot Scanning and Customization:

 Foot scanning technologies, like 3D foot scanners, are used to create highly
accurate foot measurements for custom shoe designs.
 Customization platforms allow customers to design and order bespoke shoes
online, with options for personalized styles, colour, and sizing.
3. Cutting and Material Handling:

 Automated cutting machines use computer-controlled systems to cut shoe
components with high precision, reducing material waste.
 Robotics and automated conveyors streamline material handling and
transportation within the manufacturing process.
4. Stitching and Bonding:

 Automated stitching machines and bonding equipment improve consistency
and speed in attaching various shoe components.
 These machines are capable of intricate stitching patterns and precise adhesive
application.
 Automated lasting machines efficiently shape the shoe upper over the last,
reducing manual labour and ensuring consistent fit.
 Machinery automates the attachment of soles and outsoles, improving
adhesion quality.
6. Quality Control and Inspection:

 Computer vision systems and sensors are used for automated quality control
and inspection, identifying defects and ensuring product consistency.
 These systems can detect imperfections in stitching, materials, and finish.
7. Inventory Management and Tracking:

 RFID (Radio-Frequency Identification) technology is used for tracking raw
materials, work-in-progress, and finished products throughout the supply
chain.
 Inventory management software optimizes stock levels and reduces
overstocking or understocking issues.
SHOE MANUFACTURING PROCESS
DESIGN AND
DEVELOPMENT
MATERIAL PURCHASE RM INSPECTION

STORE OR QC
SEND TO VENDOR
REJECT
OK MATERIAL
PRODUCTION FLOOR OK OR
NOT?
CUTTING SECTION
STOCK FITTING
PREPARATION & STITCHING & CLOSING
PRINTING (UPPER +SOLE)
PACKAGING/ ASSEMBLY
FGQC/SUPER QC
GENERAL
WAREHOUSE DISPATCH
TRADE
PRODUCTIONREATAIL
PROCESS
A. SHOE MANUFACURING STEPS
Shoe manufacturing is a complex process involving multiple steps that transform raw
materials into finished footwear. The specific steps can vary depending on the type of shoe
being produced and the manufacturing methods employed. Here's a general overview of the
key steps involved in shoe manufacturing in the industry:
1. Design and Development:

 Conceptualize shoe designs based on market trends and customer preferences.
 Develop design sketches, patterns, and prototypes.
 Procure materials such as leather, synthetic materials, rubber, and textiles.
 Ensure materials meet quality and sustainability standards.
3. Cutting and Pattern Making:

 Create shoe patterns based on the design specifications.
 Cut materials into the required shapes and components.
4. Pre-Assembly Preparation:
 Prepare components, including insoles, outsoles, linings, and uppers.
 Quality control checks for materials.
5. Stitching and Sewing:

 Seamstresses and sewing machines join upper components and linings.
 Stitching creates the shoe's basic structure.
6. Lasting and Shoe Forming:

 Shoe lasts (forms) are used to shape and mould the upper to the desired form.
 Heat and pressure may be applied to set the shape.
7. Bottoming Process:
 Attach the outsole to the shoe using adhesive or stitching.
 Quality control for sole attachment.
8. Finishing and Trimming:
 Trim excess materials and threads from the shoe.
 Perform finishing touches, such as polishing, cleaning, and applying protective
coatings.
9. Quality Control and Inspection:

 Inspect each shoe for quality, consistency, and defects.
 Address any issues found during inspection.
10. Sole and Heel Assembly:

 Attach heels and any additional sole components.
 Quality checks for sole and heel attachment.
11. Lacing and Hardware Installation:

 Add laces, eyelets, zippers, or other hardware components as needed.
12. Insole Insertion:

 Insert insoles for comfort and support.
 Ensure proper alignment and fit.
13. Packaging and Labelling:

 Package shoes in boxes or other packaging materials.
 Apply labels, tags, and sizing information.
14. Quality Assurance and Final Inspection:

 Perform a final quality check to ensure the shoes meet all quality standards.
 Random sampling may be done for quality audits.

 Store finished shoes in a warehouse.
 Distribute products to retail locations, wholesalers, or customers.
16. Retail Display and Sales:
 Display shoes in retail stores.
 Sales and customer service.
17. Customer Use and Care:

 Shoes are sold to customers and worn.
 Customers maintain and care for their footwear.
18. Returns and Repairs:

 Handle returns and repairs as necessary.
 Assess and address warranty claims or defects.
19. Recycling and Sustainability:

 Explore recycling and sustainability initiatives for shoe materials and end-of-
life products.
machinery and equipment
The shoe industry relies on a wide range of machinery and equipment to facilitate the various
stages of shoe manufacturing, from design and materials preparation to assembly and
finishing. The specific machinery and equipment used can vary depending on the type of
shoes being produced and the production methods employed. Here's an overview of some
common machinery and equipment used in the shoe industry:
1. Cutting Machines:
 Clicking Presses: These hydraulic or mechanical presses are used to cut shoe
components from leather, fabric, or synthetic materials based on pattern
templates.
 Die Cutting Machines: These machines use steel dies to cut out specific shapes
from materials.
 Computerized Numerical Control (CNC) Cutting Machines: CNC technology
allows for precise and automated cutting of materials.
2. Sewing Machines:
 Industrial Sewing Machines: These specialized machines are used for stitching
various shoe components, including uppers, linings, and decorative elements.
 Zigzag Machines: Used for creating decorative stitching and attaching elastic
components.
3. Lasting Machines:
 Toe Lasting Machines: These machines shape the toe area of the shoe and
attach the upper to the last.
 Heel Lasting Machines: They shape the heel area of the shoe and attach the
upper to the last.
 Side and Seat Lasting Machines: Used to attach the sides and soles of the shoe
to the upper.
4. Bottoming Machines:
 Sole Stitching Machines: These machines stitch the sole to the shoe's upper.
 Cementing Machines: Used for adhesive bonding of soles and outsoles to the
shoe's upper.
 Sole Presses: Apply pressure to ensure proper bonding of soles and heels.
5. Moulding Machines:
 Heat Moulding Machines: Used for moulding and shaping shoe components,
such as insoles and midsoles.
 Injection Moulding Machines: Employed for manufacturing moulded outsoles
and other shoe parts using molten materials.
6. Finishing Equipment:
 Polishing and Buffing Machines: Used to achieve a smooth and polished
surface on leather or synthetic uppers.
 Edge Trimming Machines: Trim excess material from the edges of shoe
components.
 Drying and Curing Ovens: Accelerate the drying and curing of adhesives and
finishes.
7. Quality Control and Inspection Equipment:
 Computer Vision Systems: Employed for automated inspection and detection
of defects in shoes, such as stitching irregularities.
 Measuring Tools: Callipers, gauges, and rulers are used to verify dimensions
and quality standards.
8. Material Handling and Conveyor Systems:

 Conveyor belts and automated material handling systems facilitate the
movement of materials and work-in-progress (WIP) between workstations.
9. Material Testing Equipment:

 Equipment for testing the physical properties of materials, such as tensile
strength, abrasion resistance, and flexing endurance.
10. Shoe Lasts and Foot Measuring Devices:

 Lasts are foot-shaped forms used for shaping shoe components and ensuring
consistent sizing.
 Foot measuring devices and scanners capture precise measurements for
custom shoe orders.
11. Sustainability and Recycling Equipment:
 Machines for recycling and reusing materials, contributing to sustainable
practices in shoe manufacturing
12. Labelling and Packaging Equipment:
 Machines for labelling, tagging, and packaging finished shoes for distribution
and retail.
The shoe industry continually adapts to technological advancements, incorporating

automation and innovative equipment to improve efficiency, precision, and product quality.
These machines and tools play a crucial role in the design, production, and distribution of
footwear products.
a. SOLE PRODUCTION FLOWCHARTS

QUALITY CONTROL AND ASSURANCE
A.QUALITY INSPECTION STATIONS
Quality inspection stations are crucial in the shoe industry to ensure that manufactured
footwear meets established quality standards and specifications. These inspection stations are
strategically placed at various points in the production process to identify and address defects
or quality issues promptly. Here are some common quality inspection stations in a shoe
manufacturing facility:
1. Material Inspection Station:

 Incoming raw materials, such as leather, fabric, and components, are inspected
for quality, consistency, and conformity to specifications.
 Defective or substandard materials are identified and either rejected or set
aside for remediation.
2. Pattern and Cutting Inspection:

 After cutting shoe components based on patterns, an inspection station checks
for irregularities, such as inaccurate cuts or material defects.
 Misaligned patterns or poor material quality are addressed to prevent defects
in the final product.
3. Stitching and Seam Inspection:

 Stitching and seam quality are inspected at this station, ensuring that stitches
are even, consistent, and free from loose threads or skipped stitches.
 Seam strength and durability are also assessed.
4. Lasting and Bottoming Inspection:

 In the lasting and bottoming processes, workers inspect the attachment of the
upper to the sole and the overall alignment and symmetry of the shoe.
 Any discrepancies, such as misalignment or adhesive issues, are corrected.
5. Quality Control Points on the Assembly Line:

 Throughout the assembly line, there are designated quality control points
where shoes are examined for defects, finish quality, and adherence to design
specifications.
 This can include checks for proper attachment of decorative elements, logo
placement, and overall aesthetics.
6. Sole and Outsole Inspection:

 Inspectors assess the quality of soles and outsoles for proper adhesion,
alignment, and uniformity.
 Any sole or outsole defects, such as air bubbles or uneven surfaces, are
addressed.
7. Fit and Sizing Inspection:

 Shoes are periodically assessed for accurate sizing, ensuring that they meet
established size specifications.
 Workers may also check the fit and comfort of a sample of shoes to verify
their wearability.
8. Functional Testing Stations:

 Some shoes, especially those designed for specific purposes (e.g., athletic or
safety footwear), undergo functional testing stations where their performance
features are evaluated.
 Testing can include assessments of slip resistance, water resistance,
cushioning, and other functional aspects.
9. Final Inspection Station:

 This is the last checkpoint before packaging and distribution.
 A comprehensive inspection is conducted to verify that shoes meet all quality
standards, design specifications, and finish requirements.
 Any remaining defects are addressed, or the shoes may be sent for rework if
necessary.
10. Packaging Inspection:

 Before shoes are packaged, they undergo a final inspection to ensure that they
are clean, polished, and free from defects.
 Packaging materials, labels, and tags are also checked for correctness and
completeness.
11. Random Sampling and Testing:

 Random samples of finished shoes may be subjected to additional testing,
including wear testing, to assess durability and performance.
12. Documentation and Labelling Verification:

 All relevant documentation, including labels, care instructions, and product
information, is reviewed for accuracy and completeness.
13. Data and Record Keeping:

 Detailed records are maintained at each inspection station to track quality
issues, defects, and corrective actions taken.
Effective quality inspection stations are critical for maintaining product quality, minimizing
defects, and ensuring customer satisfaction in the shoe industry. Implementing these stations
at key points in the production process helps identify and rectify issues early, reducing waste
and rework costs.
B. QUALITY CONTROL MEASURES
Quality control measures in the shoe industry are essential to ensure that footwear products
meet established standards and specifications, providing customers with safe, comfortable,
and durable shoes. Effective quality control helps identify and address defects or
inconsistencies in the manufacturing process, ultimately enhancing product quality and
customer satisfaction. Here are common quality control measures employed in the shoe
industry:
1. Incoming Material Inspection:

 Thoroughly inspect raw materials, including leather, fabrics, linings, soles, and
other components, for quality, color consistency, and adherence to
specifications.
 Reject or set aside substandard materials to prevent their use in production.
2. Pattern and Cutting Inspection:

 Examine patterns and cut shoe components to ensure accuracy and precision.
 Check for defects, misaligned patterns, or poor material quality during the
cutting process.
3. Stitching and Seam Quality Control:

 Inspect stitched seams for evenness, consistency, and strength.
 Ensure there are no loose threads, skipped stitches, or irregularities in
stitching.
4. Lasting and Bottoming Quality Control:

 Evaluate the attachment of the upper to the sole, ensuring proper alignment
and symmetry.
 Check the integrity of adhesive bonds and any lasting or bottoming defects.
5. Aesthetic and Finish Inspection:

 Inspect the overall appearance of shoes for aesthetic qualities, including finish
quality, logo placement, and decorative elements.
 Verify that shoes meet design specifications and visual standards.
6. Sole and Outsole Inspection:

 Assess the quality of soles and outsoles for proper adhesion, alignment, and
uniformity.
 Check for defects such as air bubbles, uneven surfaces, or separation.
7. Fit and Sizing Verification:
 Periodically measure and verify shoe sizing to ensure conformity to
established size specifications.
 Conduct fit and comfort assessments to evaluate wearability.
8. Functional Testing:
 Test shoes for functional characteristics related to their intended use, such as
slip resistance, water resistance, cushioning, and support.
 Verify that safety footwear meets relevant safety standards.
9. Durability Testing:
 Subject shoes to durability testing, including wear tests and abrasion resistance
tests, to assess their long-term performance and durability.
10. Random Sampling and Testing:

 Select random samples of finished shoes for additional testing, including wear
testing, to assess overall quality and durability.
11. Quality Control Points on the Assembly Line:

 Implement quality control checkpoints at various stages of the assembly line
to identify and address defects promptly.
 Empower line workers to reject or set aside any shoes that do not meet quality
standards.
12. Final Inspection:

 Conduct a comprehensive final inspection of all shoes to ensure they meet all
quality standards, design specifications, and finish requirements.
 Address any remaining defects or issues before packaging.
13. Packaging Inspection:

 Inspect shoes before packaging to ensure they are clean, polished, and free
from defects.
 Verify the correctness and completeness of packaging materials, labels, and
tags.
14. Documentation and Record Keeping:

 Maintain detailed records at each quality control checkpoint, documenting
quality issues, defects, and corrective actions taken.
 Use data for continuous improvement efforts.
15. Employee Training and Quality Awareness:

 Provide training to employees on quality control procedures, visual standards,
and defect recognition.
 Encourage a culture of quality awareness and continuous improvement among
staff.
16. Supplier and Subcontractor Audits:

 Regularly audit and assess the quality of materials and components supplied
by external vendors.
 Ensure suppliers and subcontractors adhere to established quality standards.
17. Root Cause Analysis and Corrective Actions:

 Investigate the root causes of quality issues and implement corrective actions
to prevent recurrence.
 Continuously monitor and assess the effectiveness of corrective measures.
18. Customer Feedback and Warranty Management:

 Gather and analyse customer feedback and warranty claims to identify
recurring quality issues and make necessary improvements.
COMPLIANCE WITH INDUSTRY STANDARDS
Compliance with industry standards is crucial in the shoe industry to ensure the safety,
quality, and performance of footwear products. Various standards and regulations exist at the
international, national, and regional levels to govern different aspects of shoe manufacturing
and distribution. Here are some key areas of compliance in the shoe industry:
1. Safety Standards: Safety standards are essential to protect consumers from potential
hazards associated with footwear. Compliance with safety standards helps ensure that
shoes do not pose risks to wearers. Some relevant safety standards include:
 ASTM F2412 and F2413: Standards for safety footwear, including
requirements for impact resistance and protection against electrical hazards.
 EN ISO 20345, EN ISO 20346, and EN ISO 20347: European standards for
safety, protective, and occupational footwear.
 CSA Z195: Canadian standards for protective footwear.
2. Material Standards: Compliance with material standards is critical to ensure that

shoe components and materials meet quality and safety criteria. These standards cover
aspects such as:
 Leather quality and characteristics.
 Synthetic material standards.
 Testing for harmful substances, including restricted substances and allergens
(e.g., REACH regulations in the European Union).
3. Environmental Regulations: The shoe industry is increasingly focused on

environmental sustainability. Compliance with environmental regulations and
standards is important for reducing the environmental impact of shoe manufacturing.
Relevant standards include:
 ISO 14001: Environmental management system standard.
 Restricted substance regulations, such as Proposition 65 in California and the
European Union's REACH regulation.
4. Quality Standards:
 Quality standards help ensure that footwear products meet established quality
criteria, including workmanship, materials, and performance.
 Quality management systems like ISO 9001 are commonly used to
demonstrate commitment to quality.
5. Product Labelling and Marking:
 Compliance with labelling and marking requirements is essential for providing
consumers with accurate and useful information about footwear products.
 This includes labelling for sizing, country of origin, safety features, and care
instructions.
6. Customs and Trade Regulations:

 Compliance with customs and trade regulations is crucial for international
trade in footwear products.
 This includes adherence to customs classifications, tariff codes, and
import/export documentation requirements.
7. Child Labor and Labor Standards:

 Compliance with labour standards and regulations, including those related to
child labour, fair labour practices, and occupational health and safety, is
essential to uphold ethical and social responsibility in the industry.
8. Patents and Intellectual Property:

 Shoe manufacturers must respect patents and intellectual property rights
related to shoe designs, technologies, and branding. This ensures legal and
ethical business practices.
9. Packaging and Packaging Waste Regulations:

 Compliance with regulations related to packaging materials and waste
management helps reduce the environmental impact of packaging materials
and ensures proper disposal or recycling.
10. Country-Specific Regulations:

 Different countries may have specific regulations and standards that apply to
footwear. Manufacturers and distributors should be aware of and comply with
these regulations in regions where they sell their products.
To ensure compliance with industry standards, shoe manufacturers often establish quality
control and assurance processes, conduct product testing and certification, and engage in
regular audits and inspections. Collaborating with reputable third-party testing and
certification organizations can also help verify compliance and build consumer trust.
In summary, compliance with industry standards is essential for ensuring the safety, quality,
and legality of footwear products, as well as for maintaining ethical and sustainable practices
in the shoe industry. Manufacturers and distributors should stay informed about evolving
standards and regulations that impact their products and markets.
Logistics and supply chain
a. Inventory management
Inventory management is a critical aspect of running a successful shoe industry business.
Effective inventory management ensures that you have the right amount of footwear products
and materials on hand to meet customer demand while minimizing carrying costs and waste.
Here are some key principles and strategies for inventory management in the shoe industry:
1. Demand Forecasting:
 Use historical sales data, market trends, and customer feedback to forecast
demand for different shoe styles and sizes.
 Collaborate with sales and marketing teams to gather insights on customer
preferences and upcoming promotions.
2. ABC Analysis:
 Implement an ABC analysis to categorize your shoe inventory into three
categories: A, B, and C.
 Category A represents high-value items with the highest sales frequency,
while category C includes lower-value, slow-moving items.
 Allocate more resources to managing and restocking category A items and less
for category C.
3. Safety Stock:
 Maintain a safety stock of popular shoe styles and sizes to avoid stockouts
during unexpected spikes in demand or supply disruptions.
 Safety stock levels should be determined based on lead times, demand
variability, and service level objectives.
4. Just-in-Time (JIT) Inventory:

 Implement JIT principles to minimize carrying costs by receiving materials
and components from suppliers as needed.
 This approach reduces excess inventory and storage costs but requires reliable
and efficient supply chain management.
5. Supplier Collaboration:
 Work closely with suppliers to establish clear communication channels and
optimize lead times for the procurement of raw materials and components.
 Consider vendor-managed inventory (VMI) arrangements with key suppliers
to streamline replenishment.
6. Inventory Tracking and Management Software:
 Invest in inventory management software that provides real-time visibility into
your stock levels, sales, and order fulfilment.
 Utilize barcode scanning and RFID technology to enhance accuracy and
efficiency in inventory tracking.
7. Batch and Lot Tracking:

 Implement batch and lot tracking systems for materials to trace and recall
specific components in case of quality issues or recalls.
 This is particularly important for ensuring product safety and compliance.
8. Regular Audits and Cycle Counts:

 Conduct regular physical inventory audits and cycle counts to reconcile actual
stock levels with recorded inventory data.
 Address any discrepancies promptly to maintain accurate records.
9. Economic Order Quantity (EOQ):

 Calculate the EOQ for each shoe style and size to determine the optimal order
quantity that minimizes total inventory costs (including ordering and holding
costs).
10. Supplier Performance Monitoring:

 Monitor supplier performance in terms of quality, on-time deliveries, and lead
times.
 Develop relationships with reliable suppliers and have backup sources to
mitigate supply chain disruptions.
11. Obsolete Inventory Management:

 Identify and manage obsolete or slow-moving inventory effectively.
 Consider clearance sales, repurposing materials, or recycling to minimize
losses.
12. Technology Integration:
 Integrate your inventory management system with other business processes,
such as sales, procurement, and accounting, for better coordination and
decision-making.
13. Collaboration with Sales and Marketing:

 Maintain open lines of communication with sales and marketing teams to align
inventory levels with upcoming promotions, seasonal trends, and marketing
campaigns.
14. Sustainability Considerations:

 Promote sustainability by managing inventory efficiently to reduce waste,
minimize overproduction, and optimize materials usage.

 Regularly evaluate your inventory management processes and performance
metrics to identify areas for improvement and cost reduction.
B. SUPPY CHAIN INTEGRATION
Supply chain integration in the shoe industry involves coordinating and optimizing the
various processes, stakeholders, and resources involved in the design, production,
distribution, and retail of footwear. Integration enhances efficiency, reduces costs, and
improves responsiveness to customer demands. Here's an overview of supply chain
integration practices in the shoe industry:
 Collaborate closely with material suppliers, component manufacturers, and
subcontractors to align production and delivery schedules with demand.
 Share demand forecasts and market insights to help suppliers plan production
effectively.
2. Information Sharing:
 Implement integrated information systems that facilitate real-time data sharing
and communication between supply chain partners.
 Share data on inventory levels, order status, quality control, and logistics
information
.
3. Vendor-Managed Inventory (VMI):
 Consider VMI agreements with key suppliers, allowing them to manage and
replenish inventory based on agreed-upon parameters.
 VMI reduces the risk of stockouts, minimizes carrying costs, and streamlines
replenishment.
4. Technology Integration:
 Invest in supply chain management software and tools that integrate with ERP
systems.
 Leverage technologies like RFID, IoT, and AI for demand forecasting,
inventory tracking, and order management.
5. Demand Forecasting:
 Collaborate with suppliers and retailers to improve demand forecasting
accuracy.
 Use historical data, market trends, and consumer insights to enhance forecast
models.
6. Inventory Optimization:
 Implement inventory optimization techniques, including safety stock
management and just-in-time (JIT) practices.
 Use demand-driven replenishment to minimize excess inventory and reduce
carrying costs.
7. Quality Assurance:
 Establish stringent quality standards and conduct regular audits of suppliers to
ensure materials and components meet quality requirements.
 Implement corrective actions when quality issues arise.
8. Logistics and Transportation Management:

 Integrate logistics and transportation management systems to optimize the
movement of raw materials and finished products.
 Optimize transportation routes and modes to minimize costs and reduce
delivery lead times.
9. Sustainability Initiatives:
 Collaborate with suppliers to align with sustainability goals, such as using
sustainable materials and adopting eco-friendly production practices.
 Promote ethical and eco-conscious footwear manufacturing.
10. Ethical and Social Responsibility:

 Ensure suppliers adhere to ethical labour practices, fair wages, and responsible
sourcing of materials.
 Consider certifications and audits related to social responsibility.
11. Risk Management:

 Develop risk mitigation strategies for supply chain disruptions, such as natural
disasters, geopolitical issues, and economic fluctuations.
 Diversify suppliers and maintain contingency plans.
12. Collaboration with Retailers:

 Work closely with retail partners to align inventory levels with consumer
demand.
 Share point-of-sale data to improve demand forecasting and optimize
replenishment.
13. Traceability and Transparency:

 Implement traceability systems to track the origin of materials and
components for quality control and compliance.
 Enhance transparency in the supply chain to build consumer trust.

 Regularly assess supply chain processes and performance metrics.
 Seek opportunities for continuous improvement in efficiency, cost reduction,
and customer service.
15. E-commerce Integration:

 Integrate e-commerce platforms with supply chain systems to streamline
online order processing, inventory management, and fulfilment.
Effective supply chain integration in the shoe industry enables companies to respond quickly
to changing market conditions, reduce lead times, minimize costs, and deliver high-quality
products to customers. It also supports sustainability and ethical practices, aligning with
evolving consumer expectations.
shipping and distribution
Shipping and distribution are critical components of the supply chain in the shoe industry.
Efficient logistics and distribution processes are essential for getting footwear products from
manufacturers to retailers or directly to consumers. Here's an overview of the shipping and
distribution practices in the shoe industry:
1. Distribution Channels:
 Shoe companies can distribute their products through various channels,
including wholesale to retailers, direct-to-consumer (DTC) online sales, and
company-owned retail stores.
2. Warehousing and Storage:

 Shoes are typically stored in warehouses or distribution centres before they are
shipped to retailers or customers.
 These facilities must be well-organized to ensure quick and accurate order
fulfilment.
3. Order Processing:
 Orders from retailers or online customers are processed through an order
management system.
 Order details, including product SKUs, quantities, and delivery addresses, are
recorded and prepared for picking and packing.
4. Inventory Management:
 Inventory levels are closely monitored to prevent overstocking or stockouts.
 Advanced inventory management systems help track the movement of shoes
within warehouses and distribution centres.
5. Picking and Packing:

 Shoes are picked from inventory, packaged, and prepared for shipment.
 Packaging materials should protect the shoes from damage during transit.
6. Shipping Options:
 Shoe companies offer various shipping options, including standard, expedited,
and overnight shipping.
 Customers may also have the choice of using different carriers (e.g., UPS,
FedEx, DHL).
7. Distribution Strategies:
 Companies may adopt different distribution strategies based on their target
markets. For example, they may focus on retail distribution or emphasize e-
commerce and DTC sales.
8. Cross-Docking:
 In some cases, shoe companies may employ cross-docking facilities to
streamline the distribution process. This involves receiving incoming goods
and immediately shipping them out without long-term storage.
9. Drop shipping:
 In online sales, some companies opt for drop shipping, where products are
shipped directly from manufacturers or third-party suppliers to customers.
This minimizes the need for warehousing.
10. Reverse Logistics:

 Shoe companies must also manage returns and exchanges efficiently through
reverse logistics processes.
 Returned shoes can be inspected, refurbished, and restocked for resale.
11. E-commerce Integration:

 For DTC sales, shoe companies integrate their e-commerce platforms with
order management and shipping systems.
 Real-time inventory updates ensure accurate product availability for online
customers.
12. Tracking and Traceability:

 Advanced tracking systems and barcoding enable customers to track their
shipments and provide visibility into the shipping process.
13. International Shipping:

 For global markets, shoe companies must navigate international shipping
regulations, customs clearance, and duties.
 Collaboration with experienced international carriers is essential.
14. Sustainability Considerations:
 Some shoe companies focus on sustainable shipping and distribution practices,
including eco-friendly packaging and transportation options.
15. Customer Service:

 Effective communication and customer support during the shipping process
are crucial for customer satisfaction.
 Addressing shipping-related inquiries and issues promptly is important.
16. Retailer Support:

 When distributing to retailers, shoe companies provide support in terms of
merchandising, marketing, and order fulfilment to ensure product availability
on store shelves.

 Regularly analyse shipping and distribution processes to identify areas for
improvement, cost reduction, and enhanced service levels.
Sustainability initiatives
a. Environmental considerations
The shoe industry, like many other manufacturing sectors, has a significant impact on the
environment due to the use of materials, energy, and various production processes. However,
there is a growing awareness within the industry about the need for more sustainable and
environmentally friendly practices. Here are some important environmental considerations
and initiatives in the shoe industry:
1. Sustainable Materials:
 The choice of materials is a critical factor in reducing the environmental
impact of shoe production. Shoe manufacturers are increasingly using
sustainable and eco-friendly materials, such as organic cotton, recycled
polyester, and leather alternatives made from plant-based or synthetic
materials.
 Initiatives like sourcing leather from certified tanneries that follow
environmentally responsible practices are gaining traction.
2. Reducing Chemical Use:

 Shoe manufacturing often involves the use of various chemicals, including
adhesives and dyes. Companies are working to reduce the use of hazardous
chemicals and replace them with safer alternatives.
 Compliance with regulations like REACH in the European Union, which
addresses the use of chemicals, is essential.
3. Energy Efficiency:
 Shoe manufacturers are adopting energy-efficient technologies and processes
in their production facilities to reduce energy consumption and greenhouse gas
emissions.
 Transitioning to renewable energy sources, such as solar and wind power, is
becoming more common.
4. Waste Reduction and Recycling:

 Minimizing waste and promoting recycling are key environmental goals.
Companies are implementing waste reduction strategies and recycling
programs for materials like rubber, foam, and textiles.
 Some shoe brands are designing shoes with disassembly in mind, making it
easier to recycle components at the end of their life.
5. Water Conservation:
 The tanning and dyeing processes in leather and textile production can be
water-intensive. Companies are adopting technologies and practices to reduce
water usage and wastewater pollution.
 Water recycling and treatment systems are being implemented to minimize the
environmental impact of water usage.
6. Supply Chain Transparency:

 Brands are working to increase transparency within their supply chains. This
includes monitoring the environmental practices of suppliers and ensuring that
they adhere to sustainability standards.
 Brands are also encouraging responsible sourcing of materials to reduce the
environmental and social impact of raw material extraction.
7. Circular Economy Initiatives:

 Some shoe companies are exploring circular economy models, where products
are designed for durability, repairability, and eventual recycling.
 Programs for shoe take-back, refurbishment, and resale are being introduced.
8. Certifications and Standards:

 Certifications like the Global Organic Textile Standard (GOTS), Leather
Working Group (LWG), and Cradle to Cradle Certified are being used to
verify environmental and social responsibility in shoe manufacturing.
9. Consumer Education:
 Brands are educating consumers about the environmental impact of footwear
choices and promoting sustainable consumption habits.
 Information about the environmental footprint of shoes, including materials
and production processes, is often provided to consumers.
10. Collaboration and Industry Initiatives:

 Shoe companies are collaborating with industry organizations, NGOs, and
other stakeholders to drive sustainability initiatives and share best practices.
 Initiatives like the Sustainable Apparel Coalition's Higg Index are used to
measure and improve the sustainability of products.

 Companies are ensuring compliance with environmental regulations in various
regions, including product labelling requirements, chemical restrictions, and
waste management regulations.
By addressing these environmental considerations and adopting sustainable practices, the

shoe industry is working toward reducing its environmental footprint and becoming more
responsible in its production processes. These efforts not only benefit the environment but
also contribute to meeting the growing demand for eco-conscious products from consumers.
Sustainable practices in plant layout
Sustainable practices in plant layout in the shoe industry aim to reduce the environmental
impact of manufacturing processes while optimizing efficiency and worker well-being. Here
are some sustainable practices to consider when designing the layout of a shoe manufacturing
plant:
 Design the plant layout to maximize natural lighting and ventilation, reducing
the need for artificial lighting and air conditioning.
 Implement energy-efficient lighting systems, HVAC (heating, ventilation, and
air conditioning), and machinery to reduce energy consumption.
 Consider the use of renewable energy sources, such as solar panels, to power
the facility.
2. Water Conservation:
 Install water-efficient fixtures and equipment in restrooms and manufacturing
processes.
 Implement water recycling systems to capture and treat wastewater for reuse
in non-potable applications.
 Minimize water use in dyeing and finishing processes through efficient
equipment and practices.
3. Waste Reduction and Recycling:

 Design waste sorting and recycling stations throughout the plant to encourage
proper waste disposal.
 Work with suppliers to minimize packaging waste and ensure materials arrive
in eco-friendly packaging.
 Explore opportunities for recycling or repurposing scrap materials generated
during shoe production.
4. Material Efficiency:
 Optimize material usage by reducing material waste in cutting and
manufacturing processes.
 Implement lean manufacturing principles to reduce overproduction and excess
inventory.
 Choose sustainable and eco-friendly materials, such as recycled or bio-based
materials, whenever possible.
5. Lean Manufacturing Principles:
 Adopt lean manufacturing practices to reduce waste, improve process
efficiency, and minimize excess inventory.
 Implement a pull production system that produces shoes based on actual
demand to reduce overproduction.
6. Green Building Design:

 Consider green building design principles when constructing or renovating
plant facilities.
 Use sustainable building materials, enhance insulation, and incorporate
energy-efficient building systems.
7. Air Quality and Ventilation:

 Install effective ventilation systems to maintain good indoor air quality and
remove pollutants generated during shoe manufacturing.
 Use low-VOC (volatile organic compound) paints and adhesives to minimize
air pollution.
8. Worker Well-being:
 Prioritize worker comfort and well-being in plant layout, providing ergonomic
workstations, break areas, and safety measures.
 Implement health and safety programs to protect workers from potential
hazards associated with shoe manufacturing.
9. Transportation Optimization:
 Plan the layout to minimize the distances that materials and products need to
be transported within the plant.
 Use electric or hybrid forklifts and other material handling equipment to
reduce emissions.
10. Green Certification and Compliance:

 Seek green building certifications, such as LEED (Leadership in Energy and
Environmental Design), to ensure compliance with sustainable building
practices.
 Stay up-to-date with environmental regulations and ensure the plant layout
complies with local and national environmental standards.

 Continuously monitor and assess the plant layout for opportunities to further
enhance sustainability and efficiency.
 Involve employees in identifying and implementing sustainable practices.
12. Supplier Sustainability:

 Collaborate with suppliers who share a commitment to sustainability,
including eco-friendly materials, ethical labour practices, and environmental
responsibility.
Implementing these sustainable practices in plant layout not only reduces the environmental
impact of shoe manufacturing but also contributes to cost savings, compliance with
regulations, and improved worker morale and productivity. Sustainable plant design aligns
with the growing consumer demand for eco-conscious products and can enhance the
reputation of shoe manufacturers in the market.
5S METHODOLOGY
SORT
SUSTAIN SET IN ORDER
STANDARDIZE SHINE
The 5S methodology is a Lean manufacturing tool that can be applied to the production of
shoes to improve efficiency, organization, and workplace safety. The 5S framework consists
of five principles, each beginning with the letter "S," which represent different aspects of
workplace optimization. Here's how you can apply the 5S method in the production of shoes:
1. Sort (Seiri):
 The first step is to declutter and eliminate unnecessary items from the
production area.
 Remove any tools, materials, or equipment that are not needed for the current
shoe production process.
 Sort and organize materials and components, keeping only what is essential
for the current production run.
2. Set in Order (Seiton):

 Organize the remaining items in a logical and efficient manner.
 Assign specific locations for tools, materials, and equipment to minimize
search and setup times.
 Use clear labels, color-coding, and visual cues to indicate the proper place for
each item.
3. Shine (Seiso):
 Clean and maintain the production area regularly to ensure a safe and
productive environment.
 Implement cleaning schedules and procedures for workstations, machinery,
and storage areas.
 Encourage employees to take responsibility for keeping their work areas clean
and tidy.
4. Standardize (Seiketsu):
 Establish standardized work practices and procedures to maintain the
improvements made in the first three steps.
 Develop checklists and guidelines for maintaining organization and
cleanliness.
 Ensure that all employees are trained in and follow the standardized processes.
5. Sustain (Shitsuke):
 Maintain a culture of continuous improvement and discipline.
 Regularly review and audit the 5S practices to ensure they are being followed
consistently.
 Encourage employee involvement in identifying and addressing areas for
improvement.
Applying the 5S methodology in the production of shoes can lead to several benefits:
 Improved Efficiency: By eliminating waste and optimizing the layout, processes

become more efficient, reducing production time and costs.
 Enhanced Quality: A well-organized and clean workspace reduces the likelihood of
errors and defects in shoe production.
 Enhanced Safety: A clutter-free and organized workspace is safer for employees,
reducing the risk of accidents and injuries.
 Increased Morale: A clean and organized workplace can boost employee morale and
engagement.
 Sustainability: 5S principles can help reduce waste and promote sustainable practices
in shoe manufacturing.
KAIZEN TECHNOLOGY
Kaizen, a Japanese term meaning "continuous improvement" is a philosophy that
emphasizes incremental and continuous improvements in all aspects of an organization's
processes, products, or services. This concept can be applied to various industries, including
the shoe industry, to enhance efficiency, quality, and overall performance. Here's how Kaizen
technology might be implemented in the shoe industry:
1. Production Process Optimization:

 Identify bottlenecks and inefficiencies in the production process.
 Implement small, incremental changes to streamline production flow.
 Use technology to automate repetitive tasks and reduce manual errors.
2. Quality Control:
 Implement a rigorous quality control system to catch defects early in the
production process.
 Utilize technology such as sensors and automated inspection systems to
enhance quality checks.
 Analyse feedback from customers and production teams to identify areas for
improvement.
3. Employee Involvement:
 Encourage and empower employees to contribute ideas for improvement.
 Foster a culture of continuous learning and skill development.
 Implement training programs to ensure that employees are equipped with the
necessary skills and knowledge.
4. Supply Chain Management:

 Collaborate closely with suppliers to improve the reliability and quality of raw
materials.
 Implement just-in-time inventory systems to minimize excess inventory and
reduce waste.
 Utilize technology for real-time tracking of shipments and inventory levels.
5. Product Design and Innovation:
 Involve designers and engineers in the continuous improvement process.
 Collect feedback from customers and frontline workers to inform product
design changes.
 Leverage technology such as 3D printing for rapid prototyping and testing.
 Evaluate energy consumption in manufacturing processes.
 Implement energy-efficient technologies and practices to reduce
environmental impact.
 Monitor and optimize energy usage through smart systems and automation.
7. Data Analysis and Continuous Monitoring:

 Collect and analyse data on various aspects of the production process.
 Use data analytics to identify trends, patterns, and areas for improvement.
 Implement real-time monitoring systems to address issues promptly.
8. Lean Manufacturing Principles:

 Implement lean manufacturing principles to eliminate waste and improve
efficiency.
 Apply concepts such as 5S (Sort, Set in order, Shine, Standardize, Sustain) for
workplace organization and cleanliness.
9. Customer Feedback and Market Trends:

 Regularly gather feedback from customers on product satisfaction and
expectations.
 Stay informed about market trends and integrate relevant features into product
design and production.
SAFETY AND EMPLOYEE WELL-BEING
A.SAFETY PROTOCOLS
Safety protocols in the shoe industry are crucial to protect workers from potential hazards and
ensure a safe working environment. The following are some key safety protocols and
practices that should be implemented in a shoe manufacturing facility:
1. Personal Protective Equipment (PPE):

 Mandate the use of appropriate PPE, including safety shoes, safety glasses,
gloves, and hearing protection, depending on the specific job tasks.
 Provide and maintain PPE for all employees, and conduct regular training on
its proper use.
2. Machine Safety:
 Regularly inspect and maintain machinery to ensure it is in safe working
condition.
 Install machine guards and safety interlocks to prevent accidental contact with
moving parts.
 Conduct employee training on machine operation and safety procedures.
3. Chemical Safety:
 Properly label and store chemicals, adhesives, and solvents in dedicated areas
with adequate ventilation.
 Provide Material Safety Data Sheets (MSDS) for all chemicals used, and train
employees on safe handling procedures.
 Use personal protective equipment, such as gloves and eye protection, when
working with chemicals.
4. Fire Safety:
 Install fire alarms, fire extinguishers, and smoke detectors throughout the
facility.
 Conduct regular fire drills and provide fire safety training to employees.
 Establish emergency evacuation routes and assembly points.
5. Electrical Safety:
 Inspect and maintain electrical systems and equipment to prevent electrical
hazards.
 Ensure that employees are trained in safe electrical practices, such as
lockout/tagout procedures.
6. Ergonomics:
 Design workstations and tasks to minimize ergonomic risks and reduce the
likelihood of repetitive strain injuries.
 Provide ergonomically designed tools and equipment to reduce physical stress
on workers.
7. Slip, Trip, and Fall Prevention:

 Keep work areas clean and organized to minimize slip, trip, and fall hazards.
 Use anti-slip flooring and provide proper drainage in areas where water or
liquids are present.
 Conduct regular housekeeping and maintenance to address potential hazards.
8. Lifting and Material Handling:

 Train employees in safe lifting techniques to prevent back injuries.
 Use mechanical aids, such as forklifts or conveyor systems, for heavy material
handling tasks.
 Store materials at appropriate heights to reduce the need for excessive bending
or reaching.
9. Ventilation and Air Quality:

 Ensure proper ventilation and air quality in areas where chemicals or fumes
are present.
 Monitor air quality and implement measures to control dust and airborne
contaminants.
10. Emergency Response:
 Establish a clear emergency response plan that includes procedures for
responding to injuries, chemical spills, fires, and other emergencies.
 Provide first-aid kits and ensure that designated personnel are trained in first
aid and CPR.
11. Training and Education:

 Conduct regular safety training programs for employees, including new hires
and temporary workers.
 Encourage employees to report safety concerns and incidents promptly.
12. Safety Committees:

 Establish safety committees or teams that include both management and
employee representatives to identify and address safety issues.
13. Safety Audits and Inspections:

 Conduct regular safety audits and inspections to identify and rectify potential
hazards and safety violations.
14. Documentation and Record-Keeping:

 Maintain records of safety training, incident reports, safety audits, and safety-
related communications.
 Use incident reports to investigate accidents and near-misses to prevent future
occurrences.
15. Compliance with Regulations:

 Stay informed about and comply with local, state, and national safety
regulations and standards applicable to the shoe industry.
A.EMPLOYEE FACILITIES
Providing adequate employee facilities in a shoe manufacturing facility is essential for

ensuring the well-being, safety, and productivity of the workforce. Here are some key
employee facilities and amenities commonly found in the shoe industry:
 Breakrooms and Cafeterias:

 Designated areas for employees to take breaks, eat meals, and relax during
their work shifts.
 Furnish breakrooms with tables, chairs, vending machines, microwaves, and
refrigerators.
 Restrooms and Washrooms:

 Clean and well-maintained restrooms with sufficient toilets, sinks, and
handwashing facilities.
 Provide adequate supplies of soap, paper towels, and toilet paper.
 Locker Rooms and Changing Areas:

 Locker rooms equipped with lockers or storage spaces for employees to store
personal belongings and work attire.
 Changing areas with benches or seating for employees to change into and out
of work attire.
 First Aid Stations:

 Establish first aid stations with basic medical supplies and equipment for
addressing minor injuries and health concerns.
 Ensure that designated personnel are trained in first aid and CPR.\
 Safety Equipment Storage:

 Designated areas for storing personal protective equipment (PPE), including
safety shoes, gloves, goggles, and hearing protection.
 Clearly label and organize storage areas for easy access.
 Smoking Areas:
 Designated smoking areas with proper ventilation and smoking shelters
located away from workspaces and entrances.
 Promote a smoke-free work environment.
 Recreation Areas:
 Outdoor or indoor recreation areas, if space permits, for employees to engage
in physical activities or relax during breaks.
 Equip recreation areas with benches, tables, and, if possible, fitness
equipment.
 Quiet Areas:
 Create quiet spaces where employees can take short breaks or make personal
phone calls without disturbing others.
 Consider providing noise-cancelling headphones or quiet rooms.
 Training and Meeting Rooms:

 Dedicated rooms for employee training sessions, safety meetings, and team
discussions.
 Outfit meeting rooms with audiovisual equipment, whiteboards, and
comfortable seating.
 Wellness Programs:
 Offer wellness programs and initiatives, such as health screenings, fitness
classes, and counselling services.
 Promote a healthy lifestyle among employees.
 Childcare Facilities:
 In larger manufacturing facilities, consider offering on-site childcare facilities
or partnerships with local childcare providers to support employees with
children.
 Parking and Transportation:
 Adequate parking facilities for employees who commute by car, with
designated spaces for disabled individuals.
 Consider offering shuttle services or public transportation options for
employees who rely on public transit.
 Accessibility:
 Ensure that all employee facilities are accessible to individuals with
disabilities, including ramps, elevators, and accessible restrooms.
 Security Measures:
 Implement security measures, such as surveillance cameras and well-lit
parking lots, to ensure the safety of employees both during and after working
hours.
 Hygiene Facilities:
 Provide handwashing stations or hand sanitizer dispensers at key locations
throughout the facility, especially in areas where hygiene is critical.
 Employee Assistance Programs (EAPs):

 Offer EAPs to provide employees with access to counselling and support
services for personal or work-related issues.
b. Health and safety measures
Employee health and safety measures in the shoe industry are crucial to protect workers from
workplace hazards and create a safe and productive working environment. Here are some key
health and safety measures that should be implemented:
1. Safety Training:
 Provide comprehensive safety training to all employees, including new hires
and temporary workers.
 Training should cover hazard recognition, proper use of personal protective
equipment (PPE), emergency procedures, and safe work practices.
2. Personal Protective Equipment (PPE):

 Ensure that employees have access to and wear appropriate PPE, such as
safety shoes, safety glasses, gloves, ear protection, and respiratory protection,
based on job-specific hazards.
 Regularly inspect and maintain PPE, and replace damaged or worn equipment.
3. Machine Safety:
 Conduct regular machine safety inspections to identify and address potential
hazards.
 Train employees on the safe operation of machinery, including lockout/tagout
procedures.
 Install machine guards and safety interlocks to prevent accidental contact with
moving parts.
4. Chemical Safety:
 Safely store and label chemicals, adhesives, and solvents.
 Maintain Material Safety Data Sheets (MSDS) for all chemicals used and
ensure that employees are trained in safe handling and disposal practices.
 Provide adequate ventilation in areas where chemicals are used.
5. Ergonomics:
 Assess workstations and job tasks to minimize ergonomic risks and reduce the
potential for repetitive strain injuries.
 Provide ergonomically designed tools and equipment to reduce physical stress
on workers.
6. Hazard Communication:
 Implement a hazard communication program that includes clear labeling of
hazardous materials, signage, and employee education on the potential hazards
associated with their work.
7. Fire Safety:
 Install and maintain fire alarms, fire extinguishers, and smoke detectors
throughout the facility.
 Conduct regular fire drills and provide training on evacuation procedures.
 Ensure that fire exits are clearly marked and unobstructed.
8. Emergency Response:
 Establish clear emergency response procedures for incidents such as injuries,
chemical spills, fires, and natural disasters.
 Provide first-aid kits and ensure designated personnel are trained in first aid
and CPR.
9. Slip, Trip, and Fall Prevention:

 Keep work areas clean and organized to minimize slip, trip, and fall hazards.
 Use anti-slip flooring and provide proper drainage in areas where water or
liquids are present.
 Conduct regular housekeeping and maintenance.
10. Lifting and Material Handling:

 Train employees in safe lifting techniques to prevent back injuries.
 Use mechanical aids, such as forklifts, pallet jacks, and conveyor systems, for
heavy material handling tasks.
 Store materials at appropriate heights to reduce the need for excessive bending
or reaching.
11. Ventilation and Air Quality:

 Ensure proper ventilation and air quality in areas where dust, fumes, or
chemicals are present.
 Monitor air quality and implement measures to control airborne contaminants.
12. Safety Committees and Reporting:

 Establish safety committees or teams that include both management and
employee representatives to identify and address safety issues.
 Encourage employees to report safety concerns and incidents promptly.
13. Regular Inspections and Audits:

 Conduct regular safety inspections and audits to identify and rectify potential
hazards and safety violations.
 Address identified issues promptly to prevent accidents
.
14. Safety Culture:
 Foster a culture of safety by promoting open communication, encouraging
employees to participate in safety initiatives, and recognizing and rewarding
safe behaviour.

 Stay informed about and comply with local, state, and national health and
safety regulations and standards applicable to the shoe industry.
Creating and maintaining a safe working environment through these health and safety
measures is not only essential for protecting employees but also for enhancing productivity,
reducing absenteeism, and minimizing workplace accidents and injuries in the shoe industry.
Regular training, ongoing hazard assessments, and a commitment to continuous improvement
are key elements of a strong safety program.
Future improvements
C. Continuous improvement strategies

Continuous improvement strategies are essential in the shoe industry to enhance product
quality, increase efficiency, reduce costs, and stay competitive. Implementing a culture of
continuous improvement can lead to long-term success. Here are some strategies and
methodologies commonly used in the shoe industry for continuous improvement:
1. Lean Manufacturing:
 Adopt lean principles to eliminate waste and improve production efficiency.
 Implement practices such as 5S (Sort, Set in order, Shine, Standardize,
Sustain), Kanban, and value stream mapping to streamline processes.
2. Six Sigma:
 Use Six Sigma methodologies to reduce defects and variations in
manufacturing processes.
 Employ DMAIC (Define, Measure, Analyse, Improve, Control) and DFSS
(Design for Six Sigma) approaches to achieve process optimization.
3. Total Quality Management (TQM):

 Establish a culture of quality throughout the organization.
 Encourage employee involvement in quality improvement initiatives and use
tools like PDCA (Plan-Do-Check-Act) cycles.
4. Kaizen:
 Promote a culture of continuous small improvements.
 Encourage employees at all levels to suggest and implement changes that
enhance efficiency and quality.
5. Value Engineering (VE):

 Analyse the value of each component and process in shoe manufacturing to
identify opportunities for cost reduction without compromising quality.
 Seek alternatives that provide the same functionality at a lower cost.
6. Quality Circles:
 Establish quality circles, small groups of employees who meet regularly to
identify and address quality and process improvement opportunities.
 Encourage brainstorming and problem-solving within these circles.
 Collaborate closely with suppliers to improve the quality of materials and
components.
 Share feedback and engage in joint improvement efforts to enhance the overall
supply chain.
8. Continuous Monitoring and Data Analysis:

 Use data analytics to monitor production processes and product quality.
 Implement statistical process control (SPC) to identify trends and deviations
early, allowing for proactive corrective actions.
9. Employee Training and Development:

 Invest in employee training and skill development to ensure that the workforce
is capable of implementing improvements.
 Train employees in problem-solving methodologies and tools.
10. Standardization:
 Establish standardized work processes and procedures to reduce variations and
errors.
 Ensure that all employees understand and adhere to these standards.
11. Cross-Functional Teams:

 Form cross-functional teams to address specific improvement projects.
 Bring together employees from different departments to provide diverse
perspectives and expertise.
12. Continuous Product Testing and Evaluation:

 Continuously test and evaluate shoe products for quality, durability, and
performance.
 Gather feedback from customers and use it to make product improvements.
13. Supply Chain Optimization:

 Optimize supply chain operations to minimize lead times, reduce inventory
carrying costs, and improve overall efficiency.
 Collaborate with logistics and procurement teams for better supply chain
management.
14. Environmental Sustainability:

 Focus on sustainable practices, such as reducing waste, using eco-friendly
materials, and implementing energy-efficient processes.
 Seek opportunities to reduce the environmental impact of production.
15. Feedback Loops:

 Establish feedback loops with employees, customers, and suppliers to gather
input and identify improvement areas.
 Act on feedback promptly to drive positive changes.
16. Benchmarking:
 Benchmark against industry leaders and competitors to identify areas where
the company can improve.
 Adopt best practices from other successful companies.
17. Technology Adoption:
 Invest in advanced technologies, such as automation and robotics, to improve

production efficiency and quality control.
 Embrace digital tools for data analysis and process optimization.
Future expansion plans
Future expansion plans in the shoe industry should be strategic and aligned with market
trends, consumer preferences, and the company's growth objectives. Here are some key
considerations and strategies for planning expansion in the shoe industry:
1. Market Research and Analysis:

 Conduct thorough market research to identify emerging trends, consumer
demands, and potential growth opportunities.
 Analyse market data, including consumer demographics, preferences, and
buying behaviour.
2. Product Diversification:
 Explore opportunities to diversify your product range to cater to different
customer segments.
 Consider expanding into new shoe categories, such as athletic footwear, casual
wear, or sustainable and eco-friendly options.
3. Geographic Expansion:
 Evaluate potential markets for geographic expansion. Consider both domestic
and international markets.
 Assess market conditions, regulatory requirements, and consumer preferences
in target regions.
4. E-commerce and Online Sales:

 Invest in an online presence and e-commerce capabilities to reach a broader
customer base.
 Enhance the user experience on your website and optimize for mobile devices.
5. Retail Expansion:
 Consider opening new retail stores in strategic locations based on market
demand and foot traffic.
 Explore various retail formats, including flagship stores, outlet stores, and
pop-up shops.
6. Franchising and Licensing:

 Explore franchising or licensing opportunities to expand your brand's presence
without the need for significant capital investment.
 Partner with reputable franchisees or licensees who share your brand values.
7. Collaborations and Partnerships:

 Collaborate with other brands, designers, or retailers to create limited-edition
collections or exclusive product lines.
 Partnerships can help expand your brand's reach and attract new customer
segments.
8. Sustainability Initiatives:
 Consider expanding your product offerings with sustainable and eco-friendly
footwear options.
 Invest in environmentally responsible manufacturing processes and materials.
9. Customization and Personalization:

 Offer customization and personalization options to cater to individual
customer preferences.
 Implement technology that allows customers to design their own shoes.
10. Supply Chain Optimization:

 Streamline your supply chain to support expansion plans.
 Optimize inventory management, logistics, and distribution to meet increased
demand.
11. Marketing and Branding:

 Invest in marketing and branding efforts to raise brand awareness and attract
new customers.
 Utilize digital marketing, social media, and influencer collaborations to reach
a wider audience.
12. Quality Control and Innovation:

 Maintain a strong focus on product quality and innovation to differentiate your
brand in a competitive market.
 Continuously improve product designs, materials, and manufacturing
processes.
13. Financial Planning:

 Develop a comprehensive financial plan that includes budgeting, funding
requirements, and risk analysis.
 Ensure you have the necessary capital and financing options to support
expansion.
14. Talent Acquisition and Training:

 Hire and train skilled employees to support expansion efforts.
 Develop a workforce that is aligned with your brand values and customer
service expectations.
15. Customer Feedback and Adaptation:

 Continuously gather feedback from customers and adapt your strategies based
on their preferences and needs.
 Be agile and responsive to changing market conditions.
16. Compliance and Sustainability:

 Ensure compliance with regulations in new markets and maintain a
commitment to sustainability and responsible manufacturing practices.
17. Mergers and Acquisitions:

 Explore opportunities for mergers or acquisitions that align with your
expansion goals and complement your product portfolio.
18. Risk Mitigation:
 Identify potential risks associated with expansion and develop contingency
plans to address them.
 Conduct thorough due diligence before entering new markets or partnerships.
Expanding in the shoe industry requires careful planning, market intelligence, and a
willingness to adapt to changing market dynamics. By aligning your expansion plans with
customer needs and market trends, you can position your company for sustainable growth and
success.
RESEARCH METHODOLOGY
The study will be conducted to achieve the aforesaid objectives including both exploratory
and descriptive in nature that involves optimizing the plant layout effective planning, which
aims to provide easier flow of materials and production at the lowest cost based on reduced
material handling and current demand which is in questionnaire format. A Research
Methodology defines the purpose of the research, how it proceeds, how to measure progress
and what constitute success with respect to the objectives determined for carrying out the
research study. The research process that will be adopted in the present study consists of the
following stages:
RESEARCH DESIGN: Exploratory Research

A Research design is the specification of methods and procedures for acquiring the
information needed to structure or solve the problem. It is the overall operational pattern or
framework of the project that stimulates what information is to be collected from which
source and by what procedure. On the basis of major purpose of our investigation the
Exploratory Research was found to be most suitable. This kind of research has the primary
objective of development of insights into the problem. It studies the main area where the
problem lies and also tries to evaluate some appropriate courses of action.
DATA COLLECTION SOURCES

PRIMARY SOURCES:
The data required for the study has been collected from-
 Questionnaire: Survey among customers
 Personal Communication with Mentor: With company representatives regarding
consumer buying behaviour
SECONDARY SOURCES:
The secondary data has been collected from-
 Internet
 Organizational Reports
 Business Magazines
 Books
 References
SAMPLING METHOD: Survey is done by random sampling method.

SAMPLE SIZE: 91
SAMPLE AREA: Kanpur
MODE OF ANALYSIS:
The instrument used for the data collection was in the form of questionnaire. The
questionnaire was used as it facilitates the tabulation and quick analysis of data to be
collected. The data collected was subjected to simple frequency distribution and percentage
analysis.
DATA ANALYSIS
Analysis of data:
CONCLUSION
In conclusion, the shoe industry is a dynamic and competitive sector that continually evolves
to meet changing consumer demands and market trends. This report has highlighted various
aspects of the industry, including market trends, challenges, and opportunities. Additionally,
the application of Kaizen technology in the shoe industry has been discussed as a means to
achieve continuous improvement in various facets of the business.
The implementation of Kaizen principles in the production process can lead to increased
efficiency, enhanced product quality, and overall operational excellence. By optimizing
production processes, improving quality control measures, involving employees in the
improvement process, and staying attuned to market trends, companies in the shoe industry
can position themselves for sustainable growth and success.
Furthermore, the integration of technology, such as automation, data analytics, and smart
systems, plays a crucial role in driving innovation and improving overall performance. From
supply chain management to product design and customer feedback analysis, technology
offers valuable tools to streamline operations and make informed decisions.
In order to stay competitive in the dynamic landscape of the shoe industry, businesses must
not only adapt to current market demands but also anticipate and embrace future trends.
Continuous learning, employee engagement, and a commitment to sustainability are essential
components of a successful strategy.
Ultimately, by embracing Kaizen principles and leveraging technology, the shoe industry has
the potential to not only meet the expectations of today's consumers but also to drive positive
change and make a lasting impact on the global market. As the industry continues to evolve,
companies that prioritize continuous improvement and innovation are likely to thrive in this
ever-changing business environment.
RECOMMENDATIONS
After analysing the workflow in the factory departments throughout the production process
and noting the layout obstacles, it is apparent that work flow could be improved by modifying
the layout design.
The distance between the departments could be reduced to improve material handling cost
and time to facilitate timely delivery.
The new path should be proposed so that raw material to the production department to be
reduced to some meters; similarly, the distance from the inspection department for defective
pieces to return to the furnace should be reduced.
This will help to prevent accidents during material transportation by avoiding indirect routes.
The layout rearrangement should thus decrease both time and distance in the flow of work,
reducing workers’ effort and generating productivity improvement.
BIBLIOGRAPHY
 Furo Shoes Website
 www.scribd.com
 Personal communication
 Times of India Newspaper
 Search Engine www.google.com
 Course book of MBA
ANNEXURE
QUESTIONNAIRE
Q1. What are the different types of shoes you wear?
a) Formal
b) Casual
c) Sports
d) Others
Q2. Have you bought shoes recently? (In past 6 months)? If yes, which brand?
Q3. Was it a first time buy?
a) Yes
b) No
Q4. If repeat, was it the same brand?
a) Yes
b) No
Q5. What factors influenced you to switch over brands?
a) Price
b) Change in trend
c) Peer effect
d) Promotions/Discounts
e) Previous bad experience
Q6. How frequently you use the shoes?
a) Once a week
b) Twice a week
c) At weekends
d) Daily
Q7. For what purpose you wear shoes?
a) General visit
b) Party
c) Meetings
d) Sports activities
Q8. How much do you care about brands while buying shoes?
a) Not at all
b) Sometimes
c) Some what
d) Strongly
Q9. Do you buy only branded shoes?
a) Yes, always
b) Never
c) Only when quality is important
d) Rarely
e) I look at the price
Q10. You choose branded shoes because
a) They are of higher quality
b) They are impressive
c) You can afford them
d) Other
Q11. From which sources you got/collected information regarding your purchase
a) Friends
b) Internet
c) Retail outlets/salesman
d) Other
Q12. Who from below played a major role (influence) in the purchase?
a) Friends
b) Family
c) Salesman at the counter
d) Peers
e) Promotion
f) Advertisements
g) No one
Q13. From which place you like buying shoes?
a) Online websites
b) Shoe stores
Q14. If online which website?
a) Amazon
b) Flipkart
c) Myntra
d) Jabong
e) Snapdeal
f) Paytm
Q15. Which of the following, according to you, makes a good brand?
a) Quality
b) Promotion
c) Competitive pricing
d) Discounts
e) Others
If others please specify……..
Q16. Do you believe in brands that are endorsed by your favourite celebrities?
a) Yes
b) No
Q17. How would you rank following attributes on scale 1 to 10 while buying shoes?
a) Brand
b) Comfort
c) Durability
d) Function
e) Fashion
f) Price
g) Quality
h) Performance
i) Profession
j) Reliability
Q18. I wear branded products, because they reflect me/ my personality (say something about
me)
a) Strongly agree
b) Agree
c) Maybe
d) Disagree
e) Strongly disagree
Q19. I like buying imported products, because they are of high quality
a) Strongly agree
b) Agree
c) Maybe
d) Disagree
Q20. I buy products which are unique
a) Strongly agree
b) Agree
c) Maybe
d) Disagree
Q21. I like to buy products that impress people
a) Strongly agree
b) Agree
c) Maybe
d) Disagree

Sip Report... Sakshi

Uploaded by

Copyright:

Available Formats

You might also like

Sip Report... Sakshi

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sip Report... Sakshi

Uploaded by

Copyright:

Available Formats

STUDY ON PLANT LAYOUT DESIGN IN LGPL

SUMMER INTERNSHIP PROJECT

Under the guidance of

Ms. Nishtha Bhagwani

in partial fulfilment of the requirements for award of the degree of

MASTER OF BUSINESS ADMINISTRATION

Dr. A.P.J Abdul Kalam Technical University

Allenhouse Institute of Management

It has been great honor and privilege to undergo this project.

My thanks and appreciation also go to my colleagues who have willingly helped me in

Sakshi Dr. Shivani

Mr. Sabyasachi Das Dr. Shivani

 A. Background of FURO Shoes

 II. PLANT LAYOUT OVERVIEW

 Facility Size and Location

 Factors Influencing Plant Layout

 Continuous Improvement Strategies

A. BACKGROUND OF LEAYAN GLOBAL PRIVATE LTD

Outer sole Quartor Winsel

The purpose of this document is to provide a comprehensive overview of FURO Shoes’

2. Workflow Optimization: A well-designed plant layout helps streamline the

3. Safety and Compliance: Safety is a crucial consideration in any industrial setting. A

6. Communication and Collaboration: A well-documented plant layout serves as a

9. Continuous Improvement: As processes and technology evolve, a plant layout

10. Documentation and Record-Keeping: Plant layout documents serve as an official

A.Facility size and location

1. Production Capacity: Determine the required production capacity to meet current

1. Proximity to Suppliers: Consider the proximity of your facility to suppliers of raw

2. Market Access: Evaluate the location's accessibility to target markets. Proximity to

3. Transportation Infrastructure: Assess the availability of highways, railways, ports,

6. Environmental Factors: Evaluate environmental factors, such as climate, weather,

8. Competition: Assess the competitive landscape in the chosen location. Determine if

KEY PRODUCTION AREAS

1. Design and Development:

4. Cutting and Preparation:

5. Assembly and Stitching:

6. Lasting and Bottoming:

10. Warehousing and Distribution:

11. Retail Sales:

12. Customer Service and Support:

13. Marketing and Branding:

14. Research and Development (R&D):

quality, comfort, and sustainability.

16. E-commerce and Online Sales:

17. Customization and Personalization:

18. Innovation and Technology:

FLOW OF MATERIALS AND PRODUCTS

2. Material Inspection and Quality Control:

4. Cutting and Preparation:

5. Assembly and Stitching:

10. Warehousing and Distribution:

11. Retail Sales:

1. Occupational Health and Safety (OHS):

7. Supply Chain Transparency:

9. Labelling and Documentation:

10. International Standards:

11. Ethical and Labor Standards:

12. Regulatory Compliance: