Lean manufacturing strategies in small and medium enterprises: a case of a Durban shoe manufacturer.
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Date
2021
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Abstract
The study explores lean manufacturing strategies concerning supply chain processes in the shoe
industry. These processes have been mainly difficult as the practices involved cannot always be
automated which leads to large amounts of wastage. There has also been an increase in consumer
demand for quality products to be delivered in a short space of time at the lowest price. This type of
manufacturing process results in a high volume of waste that contributes to increased costs. This study
addressed all the research questions incisively from which rich and detailed data emanated which
identified and assessed lean manufacturing challenges faced by small and medium enterprises in
eliminating manufacturing waste that emanated from overproduction, transportation and motion
mismanagement, and inappropriate processing skills, among others. The study employed a qualitative
methodology and utilised data collection techniques such as interviews and observations involving all
employees categorised as product coordinators, pre-production staff, and factory supervisors who are
critical in planning, designing, material handling, and administrative responsibilities at production
sites. The value stream mapping and eight common reasons for waste in manufacturing processes
were considered in the case study by engaging a Durban shoe manufacturing company. There was a
distinct identification of waste being a non-value-adding component which involved internal delays,
over-processing, and non-delivery or late arrival of raw materials. These findings revealed that nonvalue-
adding activities, increase costs and compromises quality in the production of ladies’ sandals
and closed-fitting shoes. The recommendation is that shoe manufacturers adopt lean methods to
minimise wastage generated during unsound manufacturing processes. These lean methods consist of
standardisation of work, 5S, and Kaizen which all minimise waste in manufacturing processes if
applied strictly and consistently.
Description
Masters Degree. University of KwaZulu-Natal, Durban.