Lean manufacturing strategies in small and medium enterprises: a case of a Durban shoe manufacturer.

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.