This case study describes the implementation of Lean Manufacturing and 5S practices at one of India's largest footwear manufacturing companies and its supplier units. Over 25 days, Hash Management Services LLP helped improve productivity, create more space, remove unwanted items, reduce mix-ups and improve employee morale. Specific improvements included organizing tools, dies, stickers and spare parts, standardizing storage methods using color coding, implementing single pair flow for finishing, and rearranging the factory layout. As a result, productivity increased by 30-50% in all units, with benefits such as one room being freed up for finished goods storage. The client saw increases in production from 33-50% and asked Hash to implement Lean and 5S in

1. Case study from our Lean
Manufacturing and 5S
Implementation
At India’s Largest footwear manufacturing company and its
suppliers
Visit our websites:
www.hashllp.com
www.businessense.in

2. About us
• At Business Sense, we help medium scale manufacturing units improve their operational
efficiency through consulting engagements focusing on improving their Operations
through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools
• We promise to double the productivity in less than 33 days of our effort
• In addition, our web application would help the senior management in monitoring the
important business updates every day and provide them analytics and enable them better
decision making. Useful if your organization do not have an ERP!
• For more details, please visit www.businessense.in
• You can subscribe to our bi-weekly newsletter here.
• Follow us:
(C) Property of Hash Management Services LLP 2

3. Introduction to the case study
• This case study is based on our work with one of India’s leading footwear
manufacturer
• A total of 25 days was spent by Hash Management Services LLP for the
implementation of Lean Manufacturing (including 5S)
• Significant improvements were observed in all the units in terms of
– Higher productivity ( 30 to 50% improvement in Output)
– More space creation
– Removal of unwanted items from the shop floor
– Reduction in mix-up and
– Improved employee morale
• Recognizing the benefits, client suggested us to cover Lean and 5S implementation
in few other units also
(C) Property of Hash Management Services LLP 3

4. (C) Property of Hash Management Services LLP 4
All tools were randomly stored
leading to searches and wastage in
time
Before 5S After 5S
Tool rack was created in the central
location of the shop floor. A smaller tool
rack is also placed near the machine

5. (C) Property of Hash Management Services LLP 5
Before 5S After 5S
Excess dies were stored in the floor
without identification
Article-wise, size-wise storage of excess
dies

6. (C) Property of Hash Management Services LLP 6
Before 5S After 5S
All stickers were stored in a bin. Difficult
to retrieve and monitor quantity, more
search and time involved
Article-wise, Size-wise storage of stickers,
eliminating search and monitor quantity

7. After 5S : Color coding of dies, storage spaces, trolleys and
bins throughout the company and its supplier units
(C) Property of Hash Management Services LLP 7

8. After 5S : Color coding of dies, storage spaces, trolleys and
bins throughout the company and its supplier units
(C) Property of Hash Management Services LLP 8

9. Before 5S After 5S
(C) Property of Hash Management Services LLP 9
Spares were not stored without
identification
All spares were counted, stored in racks
with proper identification

10. (C) Property of Hash Management Services LLP 10
Racks were numbered, with identification for all items

11. A Set up trolley with wheels is created and can
be moved near the machines during set up.
(C) Property of Hash Management Services LLP 11

12. Before 5S After 5S
(C) Property of Hash Management Services LLP 12
Trimming wastes fall on the floor – needs
separate cleaning
Trimming wastes directly fall into a waste
collection bag – easy cleaning
Faces of people are blacked out for privacy reasons

13. Batch Production processes leading to very
high WIP
(C) Property of Hash Management Services LLP 13

14. Finishing happens during the last hour for
delivery, leading to confusions
(C) Property of Hash Management Services LLP 14

15. Layout change to enable single pair flow – took
2 hours
(C) Property of Hash Management Services LLP 15
Faces of people are blacked out for privacy reasons

16. Layout to enable single pair flow
(C) Property of Hash Management Services LLP 16
Faces of people are blacked out for privacy reasons

17. Benefits of Single Pair Flow: Finishing activity happens everyday and all
items produced on that day are packed on the same day. One entire
room became free and is used to store finished goods
(C) Property of Hash Management Services LLP 17

18. Benefits (sent by the owner* of the company)
(C) Property of Hash Management Services LLP 18
33%
increase in
Production
1.5 days
* - Points may have grammatical errors. We
have not edited the content sent by the
clients

19. Benefits (sent by the owner* of the company)
(C) Property of Hash Management Services LLP 19
31%
increase in
Production
1.5 days* - Points may have grammatical errors. We
have not edited the content sent by the
clients

20. Benefits (sent by the owner* of the company)
(C) Property of Hash Management Services LLP 20
50%
increase in
Production
2 days
* - Points may have grammatical errors. We
have not edited the content sent by the
clients

21. Case study from our Lean
Manufacturing and 5S
Implementation
At India’s Largest footwear manufacturing company and its
suppliers
Visit our websites:
www.hashllp.com
www.businessense.in