{"id":27165,"date":"2021-03-16T09:20:29","date_gmt":"2021-03-16T09:20:29","guid":{"rendered":"https:\/\/academy.ats-global.com\/?page_id=27165"},"modified":"2023-12-19T13:49:53","modified_gmt":"2023-12-19T13:49:53","slug":"lean-optimization-at-safety-shoe-manufacturing-plant","status":"publish","type":"page","link":"https:\/\/academy.ats-global.com\/cs\/references-best-practices\/lean-optimization-at-safety-shoe-manufacturing-plant\/","title":{"rendered":"Lean: Optimization at Safety Shoe Manufacturing Plant"},"content":{"rendered":"<div class=\"fusion-fullwidth fullwidth-box fusion-builder-row-1 fusion-flex-container nonhundred-percent-fullwidth non-hundred-percent-height-scrolling\" style=\"--awb-border-radius-top-left:0px;--awb-border-radius-top-right:0px;--awb-border-radius-bottom-right:0px;--awb-border-radius-bottom-left:0px;--awb-flex-wrap:wrap;\" ><div class=\"fusion-builder-row fusion-row fusion-flex-align-items-flex-start fusion-flex-content-wrap\" style=\"max-width:1248px;margin-left: calc(-4% \/ 2 );margin-right: calc(-4% \/ 2 );\"><div class=\"fusion-layout-column fusion_builder_column fusion-builder-column-0 fusion_builder_column_1_1 1_1 fusion-flex-column\" style=\"--awb-bg-size:cover;--awb-width-large:100%;--awb-margin-top-large:0px;--awb-spacing-right-large:1.92%;--awb-margin-bottom-large:20px;--awb-spacing-left-large:1.92%;--awb-width-medium:100%;--awb-order-medium:0;--awb-spacing-right-medium:1.92%;--awb-spacing-left-medium:1.92%;--awb-width-small:100%;--awb-order-small:0;--awb-spacing-right-small:1.92%;--awb-spacing-left-small:1.92%;\"><div class=\"fusion-column-wrapper fusion-column-has-shadow fusion-flex-justify-content-flex-start fusion-content-layout-column\"><div class=\"fusion-text fusion-text-1\"><h2>Lean: Optimization at Safety Shoe Manufacturing Plant<\/h2>\n<\/div><div class=\"fusion-builder-row fusion-builder-row-inner fusion-row fusion-flex-align-items-flex-start fusion-flex-content-wrap\" style=\"--awb-flex-grow:0;--awb-flex-grow-medium:0;--awb-flex-grow-small:0;--awb-flex-shrink:0;--awb-flex-shrink-medium:0;--awb-flex-shrink-small:0;width:104% !important;max-width:104% !important;margin-left: calc(-4% \/ 2 );margin-right: calc(-4% \/ 2 );\"><div class=\"fusion-layout-column fusion_builder_column_inner fusion-builder-nested-column-0 fusion_builder_column_inner_1_6 1_6 fusion-flex-column\" style=\"--awb-bg-size:cover;--awb-width-large:16.666666666667%;--awb-margin-top-large:0px;--awb-spacing-right-large:11.52%;--awb-margin-bottom-large:20px;--awb-spacing-left-large:11.52%;--awb-width-medium:100%;--awb-order-medium:0;--awb-spacing-right-medium:1.92%;--awb-spacing-left-medium:1.92%;--awb-width-small:100%;--awb-order-small:0;--awb-spacing-right-small:1.92%;--awb-spacing-left-small:1.92%;\"><div class=\"fusion-column-wrapper fusion-column-has-shadow fusion-flex-justify-content-flex-start fusion-content-layout-column\"><div class=\"fusion-text fusion-text-2\"><p><img decoding=\"async\" data-src=\"https:\/\/academy.ats-global.com\/storage\/images\/article\/thumbs\/ATSLogoNEW1.png\" src=\"data:image\/svg+xml;base64,PHN2ZyB3aWR0aD0iMSIgaGVpZ2h0PSIxIiB4bWxucz0iaHR0cDovL3d3dy53My5vcmcvMjAwMC9zdmciPjwvc3ZnPg==\" class=\"lazyload\" \/><\/p>\n<\/div><\/div><\/div><div class=\"fusion-layout-column fusion_builder_column_inner fusion-builder-nested-column-1 fusion_builder_column_inner_5_6 5_6 fusion-flex-column\" style=\"--awb-bg-size:cover;--awb-width-large:83.333333333333%;--awb-margin-top-large:0px;--awb-spacing-right-large:2.304%;--awb-margin-bottom-large:20px;--awb-spacing-left-large:2.304%;--awb-width-medium:100%;--awb-order-medium:0;--awb-spacing-right-medium:1.92%;--awb-spacing-left-medium:1.92%;--awb-width-small:100%;--awb-order-small:0;--awb-spacing-right-small:1.92%;--awb-spacing-left-small:1.92%;\"><div class=\"fusion-column-wrapper fusion-column-has-shadow fusion-flex-justify-content-flex-start fusion-content-layout-column\"><div class=\"fusion-text fusion-text-3\"><p>Our customer, a leading safety shoe manufacturer achieved major benefits by means of waste elimination and improve their production efficiency. Primary targets are the creation of a \u2018Clean &amp; Healthy\u2019 Plant floor &amp; Working environment and succeeded in Controlling the process, Balancing the lines and drastically Reducing rework.<\/p>\n<\/div><\/div><\/div><\/div><div class=\"fusion-text fusion-text-4\"><p><b>ATS Case Study:<\/b><\/p>\n<h3>Optimization at Safety Shoe Manufacturing Plant<\/h3>\n<p><i>Project duration:<\/i>\u00a04 months<br \/>\n<i>Project Saves:<\/i>\u00a020 % factory space, 15 % Rework reduction<\/p>\n<h3>ATS:<\/h3>\n<p>Lean is a structured proven method for improving business performance focusing on waste elimination. ATS is a leading company supporting companies implementing the Lean methods by offering Lean Training and Consultancy.<\/p>\n<h3>Project briefing:<\/h3>\n<p>A full\u00a0<b>5S program<\/b>\u00a0was started in order to clean and organize the workplace. Mayor attention was paid in building a clear understanding between operators of the importance of a clean and well organized plant floor, instilling ownership of the process. Among other actions, unnecessary tools\/machines were removed, tool location were defined, corridors and material storages were delimited, work was standardized and autonomous machine cleaning and tool changes preparation were scheduled.<\/p>\n<p>The implementation of a\u00a0<b>Supermarket system<\/b>\u00a0reduced plant floor stock and material space considerably. Small shoe components like shoelaces and heels were kept on stock 10 times more then the daily production needed and work was regularly disrupted because of shortages and unplanned refilling. For example, a simple but very effective action taken like a two colour strip system (<b>canban<\/b>) indicating when the amount of components needed to be refilled, improved the refilling process considerably. When the level of components in a box decreases below a minimum, the red part of the coloured strip becomes visible indicating the re-filler requires to fill the box with components.<\/p>\n<p><b>Value stream mapping<\/b>\u00a0was used to analyse waste and rework origins in the production processes. Visualising the rework process improved the management focus to decrease rework actions.\u00a0<b>Plant layout analysis<\/b>\u00a0exposed large and unnecessary amount of material and personnel movements. Relocation of machines and (temporary) storages, as well as a new design promoting a FIFO structure for material consumption led to a reduction of 20 % of factory space. Manual and electronic Poka Yokes and process Malfunction &amp; manufacturing Inconsistency Alerting and Detection Systems reduced rework with 15 %.<\/p>\n<h3>Training News<\/h3>\n<ul>\n<li><i>0000-00-00<\/i>\u00a0Lean: Optimization at Safety Shoe Manufacturing Plant<\/li>\n<li><i>0000-00-00<\/i>\u00a0Close Watch on Cabbage Production<\/li>\n<li><i>0000-00-00<\/i>\u00a0Consumer Paper Products<\/li>\n<li><i>0000-00-00<\/i>\u00a0Case Study: Process Improvement Unilever Purfleet<\/li>\n<li><i>0000-00-00<\/i>\u00a0Compost Recycling Plant&#8217;s Breakdowns Caused by Corrosion<\/li>\n<li><i>0000-00-00<\/i>\u00a0Department Stores and Supermarkets<\/li>\n<li><i>0000-00-00<\/i>\u00a0Data Traceability in Pharmaceutical Manufacturing<\/li>\n<li><i>0000-00-00<\/i>\u00a0Carlsberg MES Project &#8211; Delivering a Manufacturing Execution System to improve Productivity and Quality at 15 European Breweries<\/li>\n<li><i>0000-00-00<\/i>\u00a0Manufacturing Intelligence at Bosch in Australia<\/li>\n<li><i>0000-00-00<\/i>\u00a0Duracell: Line Operators become Line Managers with Manufacturing Intelligence from Activplant and ATS<\/li>\n<li><i>0000-00-00<\/i>\u00a0Faurecia Line Flexibity Project<\/li>\n<li><i>0000-00-00<\/i>\u00a0Efficient Product Handling at GM and Faurecia<\/li>\n<li><i>0000-00-00<\/i>\u00a0Manufacturing Intelligence and Visual Inspection Systems to improve Productivity and Quality<\/li>\n<li><i>0000-00-00<\/i>\u00a0Six Sigma Project: &#8218;Optimization of the Injection Machine Purge Process&#8216;<\/li>\n<li><i>0000-00-00<\/i>\u00a0Carlsberg MES Project &#8211; In-line and At-line Quality Results Recording &amp; Reporting<\/li>\n<\/ul>\n<\/div><\/div><\/div><\/div><\/div>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":8,"featured_media":0,"parent":27157,"menu_order":33,"comment_status":"closed","ping_status":"closed","template":"","meta":{"content-type":"","footnotes":""},"class_list":["post-27165","page","type-page","status-publish","hentry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v27.7 (Yoast SEO v27.7) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Lean: Optimization at Safety Shoe Manufacturing Plant - ATS Academy<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/academy.ats-global.com\/cs\/references-best-practices\/lean-optimization-at-safety-shoe-manufacturing-plant\/\" \/>\n<meta property=\"og:locale\" content=\"cs_CZ\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Lean: Optimization at Safety Shoe Manufacturing Plant\" \/>\n<meta property=\"og:url\" content=\"https:\/\/academy.ats-global.com\/cs\/references-best-practices\/lean-optimization-at-safety-shoe-manufacturing-plant\/\" \/>\n<meta property=\"og:site_name\" content=\"ATS Academy\" \/>\n<meta property=\"article:modified_time\" content=\"2023-12-19T13:49:53+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/academy.ats-global.com\/storage\/images\/article\/thumbs\/ATSLogoNEW1.png\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Odhadovan\u00e1 doba \u010dten\u00ed\" \/>\n\t<meta name=\"twitter:data1\" content=\"3 minuty\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/\",\"url\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/\",\"name\":\"Lean: Optimization at Safety Shoe Manufacturing Plant - ATS Academy\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/academy.ats-global.com\\\/storage\\\/images\\\/article\\\/thumbs\\\/ATSLogoNEW1.png\",\"datePublished\":\"2021-03-16T09:20:29+00:00\",\"dateModified\":\"2023-12-19T13:49:53+00:00\",\"breadcrumb\":{\"@id\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/#breadcrumb\"},\"inLanguage\":\"cs\",\"potentialAction\":[{\"@type\":\"ReadAction\",\"target\":[\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/\"]}]},{\"@type\":\"ImageObject\",\"inLanguage\":\"cs\",\"@id\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/#primaryimage\",\"url\":\"https:\\\/\\\/academy.ats-global.com\\\/storage\\\/images\\\/article\\\/thumbs\\\/ATSLogoNEW1.png\",\"contentUrl\":\"https:\\\/\\\/academy.ats-global.com\\\/storage\\\/images\\\/article\\\/thumbs\\\/ATSLogoNEW1.png\"},{\"@type\":\"BreadcrumbList\",\"@id\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/references-best-practices\\\/lean-optimization-at-safety-shoe-manufacturing-plant\\\/#breadcrumb\",\"itemListElement\":[{\"@type\":\"ListItem\",\"position\":1,\"name\":\"Home\",\"item\":\"https:\\\/\\\/academy.ats-global.com\\\/cs\\\/\"},{\"@type\":\"ListItem\",\"position\":2,\"name\":\"References &#038; 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