Title: Application of Six Sigma tools in footwear industry: an emerging economy case

Authors: Tamzed Ahmed; Rahela Begum; Sayem Ahmed

Addresses: Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, 141 and 142, Love Road, Tejgaon Industrial Area, Dhaka-1208, Bangladesh ' Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, 141 and 142, Love Road, Tejgaon Industrial Area, Dhaka-1208, Bangladesh ' Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, 141 and 142, Love Road, Tejgaon Industrial Area, Dhaka-1208, Bangladesh Fax: (8802)-8870417-18

Abstract: The footwear industry is in a preliminary position to significantly impact the export fortunes of emerging economies like Bangladesh over the next decade. This research indicates the benefits of adopting Six Sigma tools to reduce the significant losses, non-value-added activities, and ensure proper labour utilisation of a sewing line of a renowned local footwear company in Bangladesh. In this study, cause and effect diagram (CED) has been applied to determine the reason behind higher manufacturing cost of the existing process. Pareto analysis reveals the most significant equipment loss, and the fault tree analysis (FTA) identifies the root causes of the most significant loss obtained from Pareto analysis. Value stream mapping (VSM) seeks to recognise and remove the non-value-added activity. Cost reduction can be possible in a range of BDT 1589581 to BDT 2384372, and overall equipment efficiency (OEE) is increased to 61.5% from 51%, by reducing the root causes of significant losses. This study will guide the industrial managers to implement Six Sigma practices in the footwear industries for reducing the non-value-added process, production cost, and significant losses for maximising OEE.

Keywords: cause and effect diagram; CED; fault tree analysis; FTA; footwear; line balancing; overall equipment efficiency; OEE; value stream mapping; VSM.

DOI: 10.1504/IJPQM.2023.129607

International Journal of Productivity and Quality Management, 2023 Vol.38 No.2, pp.211 - 242

Received: 12 Feb 2021
Accepted: 31 May 2021
Published online: 17 Mar 2023 *

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