Synergizing ergonomic principles with lean philosophy model towards productivity improvement in the shoes manufacturing industry

Abstract

Purpose This study aims to address the gap in integrating ergonomic principles with lean principles in the shoe product manufacturing process. The objective is to develop a customized model that effectively combines and synergizes ergonomics and lean principles. Design/methodology/approach Primary data was collected through on-site observations, interviews and assessment of whole-body discomfort to evaluate the implementation of lean and ergonomic principles in each section of the shoe production process. The collected data were analysed using descriptive statistical tools, content analysis and software such as Microsoft Excel. Findings The findings of the study indicate that the case company’s underperformance, achieving only 26.96% of its designed capacity and 50.19% of its planned capacity, is primarily attributed to the poor integration of ergonomic principles with the lean philosophy model. The high prevalence of work-related musculoskeletal disorders (WMSDs) in the shoe production process significantly contributes to a loss of productivity due to increased absenteeism. The factory experiences a labour absenteeism rate of 5.59%, resulting in overtime and additional costs. To address these issues, the study proposes the adoption of 8S principles and an ergo-lean production system model. This model, conceptualized as a building construction structure, effectively eliminates waste in the shoe production process. Practical implications The study’s findings will greatly enhance productivity in the shoe manufacturing sector by establishing a work environment that prioritizes employee needs and well-being. This will have significant practical implications for improving overall productivity in the industry. Originality/value This study stands out as it investigates the proactive integration of ergonomics and lean principles in the shoe manufacturing industry, an area that has not been previously explored. By bridging the gap between these two principles, the research contributes to the existing knowledge base.