Date of Publication :17th January 2024

Abstract: This article presents a comprehensive study on enhancing efficiency in footwear manufacturing through the implementation of Value Stream Mapping (VSM) and the innovative Cut-to-Box system. The case study focuses on a Footwear Company, a four-floor factory in Istanbul, Turkey. The current state of pre-production processes is analyzed using time metrics, contributing to the design and implementation of a future value stream mapping system. The newly introduced Cut-to-Box system revolutionizes the traditional production line, streamlining warehouse operations. The study evaluates the challenges faced by the existing system. The Cut-to-Box system is assessed for its transformative impact on lead time using VSM. The results indicate a significant improvement in overall efficiency, with a reduction in lead time, process time, changeover time, transfer time, and waiting time. It concludes by emphasizing the importance of continuous analysis and optimization for maintaining competitiveness and delivering high-quality products on time.

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