The implementation of 5S and a supermarket system reduced waste at a footwear company. 5S was used to clean, organize, and standardize the workplace to improve efficiency. Unnecessary tools and machines were removed and storage areas were defined. This created a cleaner and more organized work environment. The supermarket system reduced excess stock by implementing a two-color kanban system to signal when components needed refilling. Value stream mapping also identified sources of waste and rework in production. Relocating machines and storages to follow a FIFO structure as well as poka yoke systems reduced rework and factory space by 15-20%.

1. Um pequeno exemplo de implementação do Lean no sector do calçado.
A full 5S program was 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.
The implementation of a Supermarket system reduced 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 (kanban) 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.
Value stream mapping was used to analyse waste and rework origins in the production
processes. Visualising the rework process improved the management focus to decrease rework
actions. Plant layout analysis exposed 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 yoke and process Malfunction & manufacturing
Inconsistency Alerting and Detection Systems reduced rework with 15 %.