Designing a Lean Production Model Using 5S and Systematic Layout Planning for Efficiency in Footwear Manufacturing: A Case Study

This study addresses the challenges faced by small and medium-sized footwear enterprises, such as low productivity, disorganized workflows, and excessive production times, which hinder competitiveness. Previous research has focused on large scale industries, leaving a gap in solutions tailored to SMEs. This investigation proposed a production model integrating Lean Manufacturing tools, including 5S, Systematic Layout Planning (SLP), and work standardization, to optimize efficiency and productivity. The implemented model significantly reduced non-productive times, streamlined workflows, and improved labor productivity by 54.39%. Additionally, transfer distances decreased by 17.73%, and material handling efforts were optimized, showcasing the model’s effectiveness. These findings contribute to industrial engineering by offering a replicable framework that addresses operational inefficiencies. The analysis presented here clearly outlines how socio-economic elements are related to the outcome - increasing SME competitiveness at the local and global levels. Further studies should aim to identify and explain the places of digital technologies in layout design optimization and the sustainability of Lean practices in SMEs.