DOI 10.4010/2016.

1829
ISSN 2321 3361 © 2016 IJESC
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Research Article Volume 6 Issue No. 6

Application of TPM -Tools to Improve Overall Productivity of

Closing Line in Footwear Industry
Durairaj Dhanapal1, Gebrehiwot Asfah Gebrekidan2, Tesfay Geremaryam Gezahagn3
Lecturer1, 3, Head of Leather Engineering Department2
Department of Leather
EiTEX, Bahir Dar University, Bahir Dar, Ethiopia
Dhanapal_d2k@yahoo.com1

Abstract:
Footwear industry has gone through significant changes in the recent years. Competition has increased dramatically in the global
scenario. Customers focus on product quality, product delivery time and cost of product. Because of these, a company should
introduce a quality system to improve and increase both quality and productivity continuously. Total Productive Maintenance
(TPM) is a methodology that aims to increase the production hence reducing the need for further the Capital investment. The
relationship between total quality management (TQM) and innovation is complex. Literature suggests that conflicting arguments
exist and that the impact of TQM on innovation depends both on the specific quality management element under consideration and
on the type of innovation. In this research, our goal is to analyze at what extent the introduction of TQM is indeed supporting
innovation in the footwear industry. Since this is a mature industry, whose traditional corrective base is disappearing and where
familiar to medium units dominates, our emphasis is on the study of the organizational requirements to adopt constant changes in
process technology. Investment in human resources can further result in better hardware utilization, higher product quality and
reduced labor costs. The aim of the work is to study the effectiveness and implementation of the TPM programmer for footwear
industry. Through a case study of implementing TPM in footwear industry, the practical aspects within and beyond basic TPM
theory, difficulties in the adoption of TPM and the problems encountered during the implementation are discussed and analyzed.
Moreover the critical success factors for achieving TPM are also included based on the practical results gained from the study. After
the implementation of TPM model both tangible and intangible benefits to be obtained for equipment and employees respectively to
be analyzed in the present work.

Keyword: Implementation k .k. methods, productivity, quality, cost. Delivery, Safety, Motivation

INTRODUCTION operation procedure for each footwear model is focused in this

The pressure from globalization has made
manufacturing organizations moving three competitive areas,
quality. cost and responsibility quality is a universal value and
has a global issues(l).in order to survey and able to produce
customers with goods product manufacturing organizations
are required to ensure that the process and continuously
monitored product quality are improve. In this paper research
focus the TPM tools and TQM Methods about footwear
closing line overall productivity Middle scale industry right
now facing lot of quality problems and production slackness
by poor management administration .
This research analyzing all literatures and their
Suggestion, we design the overall productive quality
parameter and techniques. Advanced techniques and financial
is utilized in large scale industry only but middle sectors is
meet of critical issues (2) Finance is big problems So
innovative working procedure is very for small footwear
sectors this paper study will focus production problems and
implement ideas to small sectors. Customer quality
requirement is very important, innovative thoughts and
administration only is very important factor in small scale
footwear industries. This paper focus customer relationship
and management about total quality issues most of the small
footwear industry today meet very low orders and is not run
properly. So advanced production method is must and
otherwise is not success in the current situations. TQM tools
and implementation techniques are very urgent for middle
industry. This paper study will reduce the manpower and
financial cost. Proper designed, work place and standard
study
This paper study will introduce lot of production
techniques to improve the overall line Footwear productions.
This main goal every year small industry will be developing
footwear process having lot of production sequences such as
leather, material selection, and leather cutting operation. Pre
closing .stitching assembly inspection packing .and export etc.
in each stages production material wastage is very important;
quality tools only will success the total productivity. So this
research focus top management administration customer
requirement, management. Customer relationship, flowchart
procedure control methods, workers training and process
motivations, customer fulfillments etc. These research papers
mainly consider the kaizen blitz process methods and six
sigma functions methods footwear industry inline working
problems and remedies is very immediate for productivity.
Leadership, customer focus .involvement and development of
the people. Continuous improvement. Supplier relationship,
marketing innovation these factors are basic for foot wear
industry.(3) Innovation such as 1.Product innovation
2.Process innovation 3.Organisation innovation
4.Management innovation will be improve the total
productivity of the industry.
INSTRUMENTAL PROCEDURE
This research paper analyzed all footwear industry
inline production failure and effect of quality issues. So
above TQM tools is designed and improve the overall
productivity in middle scale footwear sector production area

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designing is important for any footwear factories .such as
footwear industry layout plane. warehouse, cutting area
location, closing lines, assemble lines, packing lines work
place ,machinery arrangements, data collection, maintenance
record ,product technical standard operation
procedure(SOP)is consider this paper, in all process
sequences is very important for footwear productions.
I.WARE HOUSE QUALITY
All warehouse material will visually will inspected
after that lab test will conducted .material quality is very big
issues in the footwear industry, ware house material to be
divided in five areas are 1. Inspection area 2.Under
inspection area 3.Released area .4 .Rejection area 5.Left out
martial area. FIFO system is better for material easily handling
as per expiry date wise material will arrange in this system.
FIFO (first in first out) monthly. Monthly indication sticker is
very useful for warehouse material handling and special
sticker such as GREEN COLOUR (fixed released
material)).YELLOW (inspected material). BLUE sticker
(under inspection material). RED color (Rejection
material).GREY color (left out material), warehouse material
as per model wise wi l l handover to production control team.
2. LEATHER GRADE SELECTION-TQM METHOD.
As per the customer requirement leather processed
based on the sample shoe or swatch after that leather will a
assorted by leather inspection area, here SATRA grading rule
followed, cutting co efficiency’s very important for foot wear
industry leather defects. Color appearance thickness, is very
important role in leather assorting process. Quality issues are
will avoided by strong decision making.
3. LEATHER CUTTING -TOTAL QUALITY
MANAGEMENT
Leather cutting is main role in footwear
manufacturing .leather cut ability techniques. Cutting wastage
.leather savings very important, well cutting training will
conducted to material and upper cutting operator. Cutting
allocation sheet ,cutting die items, board surfacing record,
cutting board color managements, cutting Model SOP
(Standard operating procedure ) will introduced .Cutting die
inspection Checklist, damage die cabinet information system
to be followed to improve the total productivity.
4. EMBOSSING AND SKIVING AREA.
In this area article model, size, customer name and
logo will be consider and up normal issues Will initially
avoided, first piece confirmation sample arranged in working
areas, process SOP. Machine pressure, Woven temperature
will be monitored by rowing QC person in every 2 hours.
Quality parameter will be considered in this area by proper
inspection. Skiving is the main part for closing lines skiving
machine guide allocations information, model process SOP,
thickness gauge meter will arranged in this area. So ski ving
quality issues will thoroughly controlled in this part.
5. STITCHING LINE TQM METHOD.
Stitching is main frame for upper closing lines so
advanced machinery line arrangements, is very important.
Stitching supervisor. Stitching rowing QC will monitoring all
stitching sequences, all machine maintained record systems
,line production model process SOP ,inch scale for all
machines for measuring stitching length. Rowing QC will
record Quality RFT (right and first time ) every one hour’s.
International Journal of Engineering Science and Computing, June 2016
All stitching material to be checked against customer
confirmation samples before line production
6. UPPER INSPECTION AREA
In this part first piece confirmation samples will
introduced by proper quality checking. Threads eyelet,
stitching margins, thread cutting and cleaning will checked by
upper QC persons. If any repair in upper immediately will in
formed to stitching lines for further correction.
7. ASSEMBLY LINE QUALITY METHODS
Assembly line machinery arrangement to be properly
arranged. Machine maintained record .temperature, pressures
control chart .line production model and size process SOP
instruction to be placed in all machines. Working time study
system will monitoring the production speeds in lines.
Moulding, handlasting. Strobling, marking, buffing in all area
properly monitored by line supervisor and QC supervisor
.Cementing and priming area colour bowl and brush systems
introduced in every 1 hours
Colour systems followed, over cementing monitored
by QC and outsole machine pressing record regularly two
time s to be checked because delaminating problem properly
avoided, delasting and socks attaching .cleaning area process
SOP to be fixed. Final QC area having sample shoe, B grade
cabinet, inch scale, steel ruler,.pincer,silver refill .tape .
Knife. Here hourly RFT quality record to be maintained to
improve the overall quality in lines and line breakdown
system entry aslo is followed for action plane
8. PACKING AREA.
Here all finished goods will packed by customer
packing requirements. Such as cottons, hand tags, stickers,
size label, box sizes, QC checking label etc metal deduction
machine also to be introduced. Every week parking training
will give to all packing workers.
RESULTS AND DISCUSION
In this paper research only focused in line
quality issues .The above techniques is to be very useful
for middle scale footwear industries, advanced TQM
tools and their parameters will considered to avoid over
all line productivity issues. This system will reduce the
total manpower and material cost. It will be appkei in
middle footwear companies and result will be profitable
incurring situation. Middle scale industry to be organized
the TQM below method
1. Leadership methods
2. Customer focus
3.1nvolment and improvement of the peoples
4. Implemetation training and programs methods
5. Condtinues improvement methods
6. Supplier relationship methods
7. Techinical team for production
8. Core Assemly team (multi skill person)
9 .Material discard team
10. Fire and safety team.
11. Motivation and Reward methods
TOP MANAGEMENT TO BE DISIGNED BY
INNOVATION METHODS
1. Production innovation
2. Process innovation
3. Organisation innovation
4. Management innovation
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 In this research discussion analyzed footwear
industry overall line quality issues and action planes ware
house kaizen process methods and six sigma functional
methods (4) followed to control the quality issues and improve
the total productivity. In this study leather grade selection rule
followed as per the international standards, colour finishing
quality issues will avoided in this inspection methods, visual
test and physical testing of leather will introduced .Cutting
sections is very critical part in footwear industry cutting
trainees programme to be given by improving the quality of
productivity. Weekly two time discard material wi l l disposed
in all lines. ulling co efficiency .wastages minimizes .material
saving, cutting checklist damage die information chart, cutting
allocations sheet systems .cutting board coluor management
systems, cutting SOP instructions to be improve the
production and avoid the production issues. Middle scale
footwear industry will economical improved by this above
systems approaches .Stitching line main part in the upper
productions .customer satisfactions in very important for
production companies This paper research analyzed all
production failure in closing lines .model information book ,
Process SOP. Machine maintained record stitching
training programme systems, Customer quality comments.
This TQM system will solved abnormal-al quality issues in
production lines.(5) Stitching rowing QC every hour
inspected and maim and RFT quality record .if any line quality
issues immediately line gathering will organized and solve the
Hen problems. This systems is very useful for maintain in line
overall line quality.(6)Closing lines quality management is
important for full shoe making procers.no days lot of
advanced Machinery introduced in footwear sectors, but
quality but quality and production issues is major problems in
all footwear sectors .system approach only will success in any
productivity organizations(7) in this research thoroughly
focused all problem in assembly lines. Process flow chart
and SOP systems .assembly Rowing QC hourly quality record
systems, machineries process control record and instruction
for buffing and sand paper grade intimation.
CONCLUSIONS
In this paper study research analyze current footwear
industry current problems in every stage quality issues
monitored in this research and introduced advanced quality
techniques. This study will control the manpower
cost,maintance cost, material wastages, time consumption,
overload .this system is compared with current footwear
production line situations it is very profitable for middle scale
industry and their future development activities. Footwear
industry today meet lot of problems so advanced techniques
and system approach only solve such types of above issues.
Manpower is one of biggest problems in all footwear
industry .This research introduce CORE ASSEMLY and
STITCHING team this is very useful for production. In case
some worker absent suddenly at the time this team members
balance the line production .This is methods is very important
role for middle sectors(9)footwear industry, today meet lot of
problems so advanced techniques and system approach only
need such types of above issues .Manpower is one of
biggest problems in all footwear industry this research
introduce CORE ASSEMLY and STITCHING team this is
very useful for production in case some work absent suddenly
at the time this team balance the line production .This is
methods is very important role for middle sectors. Middle
scale industry product is very challenge in marketing so
proper advanced TQM techniques and procedure will
International Journal of Engineering Science and Computing, June 2016
determine the company economy. Industry that facing a
process of dynamic transformation, is must look for new
competitive factors to maintain and gain
The global markets. This study focus customer requirements
and company relationship.TQM implementation team and QC
control activities more valuable (10) than other current
footwear production methods. Process flow chart, allocation
sheet methods is control the abnormal quality problems, this
results is very profitable for company management
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