As the saying goes ‘Example is better than precept’. This applies in particular to the lean-production philosophy of the Japanese. Bata Industrials has adopted this method of working, and has applied these ideas at its safety shoes factory in Best (Netherlands). It is an ambitious undertaking, but the results are encouraging. A maximum level of productivity is now being achieved with a minimum number of activities.

Superfluous activities and actions which do not bring any added value will be eliminated as much as possible. Streamlining the production process actually consists of mastering the art of omission. Using lean production methods, Bata also aims to spot problems in products faster, and to shorten total production time.

Areas of improvement
Lean production is a matter of organising, simplifying and optimising. In this respect, Bata is on the right track. The Desma Carousel in particular, also referred to in daily practice as the Desma 423, is the picture of efficiency. However, there are a considerable number of areas where the procedure may be improved, both before and after injecting the soles.

Supply of shafts
Minor incidents can have major consequences. By applying a different method of supplying the shafts, the upper part of the shoe, during the production process, it has been possible to omit unnecessary actions. This frees up time for employees to perform other tasks. The new method of supplying shafts also reduces the likelihood of errors since these are synchronized with the Desma lasts.

Ergonomics
Changing the layout of the workplace also generates benefits in terms of ergonomics. An employee now only has to swivel 90 degrees instead of 180 during certain tasks, and can now grab shafts without having to make potentially harmful moves to do so. All of the materials are within arm’s reach, at the perfect working height, and move along with production.

Logistics
During the procedure following the injection of the soles, the new lay-out of the finishing department has proven its added value. Since laces and inlay soles are already prepared, it is no longer necessary for employees to leave their work station to go looking for components. The stock management system has also been simplified. Thanks to numbered racks, shoes are stored in pairs and according to size. This eliminates unnecessary logistical activities.

Bata’s starting points
Lean production is also bearing fruit when it comes to quality. Any problems with a product are spotted much faster. By keeping the interim stocks low, it is possible to take immediate action. Additionally, a new system using three teams shortens the completion time. Shoes which are manufactured and packaged in the afternoon and at night will be moved to the warehouse the next morning.