Towards Lean Manufacturing from Theory of Constraints: A Case Study in Footwear Industry

Abstract

The present research proposes a implementation model of Lean Manufacturing starting from a production system defined with Theory of Constraints (TOC). The paper describes a case study at a major Ecuadorian footwear company with the aim of reducing delivery times and inventories generated by work in process. Value stream mapping is used to identify wasteful action as opportunities for improvement and with the implementation model both Lean and Theory of Constraints tools are applied. The analysis of activities that add and do not add value in the value stream of the current state and then allows to develop the map of the future state from the relationship between the analysis of constraints and the inventory of the TOC and Pull production and takt time of Lean. The results allow to demonstrate the successful application of the model in the footwear industry with a reduction in nonvalue-added time and inventory of 40% and 78% respectively.