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Purpose: This research aims to improve the performance and productivity of low-level technology organizations using lean tools – value stream mapping (VSM). In order to investigate the application of VSM in low-level technology organizations, this study takes footwear manufacturing organizations as a case study. Design/methodology/approach: Identifying a suitable organization was the first step for conducting the case study, followed by product family identification. Time and motion studies are used to determine the cycle time and identify the value-adding and non-value-adding activities, respectively. After making necessary observations and calculations, the current state map was developed. Different improvement proposals were identified, and the future state map was constructed. Findings: As a result, 56.3% cycle time reduction and 69.7% reduction in lead time were obtained, confirming its application in low-level technology organizations to improve their performance and productivity. This promising result indicates that a significant improvement can be achieved if VSM is applied in low-level organizations other than footwear industries, such as the clothing and furniture industries. Speed is investigated to be one of the parameters in motion study. Research limitations/implications: This study focuses on low-level technology organizations, specifically leather shoe manufacturing industries. But experiences gained from implementing this study are realistic and applicable in similar organizations. Practical implications: Performance and productivity improvement are critical issues to be addressed in low-level technology organizations, especially in the leather footwear manufacturing sector. This can be achieved through VSM by identifying and removing the wastes. VSM can be applied to low-level organizations as well. VSM is a powerful tool that helps managers and practitioners in identifying wastes and opportunities for improvement. Originality/value: The paper addresses applicability of VSM in the production process of low-level technology organizations with an original industrial case study in Ethiopia. [ABSTRACT FROM AUTHOR]

Lean manufacturing (LM) practices and tools have played vital role in several manufacturing industries to enhance the competitive edge in in the global market. The purpose of this paper is to use the lean principles, practice and tools in Hibret Manufacturing & Machine Building Industries (HMMBI) in Ethiopia. The existence of high production lead time is getting the basic problem for HMBI that is why this research gives more attention. The study aims to improve the production lead time by minimizing non-value adding activities associated with several resources in the process. Both qualitative and quantitative data collection methods are used. The process time and floor layout are studied and mapped using Value Stream Mapping, and Spaghetti Diagram to identify wastes. The result shows that production lead time, work in process (WIP), non-value adding time (waiting time) and total distance traveled are reduced by 23.66%, 8.6%, 37.74%, 61.2% respectively. Finally, the process cycle efficiency is improved by 25.59%. The study is found significant for Hibret Manufacturing & Machine Building Industries (HMMBI) and for similar manufacturing industries. [ABSTRACT FROM AUTHOR]