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Efficiency, Productivity, and Production layout are crucial metrics to the company’s operations. However, several complexities are found in hat manufacturing, leading to unavoidable dilemmas. Observations at a hat company revealed several critical issues such as insufficient manpower causing productivity problems, workers juggling multiple roles leading to delays, lengthy travel times between stations, delays due to defects and machine malfunctions, and inefficient production methods. To address these issues, engineering methods shall be utilized. This study employed industrial engineering tools such as the fishbone diagram for cause and effect analysis in 5Ms and Pareto chart to identify significant potential problems in the company that can impact operations. The study aims to improve manpower, layout, hat production, eliminate delays, and ensure sufficient supply and storage for fixtures and equipment in the manufacturing company utilizing ProModel Software. The techniques used in process optimization, product quality, and cost reduction are Time and Motion Study and function cost matrix. This study proposes methods for product, process, and cost management in the hat manufacturing company. The results show a total cost savings of 39.2% in the function cost matrix. In the time and motion study and ProModel simulation, the current yield results in 67 cycles and the proposed 81 cycles. The VA/VE approach helps in reaching optimum results for the company’s efficiency with a comparison of cost and process improvement. Utilizing tools like Value Analysis and Value Engineering (VA/VE) has played a major role in achieving the necessary improvements that the company will benefit from in the long term. Directions for future study include producing new research that will explore further alternative methodologies for existing industry problems. [ABSTRACT FROM AUTHOR]

For the success of manufacturing activity, an effective facility layout is essential. It ensures smooth workflow processes, reduces unnecessary usage, and improves the effectiveness of resource utilization. As a way to implement another possibility of optimizing a facility layout, this study aims to enhance productivity and efficiency by optimizing the production area layout through a ProModel simulation approach. The study identified inefficiencies in the production workflow, particularly related to long travel times and improper arrangements. Using time and motion studies, this paper analyzed task completion times and motions to address bottlenecks and improve workflow. The conceptual framework integrated data collection, analysis, simulation, and process optimization to enhance the facility layout and operational processes. The study's findings emphasize the importance of a well-designed factory layout in boosting worker productivity and machinery efficiency. A new facility layout was recommended, which has the ability to produce 14 batches of handbooks compared to the existing production process of 10 batches only. This shows a significant improvement of 40% in the company's production output, aligning with the project's objectives for meaningful improvements in the production area. [ABSTRACT FROM AUTHOR]

In today's highly competitive global world, the study explores the production challenges of the footwear industry. A company's most common problem is the bottlenecks and production inefficiencies. In addressing this pressing problem, the study sought to apply engineering tools such as ProModel Simulation and Time and Motion Study; the paper enables the proposed new design facility layout as a solution to boost the number of outputs in a company. This paper presents two strategic solutions: The Lean Six Sigma Approach emphasizes the need to reduce waste, improve processes, and increase product and process quality through running in the ProModel Simulation. The number of outputs increases from 136 to 172. At the same time, the U-shaped line Production Methodology arranges the process in a closer environment, aiming to have less transportation and allocate tasks more cohesively. The outputs from this method also increased from 136 to 151 exits. These solutions focus on streamlining production to enhance productivity and efficiency within the company. Overall, the study provides valuable insights and practical strategies for improving production efficiency in the footwear industry. For future research, others may include the company’s monetary value to give a better approach and strengthen the results that would benefit the company’s growth and development. [ABSTRACT FROM AUTHOR]

Shoe manufacturing industry in the Philippines provides a variety of footwear worldwide. Despite numerous clients, this industry still experiences challenges in production. Hence, this study addresses the challenges faced by the shoe manufacturing industry in Marikina City, Philippines, particularly in optimizing production and efficiency. The company is experiencing productivity challenges that are affecting manufacturing as well as product quality. Poor performance, inefficient work methods, and an unhealthy workplace all contribute to lower productivity. This study aims to minimize inefficiency and enhance productivity in production processes through time and motion study, Promodel simulation, value analysis/value engineering, and quality tools. The study suggests establishing a standard time to reduce defects, and delays while increasing productivity. The study findings highlighted significant improvements in efficiency through specific operational guidelines, inspections, and storage procedures, targeting a total process increase of 21.80%. By implementing a function cost matrix, the manufacturing saved 24.76%. Utilizing ProModel, the study proposed operational adjustments and layout reorganization to eliminate bottlenecks and enhance employee well-being facilities. These changes reduced typical time without compromising company efficiency, productivity, or product quality. The strategic measures outlined in this study hold promise for ushering in a new era of enhanced productivity and operational efficiency within the shoe manufacturing sector in Marikina City. Through concerted efforts to optimize processes and create a conducive workplace environment, manufacturing can pave the way for sustained growth and competitiveness in the industry. [ABSTRACT FROM AUTHOR]