Simulation Optimization: A Case Study of Lean Six Sigma and U-Shaped Production Principle in a Footwear Manufacturing Company in the Philippines.

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]