Achieved 20% Higher Productivity and 30% Faster Deliveries by Eliminating Production Bottlenecks through Lean Manufacturing
Client Overview
- Company: AeroBlue Footwear
- Industry: Footwear Manufacturing
- Location: India (Domestic and Export Markets)
- Employees: 250+
- Products/Services: Men’s and Women’s Fashion Footwear
- Market Presence: Strong brand with global exports
Challenges (Before Greendot)
DAeroBlue Footwear faced multiple inefficiencies across its production operations:
- Production Bottlenecks: Frequent process interruptions cause delays and rework.
- Delivery Delays: Long lead times are impacting customer satisfaction and export schedules.
- Operational Inefficiency: Excessive waste of time, manpower, and space leading to productivity loss.
- Quality Concerns: Lack of standardized work methods causes variation and defects.
- Employee Resistance: Low awareness of Lean concepts and benefits, leading to inconsistent adoption
Our Approach
Greendot designed a phased Lean implementation roadmap tailored for the footwear industry:
- Diagnostic Study: Collected process data, identified high-impact areas using time–motion analysis.
- Strategy Design: Selected 5S, VSM, and Kaizen as key tools to improve flow and quality.
- Implementation: Conducted employee training, pilot projects, and structured rollout across production lines.
- Review Mechanism: Weekly KPI reviews, feedback meetings, and monthly productivity audits
Solutions Implemented
| Area | Solution |
| Workplace Organization | Employee feedback loop and regular Lean training sessions are conducted |
| Productivity | Value Stream Mapping (VSM) to identify bottlenecks and balance workflow |
| Quality | SOP standardization reduced production errors by 10% |
| Culture | Kaizen workshops encouraged continuous improvement and waste elimination |
| Engagement | Employee feedback loop and regular Lean training sessions are conducted |
Client Testimonial
“Greendot’s Lean training transformed our production floor. We saw immediate gains in output and quality — and our team now takes pride in maintaining world-class standards.â€
— Mr. Ramesh Mehta, Operations Head, AeroBlue Footwear
Results Achieved
- 20% Increase in Productivity: Achieved within just 2 months through streamlined processes and reduced waste.
- 30% Reduction in Delivery Lead Time: Faster order completion and improved customer satisfaction.
- 15% Reduction in Production Defects: Enhanced process control and operator discipline.
- Employee Morale Boost: 90% of the workforce reported higher satisfaction due to an organized and safe work environment.
- Improved Equipment Efficiency: 5% reduction in unplanned downtime through regular 5S “Shine†activities.
ROI: The project delivered an estimated payback within 3 months by reducing rework, space waste, and lost time.
Why It Worked (Greendot Edge)
- Hands-on Implementation: Direct coaching on the shopfloor, not just classroom sessions.
- Employee Empowerment: Involved operators in problem-solving through Kaizen.
- Data-Driven Decisions: Every improvement is measured through VSM and KPIs.
- Sustainable Systems: Periodic 5S audits and review boards ensured long-term discipline
Tools Used
- 5S
- Kaizen
- Value Stream Mapping (VSM)
- Standard Operating Procedures (SOPs)
- KPI Dashboard
