Seiri (Sort) and Seiton (Set in Order) act as the primary mechanisms for reclaiming lost time in footwear production environments. These two steps directly reduce non-productive time by physically removing non-essential items and strictly standardizing the location of necessary tools, effectively eliminating the delays caused by operators searching for components during sewing and assembly.
The core efficiency gain comes from converting "search time" into "production time." By implementing fixed-position management, you ensure that the operator's energy is spent solely on the manufacturing process, not on navigating a disorganized workspace.
The Mechanics of Time Retrieval
Seiri: Eliminating Physical Obstacles
The Seiri (Sort) phase focuses entirely on removing unnecessary items from the workspace. In a footwear factory, this means clearing away broken needles, scraps of leather, or obsolete tools that crowd the sewing stations.
By removing these distractions, you immediately reduce the cognitive load on the operator. There is no time wasted distinguishing between what is needed for the current task and what is trash.
Seiton: The Power of Fixed-Position Management
Once clutter is removed, Seiton (Set in Order) dictates that every remaining item must have a designated, permanent home. This is often referred to as fixed-position management.
For sewing and assembly machinery, this means the specific scissors, thread, and adhesives required for the job are always in the exact same spot. The operator develops muscle memory, allowing them to reach for a tool without looking or pausing.
Eradicating Search Time
The primary cause of non-productive time in unorganized factories is the "search." Even a 30-second search for a specific gauge or material creates a ripple effect of delay.
Seiton eliminates this variable entirely. When tools are fixed in position, "searching" is replaced by "retrieving," ensuring the continuity of the production process remains unbroken.
Operational Impact on Footwear Assembly
Improving Process Continuity
Footwear manufacturing relies on a seamless flow between sewing upper components and assembling soles. Disorganization interrupts this rhythm.
By applying these 6S steps, the workspace remains operationally ready at all times. The overall cleanliness and orderliness ensure that machinery changeovers or shift changes do not result in downtime while the incoming team reorganizes the space.
Understanding the Trade-offs
The Cost of Initial Setup
While the long-term gains are significant, Seiri and Seiton require an upfront investment of non-productive time to implement.
You must halt production to sort through materials and design the fixed positions. This initial "stop" is necessary to gain speed later, but it will impact output in the short term.
The Requirement for Rigid Discipline
The system fails immediately without strict adherence. If an operator places a tool down three inches away from its fixed position, the efficiency gain for the next cycle is lost.
These steps are not a one-time cleanup; they require a cultural shift where operators are trained to value precision as much as speed.
Implementing for Maximum Efficiency
To apply these principles effectively to your manufacturing line, consider your immediate objectives:
- If your primary focus is immediate floor clearance: Prioritize Seiri to remove all non-essential materials, instantly creating a safer and visually cleaner workspace.
- If your primary focus is increasing operator speed: Prioritize Seiton by installing shadow boards or marked outlines to enforce fixed-position management for all sewing tools.
True efficiency is achieved when the workspace itself guides the operator, making the correct action the only possible action.
Summary Table:
| 6S Step | Action in Footwear Factory | Impact on Productivity |
|---|---|---|
| Seiri (Sort) | Removing scrap leather, broken needles, and obsolete tools. | Reduces cognitive load and physical obstacles. |
| Seiton (Set in Order) | Placing tools/materials in designated, marked fixed positions. | Develops muscle memory and eliminates search time. |
| Operational Result | Streamlined sewing and assembly line flow. | Converts wasted movement into active production time. |
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References
- Alejandra Quiroz-Cueva, Martin Saenz-Moron. Improvement proposal to increase the production efficiency of garment with lean manufacturing tools for the textile sector in Lima. DOI: 10.18687/laccei2023.1.1.1045
This article is also based on technical information from 3515 Knowledge Base .