Identifying the causes of footwear rejection and devising better solution for the improvement of footwear quality

Background: Footwear sector is the most potential and booming export sector in Bangladesh that means, the position of this sector is just right after RMG. Besides that, Bangladesh is set to emerge as a next manufacturing hub for global footwear industry. In the world every year about 176 million pairs of shoes are rejected due to different type of defects in shoe production which costs nearly 5 billion US dollar. The footwear production of Bangladesh is also included in that figure is the causes of serious economic loss of the country. The present work is aimed to identify the causes of footwear rejection and devising better solution for the improvement of footwear quality. Footwear industries situated at different regions of Dhaka was selected. Questionnaire survey was done with quality managers. After interviewing production and quality stuffs and investing the workplace physically solutions of some major and frequent defects were suggested. Objectives: (a) Primary objective: • To find out the relative figure about the rejection in footwear manufacture in Bangladeshi Footwear company and to find out better solution for minimizing rejection. (b) Secondary objective: • To increase depth of knowledge for controlling quality production. Methodology: To analyze the types of footwear rejection, causes of footwear rejection and find out better solutions several methods were used. To find out the causes of footwear rejection and suitable solutions different books, journals, papers was reviewed also searched through internet which helped a lot to reach to the conclusion. Results: Footwear is rejected due to faulty production, wrong distribution and preservation and improper fitting issues. The less the rejection, better the profit and no industry cannot make good profit when more than 2% products are rejected. So, it can be surely said that, rejected footwear in supply chain is a major problem. Conclusion: The study reveals that every industries should have research and development lab where engineers will work on the development of new category footwear and ensure the production without any defect. It helps us to identify the causes of footwear rejection and devise better solution for the improvement of footwear quality.