BAHIR DAR UNIVERSITY

INSTITUTE OF TECHNOLOGY [BiT]

FACULTY OF MECHANICAL AND INDUSTRIAL
ENGINEERING [FMIE]
DEPARTEMENT OF INDUSTRIAAL ENGINEERING
INDUSTRIAL DESIGN SEMESTER PROJECT

TITLE: DESIGN WOMEN'S AND CHILDREN'S FOOTWEAR INDUSTRY IN BAHIR DAR.

PREPARED BY:

NAME: ID:

1. ASAYEHEGN DESTA………………………………………..BDU1405707
2. MISGANA TAGESSE…………………………………………BDU1405708
3. MINTESNOT MENGISTU…………………………………….BDU1405758
Table of Contents:

1. Introduction

1.1 Background & Motivation

1.2 Problem Statement

1.3 Objectives of the Project

1.4 Scope of Project

1. Literature Review

2.1 Overview of Footwear Manufacturing

2.2 Industrial Engineering Principles in Factory Design

2.3 Case Studies of Existing Footwear Factories

2. Market Analysis

3.1 Demand for Women’s and Children’s Footwear

3.2 Target Customers & Product Segmentation

3.3 Competitive Landscape

3. Product Design Overview

4.1 Types of Footwear.

4.2 Design Requirements for Women vs. Children

4.3 Ergonomics & Safety Considerations

4. Process Design

5.1 Manufacturing Process Flowchart

5.2 Description of Key Operations

5.3 Process Optimization Techniques

5. Facility Layout Planning

6.1 Block Layout & Departmental Arrangement

6.2 Material Flow & Space Utilization

6.3 Layout Alternatives & Selection Criteria

6. Work Study & Ergonomics

7.1 Time & Motion Study

7.2 Workstation Design

7.3 Ergonomic Considerations for Workers

7. Equipment & Technology Selection

8.1 Machinery for Cutting, Stitching, Lasting, Finishing

8.2 Automation & Digital Tools

8.3 Maintenance Planning

8. Supply Chain & Inventory Management

9.1 Raw Material Sourcing

9.2 Inventory Control Systems

9.3 Vendor & Logistics Planning

9. Human Resource Planning

10.1 Staffing Requirements

10.2 Skill Development & Training

10.3 Health, Safety & Welfare

10. Quality Assurance & Control

11.1 Inspection Procedures

11.2 Defect Analysis

11.3 Standards for Women’s & Children’s Footwear

11. Environmental & Sustainability Considerations

12.1 Waste Management

12.2 Energy Efficiency

12.3 Eco-friendly Materials

12. Financial Analysis

13.1 Cost Estimation (Capital & Operational)

 13.2 Break-even Analysis

13.3 Budgeting & Investment Planning

13. Project Management

14.1 Gantt Chart or Timeline

14.2 Risk Assessment

14.3 Monitoring & Evaluation Plan

14. Conclusion & Recommendations

15.1 Summary of Findings

15.2 Design Justifications

15.3 Future Scope

16. References

17. Appendices

1. CAD Layouts
2. Equipment Specifications
3. Survey or Interview Data
4. Regulatory Checklists
1. Introduction

1.1 Background & Motivation

Empowering women and supporting children are foundational pillars of sustainable

development and social equity. In Ethiopia, despite growing awareness of gender
inclusion and child welfare, there remains a significant gap in the availability of
dedicated manufacturing facilities that cater specifically to the needs of women and
children. Products such as maternity wear, baby clothing, hygiene essentials, and
educational toys are often imported or produced in limited quantities, with minimal
attention to local cultural preferences, affordability, and accessibility.

Recognizing this gap, our team has chosen to focus on the design and development of
a women’s and children’s product manufacturing factory in Bahir Dar. This city,
strategically located near Lake Tana and serving as a regional hub, offers access to
skilled labor, transportation networks, and raw materials such as cotton and textiles
sourced from nearby agricultural zones. Yet, there is currently no modern facility in
Bahir Dar dedicated to producing high-quality, locally tailored goods for women and
children.

According to a 2024 report Ministry of Women and Social Affairs Official Site,
women in the Amhara region face challenges in accessing affordable maternity and
childcare products, while local artisans and small businesses struggle to scale due to
limited infrastructure and technical support. This unmet demand highlights the urgent
need for a facility that not only manufactures essential goods but also fosters inclusive
employment and skill development for women.

Establishing a women’s and children’s factory in Bahir Dar would address multiple
socioeconomic challenges: it would create jobs for women, promote child-friendly
product innovation, reduce dependency on imports, and contribute to Ethiopia’s
broader industrialization and gender equity goals. From an industrial engineering
standpoint, this project encompasses key principles such as ergonomic facility design,
sustainable material sourcing, production line optimization, and quality assurance
tailored to sensitive consumer segments.

By undertaking this initiative, our team aims to demonstrate how industrial

engineering can be leveraged to build a socially responsive and economically viable
manufacturing enterprise—one that uplifts communities and meets the evolving needs
of Ethiopia’s women and children.
1.2 Problem Statement

The demand for women’s and children’s footwear in Ethiopia has grown steadily in
recent years, driven by population growth, urbanization, and increasing awareness of
fashion, comfort, and health. However, the local footwear manufacturing sector has
not kept pace with this demand. Many small and medium-sized enterprises (SMEs)
continue to rely on outdated production systems, manual labor-intensive processes,
and poorly organized facility layouts. These limitations hinder their ability to produce
high-quality products at competitive prices and in sufficient quantities.

One of the most pressing challenges is the lack of automation and modern machinery.
Most local factories operate with minimal mechanization, which leads to slow
production cycles, inconsistent product quality, and high rates of material waste. In
addition, inefficient facility layouts contribute to bottlenecks in workflow, increased
handling time, and poor space utilization. These inefficiencies not only reduce
productivity but also inflate operational costs, making it difficult for manufacturers to
scale or compete with imported footwear brands.

Quality control is another critical issue. Without standardized processes and proper
equipment, many manufacturers struggle to meet consumer expectations for durability,
comfort, and design. This is especially problematic in the women’s and children’s
segment, where product safety, ergonomic design, and aesthetic appeal are essential.
The lack of reliable quality assurance systems further undermines customer trust and
limits market expansion.

Moreover, the absence of sustainable practices—such as energy-efficient systems,

waste management protocols, and ethical labor standards—poses long-term risks to
both the environment and the workforce. As global markets increasingly prioritize
sustainability and social responsibility, Ethiopian footwear manufacturers must adapt
to remain relevant and competitive.

Given these challenges, there is a clear need for a modern, well-engineered factory
design tailored specifically to the production of women’s and children’s footwear.
Such a facility should incorporate advanced manufacturing technologies, optimized
layout planning, and robust quality management systems. It should also be designed
with scalability and sustainability in mind, enabling manufacturers to grow
responsibly while meeting evolving market demands.

This project aims to address these issues by proposing a comprehensive factory design
that enhances productivity, ensures consistent quality, reduces operational costs, and
supports long-term industrial growth in Ethiopia’s footwear sector.
1.3 Objective of project

1.3.1 General Objective

Design Women's & Children's Footwear Factory

1.3.2 Specific Objectives

 To analyze the market requirements and product specifications for women’s and children’s
footwear.
 To develop a process flowchart outlining key manufacturing stages from design to packaging.
 To design a facility layout that ensures smooth material flow, space utilization, and worker
safety.
 To select appropriate machinery and technology for cutting, stitching, lasting, and finishing
operations.
 To propose inventory and supply chain strategies for raw material sourcing and product
distribution.
 To incorporate ergonomic and environmental considerations into the factory design.
 To estimate capital and operational costs and perform a break-even analysis.
 To identify potential risks and propose mitigation strategies for factory operations.

1.5 Scope of Project

This project focuses on the conceptual and technical design of a footwear

manufacturing facility that produces shoes for women and children. It integrates
industrial engineering principles such as process optimization, facility layout planning,
ergonomic design, and resource management. The scope includes:

 Designing the production workflow from raw material intake to finished product packaging.
 Planning the facility layout to optimize space, material flow, and worker efficiency.
 Selecting appropriate machinery and technologies for both women’s and children’s footwear.
 Addressing ergonomic and safety standards for workers and end-users.
 Proposing inventory and supply chain strategies.
 Estimating financial requirements including capital investment and operational costs.
 Incorporating sustainability and environmental considerations into the design.