<![CDATA[The footwear industry is a labor-intensive sector that heavily relies on operators’ manual activities; therefore, production efficiency cannot be separated from ergonomic working conditions. PT Intidragon Suryatama faces several challenges, including process waste, high lead times, and potential ergonomic risks caused by improper working postures and repetitive work activities. These conditions may lead to decreased productivity, longer processing times, and musculoskeletal complaints that can adversely affect operators’ health and performance. Therefore, an approach that focuses not only on process efficiency but also on ergonomics as a supporting factor for productivity is required. This study aims to analyze the production flow using the Lean Manufacturing approach through Value Stream Mapping (VSM), identify operators’ ergonomic risks, and formulate work system improvement proposals by integrating VSM and ergonomic analysis using Digital Human Modeling (DHM). This research employed a descriptive qualitative method with data collected through field observations, interviews, and documentation. The analysis was conducted by developing a current-state VSM to identify value-added and non-value-added activities as well as sources of waste in the production process. Furthermore, DHM-assisted ergonomic analysis was performed to evaluate operators’ working postures and identify potential musculoskeletal disorder risks. The findings were then used as the basis for designing a future-state VSM and proposing improvement initiatives. The results indicate that the integration of Lean Manufacturing, VSM, and ergonomics can identify human-related waste and generate improvement recommendations that have the potential to reduce lead time, minimize waste, enhance workplace safety, and support sustainable improvements in operator productivity within the company. ]]>
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