LEAN THINKING AND WASTE REDUCTION IN LEATHER FINISHING. A PROCESS IMPROVEMENT PROJECT AT CONCERIA PASUBIO

The present thesis documents a project to improve the leather finishing process and reduce waste through the application of lean management and lean thinking principles. This project was carried out during a curricular internship from February to August 2025 at the Arzignano and Almisano sites of Conceria Pasubio S.p.A., a leading manufacturer of leather for the luxury automotive sector. The company is initially presented with discussion of its history, values and strategy. The subsequent presentation provides a comprehensive overview of the product and the production process, encompassing all stages from tanning to shipment to the customer. In the following section, the history of lean management will be examined, along with the principles of this methodology and the tools that have been developed for its implementation at Pasubio. The practical examples presented in this section are derived from activities carried out during the internship, in addition to the efficiency project conducted. The last part of the thesis presents the efficiency project for Line 13, also known as Line CUTA, at the Almisano plant, which is presented from a technical and technological point of view. The tools employed for enhancement are SMED, the Spaghetti Chart and the Kaizen Event, with a focus on the 6S methodology. Chapter 4 presents the AS IS state of the project: the preliminary analysis prior to the application of SMED and the areas for improvement identified during the Kaizen Event. In Chapter 5, the TO BE state is presented, which includes the reallocation of activities for the establishment of the new SMED procedure, along with the outcomes of all 6S activities. Next, the improvement projects carried out on line 13 and in the finishing department are presented with the aim of saving time, increasing production capacity and reducing chemical consumption. Finally, the 2026 Budget implementation activity is presented: through a brainstorming day at the Zermeghedo, Almisano and Arzignano plants, savings opportunities for 2026 are identified and their feasibility is analysed.