Step by step: 7 ways to improve footwear operations

Footwear manufacturing is a considerable challenge for any brand, but particularly so for those that have yet to adopt a tailored ERP that accommodates the technical requirements associated with shoe creation.

Unlike most products in fashion, a single shoe can feature 20-30 different components, from outsoles to insoles, vamps to heel counters, and toe caps to tongue linings.

Each part not only serves a specific function but demands different materials, construction techniques and quality standards.

Why footwear production is so difficult

When producing, say, a basic t-shirt, brands typically work with a few materials and components but with footwear, they could be juggling leather of varying grades, textiles, foams, rubber compounds, metals, adhesives and more, all of which must work together.

To complicate matters more, there’s also sizing complexity. While apparel might come in 5-7 standard sizes, footwear typically spans 7-14 sizes, often with multiple width options.

Every single variation changes not just the dimensions but the proportional relationships between each component.

Furthermore, there’s also the technical challenges associated with creating impeccable footwear:

• A well-crafted heel counter extends a shoe’s lifespan by up to 40%*
• The vamp (the upper front part of the shoe) accounts for 60% of consumer preferences and is the most customised component*
• Mislabelling components like the EVA midsole can increase manufacturing costs by as much as 20%*

With this in mind, it’s not surprising that up to 90% of shoe production errors occur due to miscommunication and design specifications.

Now that we understand why footwear production is challenging, let’s explore seven ways that tailored ERPs can help brands manage their products more effectively.

*Stats were reported by SHOESTUDIO’s Hélder Da Silva.

1.) Standardise footwear terminology and components

As briefly mentioned above, mislabelling components breeds confusion that inevitably leads to costly mistakes.

A design team may refer to a specific part as the “quarter” while the factory, located in an entirely different country, might call it the “side panel.”

Studies show that proper knowledge of shoe components can reduce production delays by up to 30%. Ideally, effective standardisation should look like:

• Clear, visual reference guides that name every component consistently
• Standardised specification sheets that leave no room for interpretation
• Technical training to ensure teams across design, development, and production share the same vocabulary

When each department or function calls the collar lining the collar lining (and not the “upper edge fabric” or “inner heel material”), one of the major culprits of production errors is eliminated.

2.) Create BOMs for each footwear variant

Any fashion brand worth its salt provides their manufacturers with a Bill of Materials (BOM).

It is an essential part of the process that ensures the created products accurately match the required specifications.

For footwear, however, BOMs become more complicated due to the precision needed for each item variant and their associated components.

Here are some examples to help illustrate this:

• A size 12 shoe requires significantly more leather than a size 6
• A white leather upper needs different backing materials than a black version to prevent colour transfer
• Waterproof variants require specialised adhesives that standard versions don’t
• Winter styles might incorporate thermal components absent in summer versions

It should be obvious to see that a BOM is needed for each variant, but few ERP systems actually allow brands to do so.

When the BOM specifies exactly what’s needed for a blue suede loafer in size 9.5 with a cushioned insole, manufacturers can avoid common pitfalls such as material shortages or overages.

3.) Implement a matrix-based approach to manage variants

Product ranges don’t just include the same pair of shoes in different sizes; they include all width and colourway options too.

A single pair of trainers might come in seven colourways and 14 sizes, meaning the brand has to manage, track and order 98 unique SKUs.

Matrix-based systems allow brands to view and manage all variants of a style simultaneously, making it much easier to plan production runs and track inventory levels across the entire product range.

This approach also simplifies sales order processing. When customers order an assortment of sizes in multiple colourways, brands need a system that can easily handle these complex orders without requiring manual calculations or adjustments.

4.) Coordinate material requirements across production orders

Footwear manufacturing often involves specialised materials that may have long lead times or minimum order quantities. By consolidating material requirements across production orders, brands optimise purchasing and ensure availability when needed.

For example, if a brand is producing three different boot styles that all use the same waterproof leather, a consolidated view of material requirements helps it place optimised orders with suppliers and negotiate better terms.

This approach also helps identify potential material shortages early in the process, giving the brand time to find alternatives or adjust production schedules before they impact delivery timelines.

5.) Track component-level quality and performance

In footwear, the failure of a single component can compromise the entire product. Tracking quality metrics at the component level helps identify recurring issues and improve overall product reliability.

For instance, if you notice that a particular type of adhesive is failing in hot climates, or that a specific outsole material wears too quickly, brands can make informed adjustments to their specifications before these issues affect customer satisfaction.

Component-level tracking also supports better supplier management, allowing brands to identify and address quality issues with specific materials or parts.

6.) Manage specialised tooling requirements

Unlike many fashion products, footwear often demands specialised tools and moulds for production. These tools represent significant investments and need to be carefully managed.

Tracking the location, condition, and usage of lasts (the foot-shaped forms used in shoe production), cutting dies, and sole moulds ensures that these critical resources are available when needed and properly maintained.

A tailored ERP system that connects these tooling requirements to production schedules helps prevent delays and optimise the use of these valuable assets.

7.) Integrate prepack planning with production

Footwear is typically shipped and displayed in size runs, requiring careful planning of prepack configurations. Integrating prepack planning with production ensures that the right quantities of each size are manufactured to fulfil retail and distribution requirements.

Predefined size breakdowns based on historical sales data helps optimise inventory levels and reduce the need for reorders or overstock situations.

When production planning incorporates these prepack requirements from the beginning, you minimise handling and maximise efficiency.

How we support footwear manufacturing

As experts in all things fashion (including footwear), our solutions directly address the common challenges that footwear brands face.

Here’s how our solutions can help your operations:

Comprehensive product data management
We offer centralised systems for managing all product specifications, ensuring consistent terminology and clear communication across design, production, and sales teams.

Matrix-based variant management
Our solutions offer intuitive matrix grids that make managing multiple variants simple and efficient. This is particularly valuable for footwear, where a single style might come in 7-14 sizes and multiple width options. Collections can even be spun up in as little as 10 clicks.

BOM management
We facilitate BOM creation for each variant, ensuring that all components, from leather uppers to specialised insoles, are accurately accounted for in material planning.

Integrated Material Requirement Planning
Our planning worksheet and MRP functionalities enable manufacturers to efficiently manage material requirements across all production orders, optimising purchasing and preventing shortages.

Production order management
Our systems streamline the creation and tracking of production orders, ensuring that all necessary materials and tooling are available when needed. This reduces bottlenecks and helps maintain consistent product quality.

Prepack management
We offer prepack support for logistics. Prepacks are predefined size breakdowns, assortments, and sets, making it easier to plan and fulfil orders in the size runs that retailers expect.

Landed cost and cargo management
We also offer tools to help you easily determine your landed cost and ensure optimal profitability, as well as oversee, manage, and distribute cargo to warehouses with simple-to-use features. These are critical if your products are often manufactured overseas.

Want to know more?

Footwear manufacturing is inherently specialised and that means brands producing shoes need specialised ERPs to support them with their technical requirements.

If you’d like to learn more about how K3’s fashion solutions can support your footwear manufacturing processes, feel free to drop us a line today.