It is well known that the global market is driving companies towards new productive paradigms oriented to product customization, agility and environmental sustainability. Companies have to face the problem of providing as much product variety as possible in order to rapidly satisfy a wide number of specific market segments. Even if the emerging automated agile production environments could enable them to manage product variety, in many productive fields, large waste streams, due to the practical difficulty of adapting the traditional production lines to product changes, are still present. At the same time a growing public concern for the environment, is forcing companies to investigate alternative uses for waste material. In this paper we present a practical example from the footwear industry in order to show how companies can successfully apply the concept of sustainable production taking into account the mass customization requirements but contemporarily reducing the material waste. The approach is focused on the combination in the same plant of two different production lines: one is dedicated to the primary production while the other uses the waste material to realize the secondary production.
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