This research is focused on applying the Six Sigma methodology together with the fishbone diagram, Pareto chart, FMEA, and its counterpart in the footwear industry in Bangladesh to assess quality and defect reduction in safety shoes. It tracks the defected items through various processes of the production cycle including sewing, lasting, and outsole production. It utilizes the DMAIC methodology to assess the defect in volume and their reasons in safety shoes production lines. The core research methodology employed is observational, concentrating on cycle time measurement, machine setup times, material flow, and defect counts in the order of recorded base beats. The analysis reveals that improper lasting processes and stitching-related issues are the primary sources of defects. According to Pareto analysis at least 80% of the defects are caused by 20% of the causes. The remaining problems and lacking processing are the biggest causes. The FMEA Methodology identified the most important failure modes, and actions to be taken were prioritized according to Risk Priority Numbers (RPN). Taking the steps that were recommended, including training, operator, equipment, and maintenance of standard processes showed positive and measurable changes in quality of the output. It shows that using the Six Sigma set of tools in a planned manner helps a lot in reducing the waste in manufacturing and increasing the product quality in the manufacturing of safety shoes-which also helps in improving the operational efficiency and customer satisfaction.