SEW LEAN Detailed Design Review Zain Abdelrazeq, Ryan Dillon, - - PowerPoint PPT Presentation
SEW LEAN Detailed Design Review Zain Abdelrazeq, Ryan Dillon, Melissa Dubots, Ashley Kittell & Jenn Palmer 1 Agenda Problem Definition Metric Tracking Customer Requirements Updates from Phase III KPIs (Engineering
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○ Layout Options Evaluated ○ Comparison of Options ○ Evaluation Criteria
○ Rehab Engineers ○ Defect Tracking ○ Budget
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No current documentation of layout Transportation and motion waste Several jobs that can only be performed by sighted employees
Improved layout with better flow Included “flex” area to allow for additions of commercial jobs Reduced waste (focus on transportation and motion) Additional blind/visually impaired jobs Clearly documented current state New floor layout Convert sighted jobs to blind/visually impaired Design with ergonomics, quality, and safety in mind Maintain current square footage Focus blind/visually impaired jobs along tour route Use current electrical and air connections when possible Budget proposed and approved by ABVI
Improving Flow Communication Job Conversion Balancing Line
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Improving Flow Communication Job Conversion Balancing Line
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Criteria Description Weight
Cost How expensive are the changes to make? 0.35 Safety Proper aisleways, Are we altering the culture of the floor 0.15 Flow Pockets, Reflectors, FG movement, Any elimination of waste, Proper flow of material 0.30 B/VI Tour Path Are the B/VI jobs located along the tour route? 0.10 Ease of Layout Change How easy are the machines to move 0.10
Total 1.00
Time Performance Cost Enhance Accept Constrain
Standard Matrix
Project Constraints Cost Enhance Accept Constrain
Our Matrix
Project Objectives
Project Constraints Cost Enhance Accept Constrain
Our Matrix
Project Objectives
Project Objectives:
Project Constraints:
○ Computer does not move ○ Limit additional electrical hookups
Cost:
need to be accepted
Criteria Description Weight
Cost How expensive are the changes to make? 0.35 Safety Proper aisleways, Are we altering the culture of the floor 0.15 Flow Pockets, Reflectors, FG movement, Any elimination of waste, Proper flow of material 0.30 B/VI Tour Path Are the B/VI jobs located along the tour route? 0.10 Ease of Layout Change How easy are the machines to move 0.10
Total 1.00
Weight
0.15 0.20 0.40 0.15 0.10
1.00
Criteria Weight Current State Option 1 Option 2 Option 3 Option 4
Cost 0.15 10 3 3 3 3 Safety 0.20 5 6 8 7 9 Flow 0.40 3 7 6 7 7* B/VI Tour Path 0.15 5 7 4 8 4 Ease of Layout Change 0.10 10 3 4 3 5
TOTALS
5.45 5.80 5.45 6.15 6.15 *With minor improvements we can change the 7 to a 9, increasing the total score to 6.95
Key Performance Indicator How the team will measure success of this What will this indicate Production vs. Demand Record gap of what is produced each week vs. what is demanded by the customer Improving Flow Balancing Line Cycle Time Time studies of stations and “red tag” and item through the line Improving Flow Balancing Line Non-Valued Added Time Conduct time studies Balancing Line WIP Count of all work in process on the floor Improving Flow Balancing Line
Layout Options Compiled
Ranked based on criteria.
Electrical Decision
Will electrical work be completed over winter break?
Implementation Date
Make a plan and set a date for implementation.
2017
Electricity Hookups for Mitt Line
Date for electricity implementation.
Final Layout Option Determined
Given rankings and expertise which layout will ABVI pursue.
Implementation
When are all stakeholders free to complete implementation.
2017
2017
2018
2018 TBD
Action Item Responsible Party
1 Electricity for Oven Mitt Relocation ABVI 2 Determine Final Layout ABVI 3 Meeting to Discuss Layout Plan in January ABVI & Sew Lean Team 4 Move Machines/Tables into New Layout Formation ABVI & Sew Lean Team 5 Familiarize employees on new layout Sew Lean Team & Mary Jane 6 Create 5S for Stations Sew Lean Team 7 Collect Data for New Layout Sew Lean Team 8 Provide ABVI with a clear picture of new state Sew Lean Team
4 stations were studied & NVA added
recorded. 1. Putting Reflectors
2. Sewing Lining Sides Together 3. Closing Inseam 4. Attaching Zipper to Lining
Improvement Ideas:
untangled fashion, step 3 can be shortened.
possibly reduce motion waste.
Step Number Step Description 1 Pick up a pant panel from under the machine (heat press) 2 Lay the pant panel flat on the bottom plate of the heat press 3 Pick reflector from basket and position it on the pant panel 4 Put the top plate of the heat press down 5 Wait for the machine to beep (load machine 2 simultaneously) 6 Put the top plate of the heat press up 7 Finish loading machine 2 8 Remove pant panel from machine 1 and lay it flat
9 Remove plastic from reflector
Improvement Ideas:
another person could sew the other.
Step # Step Description 1 Pick up material (back panel of lining) and line it up under the machine, hooking it to the needle 2 Grab front of lining, unhook bottom from machine and line up the two together. Then rehook both panels under the machine 3 Line up the lining leg with the sewing guide 4 Push foot pedal down and sew material. Stop and realign material as necessary. This is done for 5 passes of sewing 5 Take the material out of the machine and flip it to the
aligned. 6 Hook material under the machine 7 Line up the lining leg with the sewing guide 8 Push foot pedal down and sew material. Stop and realign material as necessary. This is done for 5 passes of sewing 9 Once material reaches the notch, stop sewing and take the material out from the machine. Quality check sew job, press counter to track it and put material off to the right on a rack
Improvement Ideas:
pants.
the floor have a guide.
Step # Step Description 1 Operator picks up the liner at the waist. Then runs their hand down the seam of the pant to get to the leg opening and places the leg opening on sewing machine 2 Aligns the ends of the pant leg and places the liner under the machine leg 3 Aligns the liner fabric again, before starting to sew 4 Sews the inseam* this step involves multiple starts/stops
5 Inspects the inseam with hand, by running fingers over the seam 6 Places the finished liner on the rack and aligns it
Step Number Step Description
1 Pick pants up and position it over the table with pants ankle facing the operator 2 On the pants ankle, turn the shell inside out 3 Align the lining & zipper attached to the shell together 4 Position pant under the machine (lining & zipper on shell) 5 Run the machine to attach the zipper 6 Align the other side of the same ankle (lining & zipper
7 Position pant under the machine 8 Run machine to attach lining to shell on ankle 9 Pick pnts and position it over the table with the other pants ankle facing the operator 10 Repeat step 2 11 Repeat step 3 12 Repeat step 4 13 Repeat step 5 14 Repeat step 6 15 Repeat step 7 16 Repeat step 8 17 Pick pants & quickly inspect the work done
Improvement Idea:
speed up the process and eliminate waste. This might involve adding a worker, so the work can be split up and balanced.
Time Cumulative Demand Total Production Difference
(Demand - Production)
11:50 am 131 2:15 pm 193 3:30 pm 225
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○ Electricity for machines near fabric cutter ○ Waiting on final cost
Technology ○ As of 12/6, still have not heard from committee ○ Decision expected by January 1st
Some of the high/severe risks that were experienced during Phase IV: Risk Effect Mitigation Likelihood Severity Importance
New Layout does not perform as expected Instead of increasing throughput, production now takes longer Perform multiple analysis techniques and seek input from various sources to make the best informed decision 3 9 27 The floor layout redesign takes 2 months to implement Sew Lean is unable to implement additional continuous improvement ideas to the sewing department Communicate effectively with ABVI so that they can adequately plan when to implement the floor layout
3 9 27 ABVI is unable to install
machines near fabric cutter The floor layout process will have to start over, a complete re-design Before anything is physically moved, be sure the work has been completed 3 6 18 Accelerated timeline Input for new floor layout not received from all stakeholders Allow as much time as possible for Kaizen event at ABVI 3 6 18 Unknown Unknowns TBD A new layout could cause unforeseen issues with production 3 3 9
SEW LEAN also continues to see and discuss Scope Creep to keep the project on track and focused.
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○ Perform new time studies ○ Count WIP ○ All new data collection
time in steps ○ Possibly changing parts presentation
information that the Rehab Engineers left
presentation etc.)
tracking app
for ABVI and handoff material we have created