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 Requirements) Rehab Engineers ● ○ Kaizen Floor Layout Outcomes Defect Tracking ● ○ Layout Options Evaluated Budget ○ ○ Comparison of Options Phase Plan ○ ● Risks ● Evaluation Criteria ○ Senior Design II Plan ● Implementation Timeline ● Action Items ● Non-Value Added Observations ● 2
Problem Statement No current documentation of layout Current State 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 Desired State Reduced waste (focus on transportation and motion) Additional blind/visually impaired jobs Clearly documented current state Project Goals & New floor layout Deliverables Convert sighted jobs to blind/visually impaired Design with ergonomics, quality, and safety in mind Maintain current square footage Key Constraints Focus blind/visually impaired jobs along tour route Use current electrical and air connections when possible Budget proposed and approved by ABVI
Updated Customer Requirements
KPIs Improving Flow Balancing Line Job Conversion Communication 5
Floor Layout Kaizen Event Updates Improving Flow Balancing Line Job Conversion Communication 6
Floor Layout Options
Option 1 Sew Lean Suggestion
Option 2 Sew Lean Suggestion
Option 3 Sew Lean Suggestion
Option 4 Mary Jane’s Suggestion
Comparison of Layout Options
Current State Flow
Option 1 Flow
Option 2 Flow
Option 3 Flow
Option 4 Flow
Original Floor Layout Criteria Criteria Description Weight Cost How expensive are the changes to make? 0.35 Safety Proper aisleways, Are we altering the culture of 0.15 the floor Flow Pockets, Reflectors, FG movement, Any 0.30 elimination of waste, Proper flow of material 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 Constrain Project Project Objectives Constraints Cost Enhance Constrain Accept Enhance Standard Matrix Accept Our Matrix Criteria Priority Matrix
Project Objectives: Enhance material flow ● Enhance view along tour route ● Project Project Objectives Constraints Limit motion to enhance safety Cost ● Constrain Project Constraints: Must move heat press into sewing area ● Must include a “flex area” ● Enhance Requests: ● Computer does not move ○ Limit additional electrical hookups ○ Accept Cost: To achieve project goals some costs ● Our Matrix need to be accepted Goal - to limit or justify required costs ●
Original Floor Layout Criteria Criteria Description Weight Weight Cost How expensive are the changes to make? 0.35 0.15 Safety Proper aisleways, Are we altering the culture of 0.15 0.20 the floor 0.40 Flow Pockets, Reflectors, FG movement, Any 0.30 elimination of waste, Proper flow of material 0.15 B/VI Tour Path Are the B/VI jobs located along the tour route? 0.10 0.10 Ease of Layout Change How easy are the machines to move 0.10 1.00 Total 1.00
Floor Layout Option Ranking Current Criteria Weight Option 1 Option 2 Option 3 Option 4 State 10 3 3 3 3 Cost 0.15 5 6 8 7 9 Safety 0.20 3 7 6 7 7 * Flow 0.40 5 7 4 8 4 B/VI Tour Path 0.15 Ease of Layout 10 3 4 3 5 0.10 Change 5.45 5.80 5.45 6.15 6.15 TOTALS *With minor improvements we can change the 7 to a 9, increasing the total score to 6.95
Layout Implementation Testing Plan Key Performance Indicator How the team will measure success of this What will this indicate Record gap of what is produced each week vs. what Improving Flow Production vs. Demand is demanded by the customer Balancing Line Time studies of stations and “red tag” and item Improving Flow Cycle Time through the line Balancing Line Non-Valued Added Time Conduct time studies Balancing Line Improving Flow WIP Count of all work in process on the floor Balancing Line
Layout Implementation Timeline Dec. 5 Dec. 7 Dec. 7 Jan. 22 Jan. 22 TBD 2017 2017 2017 2018 2018 Layout Options Implementation Electricity Hookups Final Layout Option Electrical Decision Implementation Compiled Date for Mitt Line Determined Ranked based on Will electrical work be Make a plan and set a Date for electricity Given rankings and When are all stakeholders criteria. completed over winter date for implementation. implementation. expertise which layout free to complete break? will ABVI pursue. implementation.
Action Items for Layout Implementation Action Item Responsible Party Electricity for Oven Mitt Relocation ABVI 1 ABVI Determine Final Layout 2 ABVI & Sew Lean Team Meeting to Discuss Layout Plan in January 3 Move Machines/Tables into New Layout Formation 4 ABVI & Sew Lean Team Sew Lean Team & Mary Jane Familiarize employees on new layout 5 Sew Lean Team Create 5S for Stations 6 Sew Lean Team Collect Data for New Layout 7 Sew Lean Team Provide ABVI with a clear picture of new state 8
Balancing the Line: Non-Value Added Observations
Balancing the Line: Non-Value Added Observations 4 stations were studied & NVA added observations were recorded. 1. Putting Reflectors on Pant Panels 2. Sewing Lining Sides Together 3. Closing Inseam 4. Attaching Zipper to Lining
Non-Value Added Observations: Putting Reflector on Pant Panel Step Number Step Description Pick up a pant panel from under the machine (heat 1 press) Lay the pant panel flat on the bottom plate of the 2 heat press Pick reflector from basket and position it on the 3 pant panel 4 Put the top plate of the heat press down Wait for the machine to beep (load machine 2 5 simultaneously) 6 Put the top plate of the heat press up 7 Finish loading machine 2 Remove pant panel from machine 1 and lay it flat Improvement Ideas: 8 on the table ● Parts presentation → if the reflectors are displayed in an 9 Remove plastic from reflector untangled fashion, step 3 can be shortened. ● Cell Shape → Instead of having machines 1 and 2 next to each other, an L shape with each machine placed at one side can possibly reduce motion waste.
Non-Value Added Observations: Side Seam Front & Back Lining Together Step # Step Description Pick up material (back panel of lining) and line it up 1 under the machine, hooking it to the needle Grab front of lining, unhook bottom from machine and 2 line up the two together. Then rehook both panels under the machine 3 Line up the lining leg with the sewing guide Push foot pedal down and sew material. Stop and 4 realign material as necessary. This is done for 5 passes of sewing Take the material out of the machine and flip it to the 5 other side. Smooth out the material so it is flat and aligned. 6 Hook material under the machine 7 Line up the lining leg with the sewing guide Push foot pedal down and sew material. Stop and Improvement Ideas: 8 realign material as necessary. This is done for 5 ● Split the step into two jobs - one person could sew one side and passes of sewing another person could sew the other. Once material reaches the notch, stop sewing and take ● the material out from the machine. Quality check sew Better training on how to line leg up with guide so it's quicker. 9 job, press counter to track it and put material off to the right on a rack
Non-Value Added Observations: Closing the Inseam Step # Step Description Operator picks up the liner at the waist. Then runs their 1 hand down the seam of the pant to get to the leg opening and places the leg opening on sewing machine Aligns the ends of the pant leg and places the liner under 2 the machine leg 3 Aligns the liner fabric again, before starting to sew Sews the inseam* this step involves multiple starts/stops 4 of the sewing machine to realign the liner fabric Inspects the inseam with hand, by running fingers over the 5 seam 6 Places the finished liner on the rack and aligns it Improvement Ideas: ● Parts presentation → if the liners are properly aligned, the operator can spend less time trying to find the leg of the pants. ● Removal of inspection → the following step is the final inspection of the liners before they are placed into the shells. ● Addition of a guide → this machine doesn't have a bar to help the operator align the fabric, whereas other machines on the floor have a guide.
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