Team Vision for Detailed Design PhaseSummarize:
- During the Detailed Design Phase, SEW LEAN team planned to focus on gathering floor layout options aimed towards meeting customer requirements, including improving the flow and balancing the line. To do that, a floor layout Kaizen event was initiated, where the customer had the opportunity to come up with a preferred layout option. A ranking criteria for the different layout options was created, and layout options were ranked using the criteria.
- During the Detailed Design Phase, SEW LEAN team spent time on GEMBA observing bottleneck stations to capture non-value added observations. Detailed time studies were performed on four stations and improvement recommendations were noted.
Rehab Engineers Update
- Will follow up on conversions relating to Air Force Pants
- Out of Scope: Oven Mitt time study
Defect App Creation
Current State: We are still working on compiling important information to be collected. Once done this will be given to IT to implement into an app.
Production vs. Demand Tracking Board
The above sheet allows Mary Jane, the sewing facility supervisor, to monitor whether or not the operators are keeping up with the daily demand of 225 pairs of pants. The sewing facility needs to meet a takt time of 1.87 minutes per pair of pants in order to meet this daily goal.
Prototyping, Engineering Analysis, Simulation
To get input from the folks at ABVI regarding our layout proposals, we created a board with magnets (representing the machines) and placed it at ABVI so people there could create their own layout, or layouts, by moving the magnets around into as many options as they liked. This was a way for us to simulate "what if the floor looked like this, or like this?", in an interactive way with the clients.
Drawings, Schematics, Flow Charts, Simulations
Kaizen Event at ABVI
Floor Layout Options
The following layouts were created by SEW LEAN during the preliminary detailed design phase:
This option was taken from the floor layout kaizen event. The sewing floor supervisor created this layout idea implementing what she thinks will work best at ABVI.
Comparison of Layout Options
The above image compares the number of blind/visually impaired stations located on the tour route for each floor layout presented. Colored stations are blind/visually impaired stations. Currently there are 6 blind/visually impaired stations on the tour route.
SEW LEAN worked with ABVI to create ranking criteria to help choose a layout option. The following shows the criteria and the assigned weights:
The original weights were changed because the team felt they did not accurately reflect the goals of the original project. The project specific priority matrix was created to help illustrate the team's thoughts:
After determining more appropriate weights, each of the layout options were evaluated and ranked.
Based on the results either layout 3 or 4 is preferred by the team. SEW LEAN felt that with minor adjustments to layout option 4 there could be improvement to the flow score, ranking it as the preferred option.
A timeline was created to visually map the layout implementation plan moving into MSD II.
Based on the timeline a list of Action Items were created and assigned to either ABVI or the SEW LEAN team.
Finally, to measure the success of the layout changes the team will use the KPIs created for the project. The following are the KPIs that will reflect layout changes, and the plan to measure by SEW LEAN.
We have a budget for this project. We spent some money earlier on an experiment associated with the job conversion aspect of this project. We do not have other specific conversion ideas identified at this time. As they occur, we will add them to a BOM to track total expenditures vs. budget.
Study of Non-Value Add at Bottlenecks
Balancing the Line
In efforts to improve the balance of the line, SEW Lean team went to Gemba to study bottleneck stations and recorded observations regarding non-value added steps. Detailed time studies of each station were performed and Improvement suggestions were noted.
The above image contains the Yamazumi chart of the average cycle times of all stations. Stations studied in this phase include: putting reflector on pant panel, seaming lining sides together, closing inseam, and attaching zipper to lining.
Putting Reflector on Pant Panel Station
The above image includes a chart of the Best Repeatable Time vs. Steps for the Reflectors station. As seen, steps 5 and 7 take the longest time to be performed.
Improvement ideas for the Reflectors station include:
- Parts presentation - if the reflectors are displayed in an 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.
Seaming Front & Back Sides of Lining Together Station
The above image includes the detailed steps associated with the station involving seaming the back and front sides of the lining together.
The above image includes a chart of the Best Repeatable Time vs. Steps for the station involving seaming the sides of the lining together.
Improvement ideas include:
- Split the step into two jobs - one person could sew one side and another person could sew the other.
- Better training on how to line leg up with guide so it's quicker.
Closing the Inseam Station
The above image includes the detailed steps associated with the station involving closing the inseam.
The above image includes a chart of the Best Repeatable Time vs. Steps for the station involving closing the inseam. Step 4 seems to be taking the longest time.
Improvement ideas include:
- 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.
Attaching Zipper to Lining Station
The above image includes the detailed steps associated with the station involving attaching zipper to lining.
The above image includes a chart of the Best Repeatable Time vs. Steps for the station involving attaching zipper to lining. Steps 6 & 14 take the longest time.
Improvement ideas include:
- Balancing the workload performed by the worker can potentially speed up the process and eliminate waste. This might involve adding a worker, so the work can be split up and balanced.
Testing Plan for MSD II
The below plan is an outline that the Sew Lean team would like to follow for the second semester of Senior Design. The bullet points are the main tasks we plan to achieve.
Design and Flowcharts
Our design and flowchart work for this project is addressed by the layouts, spaghetti diagrams, time studies, and other data collection and analytical exercises we have completed, which are shown on this page and the pages for previous phases.
A live document SEW LEAN is using to plan for and mitigate risks can be found here: Risk Management
Design Review Materials
The SEW LEAN Final Detailed Design Presentation can be found here: Final Detailed Design Presentation
Plans for next phase
- SEW LEAN team plans to attend a gate review before the end of the semester.
- In preparation for MSD 2, the team will make sure we and the customer are prepared for the Floor Layout Implementation; we have a plan for what needs to be done, by whom, and when.
- Individual team member 3-week plans can be found here: