P18701: ABVI Sewing Facility Improvement
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

Summarize:

Phase Plan

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Progress Report

Rehab Engineers Update

Communication Updates

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.

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.

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Comparison of Layout Options

Flow

The above image displays the material flow through the current layout

The above image displays the material flow through the current layout

The above image displays how the material will flow through floor layout option 1

The above image displays how the material will flow through floor layout option 1

The above image displays how the material will flow through floor layout option 2

The above image displays how the material will flow through floor layout option 2

The above image displays how the material will flow through floor layout option 3

The above image displays how the material will flow through floor layout option 3

The above image displays how the material will flow through floor layout option 4

The above image displays how the material will flow through floor layout option 4

Tour Route

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.

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.

Layout Implementation

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.

BOM

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.

Test Plans

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.

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.

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:

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 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.

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:

Closing the Inseam Station

The above image includes the detailed steps associated with the station involving closing the inseam.

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.

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:

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 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.

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:

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.

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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.

Risk Assessment

High Priority Risks

High Priority Risks

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

Melissa, Jenn, Ashley, Ryan, Zain


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