P18701: ABVI Sewing Facility Improvement
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Integrated System Build & Test

Table of Contents

Team Vision for Integrated System Build & Test Phase

During the Integrated System Build & Test Phase, SEW LEAN team planned to spend time with the NIB trainer to note waste reduction suggestions, finalize a list of prioritized waste reduction recommendations, come up with a plan for executing tabletop simulations, order bins for pockets, provide the customer with updates regarding the Andon cord system, compile a list of recommendations for the production ramp up, and further study the possibility of cross-training, which includes coming up with a plan to cross-train employees.

Test Results Summary

Production Ramp-up Recommendations

During Phase III SEW LEAN worked to complete a final recommendation for ABVI to increase production by 50 pants/month. New data was collected, and originally time study data was also considered.

The document created with final recommendations and calculations can be viewed here: Production Ramp-up Recommendation

Table-Top Simulations

To help teach and enforce the changes made on the production floor SEW LEAN is planning table-top simulations to demonstrate at ABVI. The simulations will be taught to supervisors and managers, and then shared with the rest of the employees.

A summary of the simulation ideas can be viewed here: Table-top Simulation Ideas

Visual/Floor Communication

Labeled bins for pocket storage

The above bins were purchased for pocket storage, we will be transferring pockets from cardboard boxes to this system. The three bins on the top will be used for raw materials, small pockets, and large pockets. The two bins on the bottom will be used for combined pockets and sewn pockets.

The above bins were purchased for pocket storage, we will be transferring pockets from cardboard boxes to this system. The three bins on the top will be used for raw materials, small pockets, and large pockets. The two bins on the bottom will be used for combined pockets and sewn pockets.

Updated cross-training chart

A document was created to visually show the cross training capabilities of ABVI. The goal is to have every employee trained on at least three tasks and to have every task known by three different employees.

The document SEW LEAN created to track cross-training can be found here: Cross Training Document

Floor andon signals

The above chart shows the pros and cons of two different andon cord options to be implemented in the sewing floor.

The above chart shows the pros and cons of two different andon cord options to be implemented in the sewing floor.

Above is a list of steps to take for successful andon cord implementation. It is important for these steps to be followed to create a culture change in the floor that all of the employees follow.

Above is a list of steps to take for successful andon cord implementation. It is important for these steps to be followed to create a culture change in the floor that all of the employees follow.

Risk and Problem Tracking

Functional Demo Materials

The SEW LEAN Phase III Presentation can be found here: Phase III Presentation

Plans for next phase

The above tasks are those that the Sew Lean Team planned to complete this semester. The tasks in green have been completed, the tasks in yellow are in progress and the red tasks have not been started. The team will be completing these tasks before the end of the semester.

The above tasks are those that the Sew Lean Team planned to complete this semester. The tasks in green have been completed, the tasks in yellow are in progress and the red tasks have not been started. The team will be completing these tasks before the end of the semester.

Melissa, Jenn, Ashley, Ryan, Zain


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