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
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
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.
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.
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
- A live document SEW LEAN is using to plan for and mitigate risks can be found here: Risk Management
- A live document SEW LEAN created to track and manage problems can be found here: 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.
- SEW LEAN team plans to execute tabletop simulations with production floor key people as well as train ABVI on how to execute tabletop simulations independently. The team also plans to install the Andon system and observe its performance. Finally, the team will provide any final recommendations that help balance the line, improve the flow, convert jobs, or enhance communication on the floor.
- Individual team member 3-week plans can be found here: