Table of Contents
Team Vision for Problem Definition Phase
- The most important portion of this phase for our team was understanding the problem we were given. We planned to visit our customer and gain a better understanding of the manufacturing process.
- During this phase our team spent a large about of time defining how we plan to work together as a team and assigning team roles. We also clearly defined our problem and customer requirements. SEW LEAN was also able to visit the customer several times to begin understanding and documentation of current state.
Project SummaryCurrently, production flow is scattered causing transportation and motion waste. Additionally, there are limited jobs that can be performed by blind or visually impaired employees. This makes meeting a requirement of 75% blind or visually impaired employees difficult.
The desired state is a more efficient floor layout that will include a flexible area that is easily modified for new jobs. The new layout will limit waste and include additional blind/visually impaired jobs.
Project BackgroundThe Association for the Blind and Visually Impaired (ABVI) empowers people with vision loss to engage in fulfilling careers by offering a variety of specialized products, including a sewing production line whose products include various uniforms for the federal government. A mix of approximately 40 blind and sighted employees work various shifts throughout the day, year round.
Project Goals and Key DeliverablesProject goals are to create a clearly documented current state of the facility, create a new floor layout, and work to convert sighted jobs to blind/visually impaired. Ergonomics, quality, and safety concerns for employees will be kept in mind during all changes.
ConstraintsThe new layout will maintain the current available square footage and will place blind/visually impaired jobs near the front of the work environment. Current electrical and pressurized air connections will be used when possible, and any budget requirements will be proposed to and approved by ABVI.
- ABVI Industrial Engineering, Quality & Production
- ABVI floor workers
- RIT MSD
- SEW LEAN
- Government Agencies (final customers)
|Use Scenario||Key Stakeholders|
|Modifications to sewing equipment||Maintenance employees, Sewing employees|
|Modifications to raw material storage||Shipping personnel|
|Blind sensitivity training||SEW LEAN team members, Sewing employees|
A live document with our Customer Requirements can be viewed here: Customer Requirements
A live document with our Engineering Requirements can be viewed here: Engineering Requirements
House of Quality
A live document with our House of Quality can be viewed here: House of Quality
To understand the process SEW LEAN completed flow diagrams of the pant and oven mitt process during this phase. The diagrams can be viewed here:
Design Review Materials
The SEW LEAN Planning & Definition Phase Presentation can be found here: Planning & Definition Presentation
Plans for next phase
- During the Design Phase SEW LEAN is committed to completing individual assignments to finish current state value stream maps, time studies, baseline measurements for all engineering requirements, and research on blind manufacturing and previous process changes that have been completed at ABVI.
- Individual team member 3-week plans can be found here: