P18701: ABVI Sewing Facility Improvement
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Subsystem Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

Summarize:

Test Results Summary

Completed Floor Layout

During this phase the floor layout at ABVI was completed.

The above image is the floor layout after the Sew Lean team and ABVI implemented the proposed changes. This layout creates a better flow in the floor and more space for future growth in the Air Force pants line.

The above image is the floor layout after the Sew Lean team and ABVI implemented the proposed changes. This layout creates a better flow in the floor and more space for future growth in the Air Force pants line.

Waste Reduction

Due to the production ramp up, takt was recalculated as shown below and was found to be 1.53 minutes.

The new takt is shown below as the dashed black line. Notice that the number of bottleneck stations is now 7.

The table below presents details about value-added and non-value added time for each of the bottleneck stations.

Thus far, the SEW LEAN team closely studied the following stations and came up with high-level recommendations that the team hopes to test-out along with other ideas that the team will be coming-up with.

Production Ramp Up

During this phase ABVI received increased demand from the government and SEW LEAN was tasked with creating a plan for the ramp up in the sewing facility.

Above is the plan that the Sew Lean team developed to collect enough data to make a recommendation for the ramp-up in production.

Above is the plan that the Sew Lean team developed to collect enough data to make a recommendation for the ramp-up in production.

Training

For increased employees new employee training will be required. NIB trainers say that it will take anywhere from six to twelve weeks to train an employee on a job. The complexity, prior sewing knowledge, and ability of the individual significantly influence the duration of the training. In order to increase productivity ABVI may need to hire new employees, cross-train current employees, or do a combination of the two in order to meet the new production rates. There are several pros and cons for each of these options, which are listed below.

Risk and Problem Tracking

Functional Demo Materials

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

Plans for next phase

Melissa, Jenn, Ashley, Ryan, Zain


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