Subsystem Build & Test
Table of Contents
Team Vision for Subsystem Level Build & Test PhaseSummarize:
- During the Subsystem Level Build & Test Phase, SEW LEAN team planned to focus on implementing the floor layout redesign, studying bottleneck stations to identify non-value added tasks and present waste-reduction recommendations, coming up with a plan to help with the production ramp up, and brainstorm ideas for tabletop simulations.
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.
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.
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
- 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 II Presentation can be found here: Phase II Presentation
Plans for next phase
- SEW LEAN team plans to help with the production ramp up by making informative decisions using data collected. The team will continue to observe bottleneck stations to identify non-value added tasks in efforts to reduce waste. Also, the team plans to meet with the sewing experts and implement visual/tactile management to aid in improving communication on the floor.
- Individual team member 3-week plans can be found here: