P18701: ABVI Sewing Facility Improvement
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Systems Design

Table of Contents

Team Vision for System-Level Design Phase

Summarize:

Functional Decomposition

Functional Decomposition Product Line: Air Force Pants

Functional Decomposition Product Line: Air Force Pants

Benchmarking

Blind Sensitivity Training

To increase understanding the team completed blind sensitivity training on Sept. 28th.

The material shared with the team during training can be viewed here: Sensitivity Training Guide

Rehab Engineers

SEW LEAN still plans to meet with Rehab Engineers at ABVI to learn more about the conversion of jobs from sighted to blind or visually impaired. Tentative plan is to meet the week of October 30th, during the next phase.

Research

The National Institute for the Blind (NIB) operates dozens of sewing facilities, employing thousands of workers across the country.

Using NIB’s resources, extensive research has been conducted as to how to convert a sewing machine so that a blind or visually impaired worker is able to operate it.

Based on this research, anything beyond simple guards on each machine is ineffective due to the various levels of sight and different abilities that are specific to each individual worker.

As we progress through this project, we will try to convert as many machines as possible while leaving ABVI with the ability to easily change the adaptations to suit the needs of future employees.

Machine Conversion

The team is using a live document to compile ideas through the trial and error that is expected with any machine conversion. This document can be viewed here:

Machine Conversion Ideas

Good Practices Observations

There are many observations the team has made while analyzing the current state of good practices currently ABVI.

Concept Development

Fishbone Diagrams

SEW LEAN created fishbone diagrams for each of the four problem focuses to help determine root cause.

Increasing Areas of Continuous Flow in the Air Force Pants Line

Increasing Areas of Continuous Flow in the Air Force Pants Line

Balancing Work and Inventory across the Air Force Pants Line

Balancing Work and Inventory across the Air Force Pants Line

Converting More Jobs to be Accessible for Blind & Visually Impaired Employees

Converting More Jobs to be Accessible for Blind & Visually Impaired Employees

Increasing Floor Communication and Awareness with Visual and Tactile Signals

Increasing Floor Communication and Awareness with Visual and Tactile Signals

Time Studies

The Sew Lean team had the opportunity to perform time studies on the AFP production line. Time studies are helpful when studying the current state and working on improving the balance as well as the flow of the line. Figure (1) below shows the data collection sheet that was created and used to collect data. The times captured include the duration of the overall process at each station as well as the duration the tool was touching the material, which was defined to be the value-added portion of the process.

Figure 1

Figure 1

Figure (2) below shows a snapshot of the sheet containing input time study data. The overall process as well as the “value-added” portion of the process at each station were timed four times, and the averages were taken to find the cycle time of the overall process versus the value-added time per station.

Figure 2

Figure 2

Finally, stations with similar functions were grouped together and their average cycle times and value-added times were added together. This is shown in Figure (3). A bar chart, displayed in Figure (4), was generated to represent the “Average Cycle Time” versus “Duration of Material Under Machine”.

Figure 3

Figure 3

Figure 4

Figure 4

Feasibility

KPIs

During this phase SEW LEAN determined Key Performance Indicators that will be measured to indicate the success of the project. Improvement will indicate project success. In addition, each indicator was tied to a project focus to ensure all focus areas were being monitored and addressed.

Summary of Team KPIs

Summary of Team KPIs

Concept Selection

Present Roles

SEW LEAN determined key areas of importance and focus for project success. The responsibilities were divided among group members to ensure focus throughout the project.

Summary of Team Roles

Systems Architecture

Value Stream Maps

During this phase the team began a current state VSM. The air force pant line being down delayed time studies, and map completion. SEW LEAN plans to complete the VSM in the next phase.
Current State VSM

Current State VSM

Spaghetti Diagram

After creating a current state floor layout SEW LEAN created spaghetti diagrams to understand and visualize all the motion and transportation throughout the AFP process.

AFP Spaghetti Diagram

AFP Spaghetti Diagram

AFP Pockets Spaghetti Diagram

AFP Pockets Spaghetti Diagram

Designs and Flowcharts

Floor Layout

During Phase II SEW LEAN continued to take measurements and update a floor layout of the current state at ABVI.

Current State Floor Layout

Current State Floor Layout

The numbers represent machine locations and correspond to the following Machine List. The orientation of each number represents the direction the operator sits while operating the machine.

Process Flow Charts

To understand the process SEW LEAN finished flow diagrams of the coast guard shorts line during this phase. All diagrams can be viewed here:

Pants Flow Diagram

Coast Guard Shorts Flow Diagram

Oven Mitt Flow Diagram

Risk Assessment

High Priority Risks

High Priority Risks

A live document SEW LEAN is using to plan for and mitigate risks can be found here: Risk Management

Design Review Materials

The SEW LEAN Systems Design Phase Presentation can be found here: Systems Design Presentation

Plans for next phase

Melissa, Jenn, Ashley, Ryan, Zain


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