110615 pyi - work out -dfp-report 080211
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This document summarizes a Kaizen workshop held by Team 3 to improve the Workout Plus shoe. The team identified ways to simplify the shoe design including standardizing eyelets, changing quarter logos to printing, and matching lining colors. Their proposals are estimated to save 4 manufacturing positions, reduce cutting dies and tools, lower overhead costs, and decrease assembly time by 22 seconds per pair. The next steps are to trial samples, make costing proposals, and implement changes in production if approved.
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110615 pyi - work out -dfp-report 080211
- 1. TEAM 3 DFM/ DFP Kaizen Workshop SS12 Product name: WORKOUT PLUS Team Members: UJANG Y M.Taufik Lili Saptaji Suherlan Yusuf Dwi Silvi Rani F Start: June 16th 2011 Update :August 1st 2011
- 2. Contents Project Overview Team Charter Lean Tools (Fishbone Diagram) RACI Gantt Chart Activities Progress Activities Pictures Best Practice Current Result Next Steps
- 3. Project overview Project name : DFM/ DFP Kaizen Workshop SS12 Model : Workout Plus Baseline Total part : 39 parts Upper : 37 parts Bottom : 2 parts Total CT : Cutting : 503.9 Assembly : 648.6 Stitching : 1410.3 Stockfitting and UV : 233.0 Direct manpower :120 (target 111 pairs/ hour) Target : Reduce Complexity of Parts, Material and process
- 4. Project overview Shoe Picture Bottom Picture Style name: WORK OUT PLUS M'S Color: WHITE/BLUE SRF: 29-111101A Factory: PYI Gender: MS First Mount Production: SS'!2 FE Product Leader: MAPLE USA Representative: BERES FORD JESSICA PGSC# : 2-J84948 Last# : RBK-943L Size Run: 6.5-15
- 5. Project Overview Style PQ Chart Product Plan 06/15/2011
- 6. Team Charter - Approve program - Provide resources - Assure commitment from the teams - Provide updates to business P. Owner Program Sponsor KS Shih Jeftha W Project Manager Ujang Y Project Core Member - M.Taufik -Silvi - Lili saptaji -Dwi - Suherlan -Rani F - Yusuf - Program responsible - Lead Kaizen events - Share lessons learn & current best practice - Review & set measurable - Visit PYI regularly - Provide Monthly update to PS - Facilitate and consult kaizen teams (Daily) - Support and follow up on Kaizen events & monitor measurable - Visit shop floor 1 X week - Provide 2X month updates to Project Manager Facilitator Agustiono Tugeno
- 7. CEDAC CEDAC (Fishbone) Critical Problem 1. Too many different color for one material 2. Complexity of part in upper shoes 3. Too many supplier 4. Process Complexity 5. Waste process for small part
- 8. Idea to simplified 1. Change nylon eyelet to common eyelet 2. Change treatment of Quarter logo with another technique (emboss) and joining quarter overlay and quarter 3. Match color between sock liner, tongue lining and collar lining 4. Provide mold for bottom part to reduce stitching process 5. Remove decoration stitching 6. Reduce punching process in tounge 1 2 3 4 5 6 7
- 9. RACI Chart
- 10. Gantt Chart Gant Chart Workout plus
- 11. Activities Progress Propose : Presentation of waste identified Attendance : Team 3 Location : Training room Date/Time : June 14th , 2011 Description : Explain Cause and Effect of waste according 8 waste principles in daily job Propose : Brainstorming Session Attendance : Team 3 Location : Training room Date/Time : June 15th , 2011 Description : Brainstorming idea to improve the current design
- 12. Activities Progress Propose : Presentation to PYI senior managers Attendance : Team 3 Location : Training room Date/Time : June 15th , 2011 Description : Explain Cause and Effect idea implementation Propose : Project review meeting with Mark Ma Attendance : Team 3 Location : Meeting Room 1st floor Date/Time : June 24h , 2011 Description : Review Project and Brainstorming season 2
- 13. After Match color between element -Change nylon eyelet to common eyelet -Change treatment for quarter logo with printing technique Before Quarter Lateral Tongue Lining Collar Lining Sockliner EliminateQuarter backer Activities Progress (Best Practice)
- 14. Before After Eliminate join stitching between bottom and upper, provide mold for treatment change Activities Progress (Best Practice) Bottom Part Before After Eliminate Decoration Stitching Decoration Stitching Before After Eliminate Pounching Pounching
- 15. 1. Change nylon eyelet with common eyelet (we suggest blue or white color) - reduce number of supplier (nylon eyelet),which means save money + $1.380/kg - reduce Stitching process, Thread, Cutting dies and 1 MP - share material between another style Activities Progress (Best Practice) Process Machine CT Ideal Man Remark Stitching Joining for Nylon Eyelet Stitching M/C 06 0,3 Eliminate Process Cutting Hole for nylon Eyelet One part of Cutting Dies 12 0,5 Replace by Eyelet Attaching
- 16. 2. Change treatment of Quarter logo with another technique (emboss ) -reduce number of supplier (Quarter logo),which is saving money for material needed Activities Progress (Best Practice)
- 17. 3. Match color between tongue lining, collar lining and sockliner - reduce materials color needs - reduce delivery/shipping cost - save confirmation and lab test time - save place to store material Activities Progress (Best Practice)
- 18. 4. Provide mold for bottom part to reduce stitching join process - more simplified - may reduce the total rejects of products - efficiency in thread,needle -reducing one process in C2B (Total TT and CT reduce) Activities Progress (Best Practice)
- 19. 5. Remove decoration stitching - Reduce one process - Reduce one tools needed - efficiency in thread,needle Activities Progress (Best Practice)
- 20. 5. Remove punching Process in Tongue section - Reduce one process - Reduce one tools needed - efficiency in thread,needle Activities Progress (Best Practice)
- 21. Best Practice Statement Reduce Complexity of Part ,Material and Process: a. Manpower saving: idea#1 : -1 person by stitching process of joining nylon eyelet idea#2 : -1 person by stitching process of joining quarter logo idea#3 : 0 Idea#4 : 1 person by stitching process of joining bottom and upper part idea#5 : 1 person by decoration stitching idea#6 : 0 Calculation : Total Manpower Saving : 4 MP Labor cost 1 operator/month =100USD 100USD x 4 = 400 USD/month = 2000 USD/SS Total CT and TT Reduce = joining nylon eyelet = 30/Pair joining quarter logo = 04/Pair joining bottom and upper part = 15/Pair joining quarter backer and lateral = 08/Pair b. Overhead: idea#1 : 0 idea#2 : reduce one number of supplier idea#3 : reduce shipping cost, streamline the material needs, idea#4 : total TT and CT reduce in C2B idea#5 : material saving for quarter backer minor reduce : reduce stitching machine maintenance, electricity, save place to storage, save lab test and confirmation time may reduce total number of defect Calculation Not Included (On Going Phase) c. Machine and tools reduce : idea #1 : little cutting dies for nylon eyelet hole = idea#2 : Cutting dies for make a hole in quarter logo section idea#3 : 0 idea#4 : 0 idea#5 : eliminate one tool and process reduce minor reduce : needle and stitching machine efficiency electricity, save place to storage, save lab test and confirmation time may reduce total number of defect efficiency of cutting dies using Cutting Dies = 17.64 USD x 2 Cutting dies = 35.28 USD Tool for Decoration Stitching Process = 9.2 USD Approx for minor reducement = 28 USD Total CT reduce = 22/Pair
- 22. Next Step (refer to Gantt Chart) Calculation Data Trial On Sample Room Make A Proposal Propose To Costing Dept Propose To Customer Implement On Production
- 23. Group Picture
Editor's Notes
- #6: This potential saving will be achieve at the condition as above, manpower reduction 136 and B-grade at assembling line down to be 5%