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 16 th 2011 Update :August 1 st 2011
Jun 24, 2015
TEAM 3DFM/ DFP Kaizen Workshop – SS12Product name: WORKOUT PLUS
Team Members:
UJANG Y M.Taufik Lili Saptaji Suherlan Yusuf Dwi Silvi Rani F
Start: June 16th 2011Update :August 1st 2011
Contents
Project Overview Team Charter Lean Tools (Fishbone Diagram) RACI Gantt Chart Activities Progress
Activities Pictures Best Practice Current Result
Next Steps
Project overview
Project name : DFM/ DFP Kaizen Workshop – SS12
Model : Workout PlusBaseline Total part : 39 parts
Upper : 37 partsBottom : 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
Project overview
Shoe Picture
Bottom Picture
Style name: WORK OUT PLUS M'SColor: WHITE/BLUESRF: 29-111101AFactory: PYIGender: M”SFirst Mount Production: SS'!2FE Product Leader: MAPLEUSA Representative: BERES FORD JESSICAPGSC# : 2-J84948Last# : RBK-943LSize Run: 6.5-15
Project Overview
Style
PQ Chart Product Plan
06/15/2011
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
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
Idea to simplified1. Change nylon eyelet to common eyelet2. Change treatment of Quarter logo with another technique (emboss) and joining quarter overlay
and quarter3. Match color between sock liner, tongue lining and collar lining4. Provide mold for bottom part to reduce stitching process\5. Remove decoration stitching6. Reduce punching process in tounge
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RACI Chart
Gantt Chart
Gant Chart Workout plus
Activities Progress
Propose : Presentation of waste identifiedAttendance : Team 3Location : Training room Date/Time : June 14th , 2011Description : Explain Cause and Effect of waste according 8 waste principles in daily job
Propose : Brainstorming SessionAttendance : Team 3Location : Training room Date/Time : June 15th , 2011Description : Brainstorming idea to improve the current design
Activities Progress
Propose : Presentation to PYI senior managersAttendance : Team 3Location : Training room Date/Time : June 15th , 2011Description : Explain Cause and Effect idea implementation
Propose : Project review meeting with Mark MaAttendance : Team 3Location : Meeting Room 1st floorDate/Time : June 24h , 2011Description : Review Project and Brainstorming season 2
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
Eliminate Quarter backer
Activities Progress (Best Practice)
Before After
Eliminate join stitching between bottom and upper, provide mold for treatment change
Activities Progress (Best Practice)
Bottom Part
Before After
Eliminate Decoration StitchingDecoration Stitching
Before After
Eliminate PounchingPounching
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
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)
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)
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)
5. Remove decoration stitching
- Reduce one process- Reduce one tools needed- efficiency in thread,needle
Activities Progress (Best Practice)
5. Remove punching Process in Tongue section
- Reduce one process- Reduce one tools needed- efficiency in thread,needle
Activities Progress (Best Practice)
Best Practice Statement Reduce Complexity of Part ,Material and Process:a. Manpower saving:
idea#1 : -1 person by stitching process of joining nylon eyeletidea#2 : -1 person by stitching process of joining quarter logo idea#3 : 0Idea#4 : 1 person by stitching process of joining bottom and upper partidea#5 : 1 person by decoration stitchingidea#6 : 0
Calculation : Total Manpower Saving : 4 MPLabor 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 : 0idea#2 : reduce one number of supplieridea#3 : reduce shipping cost, streamline the material needs,idea#4 : total TT and CT reduce in C2Bidea#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 sectionidea#3 : 0idea#4 : 0idea#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 USDTool for Decoration Stitching Process = 9.2 USDApprox for minor reducement = 28 USD
Total CT reduce = 22”/Pair
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
Group Picture