Scribd Logo
Upload

Welcome to Scribd!

  • 8 views

    Lean at Harvest Updated 1 (20140425)

    Uploaded by

    sheplu

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Lean at Harvest Updated 1 (20140425)

    Uploaded by

    sheplu
    8 views12 pages

    Original Title

    Lean at Harvest updated 1(20140425)

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    8 views12 pages

    Lean at Harvest Updated 1 (20140425)

    Uploaded by

    sheplu

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    You are on page 1of 12

    Lean at Harvest Updated

    1
    Apr 2014

    Prepared by: Hong Pan

    1
    Review Half Year Lean Progress At Harvest

    FOB and Lead


    Time

    1. Overview of 6 projects for Lean implementation


    2. Future Lean activities
    3. Benefit proposed by Harvest
    4. Next steps

    2
    Overview 6 Projects For Lean
    Implementation

    Implement 6 Projects Result and Benefit

    1. Increase efficiency
    • Cost saving
    • Lead time reduction
    1. One piece flow
    2. Increase 1st pass rate
    2. Standardized work • Improve quality
    3. Improve cash flow
    3. Material Inventory reduction
    • Lead time reduction
    • Cost saving
    4. 5S
    4. Reduce RM wastage
    5. VMB • Cost saving
    5. Information flow between Depts.
    6. Problem solving • Lead time reduction
    6. Continuous improvement mindset

    3
    Current Production Process VS Model Line

    Current Process

    Unfold Unfold Unfold Unfold


    sucking ironing inspecti fold
    fold fold on fold packing

    Line balance is bad WIP in sewing line WIP Waiting for ironing WIP Waiting for packing

    Key issues
    1. Too many machinists very difficult to have good line balance
    2. In hanger system machinists can’t see each other so no team work
    3. Piece rate creates quality issue
    4. Sewing line too long creates unnecessary WIP
    5. Too many hand off allows for more indirect labour
    6. Lead time too long between sewing and packing

    4
    Current Production Process VS Model Line

    Model Line

    Ironing, inspection, packing

    U Shape Standardized VMB 3 in 1


    work

    Changes made Benefits for Model line


    1. Team Bonus policy, creates Team work 1. Efficiency improved from 30% to 70%
    2. Line balance-Better operator utilisation in 1wk
    3. Standardized work- High quality pass 2. No WIP in waiting for ironing and
    rate packing
    4. Pull system - one hour WIP 3. High morale
    5. 3 in 1- Reduced WIP 4. Limited defect
    6. VMB – make problems transparent
    7. U Shape-creates team work Benefits for all factory
    8. No hanger system: Reduce wasted 5. Reduce 15 indirect labours(11 end line
    movement inspectors, 4 cutting piece inspectors

    5
    Material Inventory Reduction By Using
    Supermarket System

    Finished Fabric Storage Yarn Storage

    Inventory Inventory
    Before Now Target Before Now Target

    26d 15d 7d 7d 3d 1d

    6
    Harvest Is Tracking Daily 5S Results

    FG Warehouse 5S VMB Model Line

    Yarn Warehouse

    7
    VMB Is Allowing Information To Flow Between
    Departments
    Sample room Kanban Planning Kanban

    Merchandising Kanban RM warehouse Kanban

    FG Kanban Production floor Kanban

    Sewing line Kanban Mechanic Kanban

    8
    Sewing Line Is Problem Solving When
    Problem Appears

    Model Line VMB Mechanic VMB

    Problem Solving Meeting At Model Line

    9
    Future Lean Activities Will Provide PB
    Continuous

    Item Activities

    Convert rest of sewing lines to 3 in 1


    Production floor
    by July 2014

    WIP store No WIP store start from August 2014

    Finished fabric & Yarn warehouse Reduce inventory to 7d and 1d

    Management training Visit PBI in 2014

    Lead time reduction From 70 days to 63 days in 2014

    10
    Immediate Benefit Proposed By Harvest

    Leadtime
    FOB Savings
    Reduction
    Item One year Previously
    (USD$) PO Type Current L/T
    L/T
    CY2013 Total
    $16M Long LT fabric
    Turnover
    (YD, Yardage, 105d 91d
    1. Efficiency improve Marle)
    + $600K
    15%
    2. Reduce 11 QC + $66K Normal LT
    84d 70d
    fabric
    3. Reduce 4 cut pc. ins. + $24K
    4. Inventory reduce
    + $30K
    15d
    Leadtime has already been changed to the
    Sub total $720K above
    5. Labour wage
    - $320K
    increase (8%)
    Total Estimated
    = $400K
    Savings
    Est. $12M USD in repeat style, equates to
    6. PB
    2% FOBshare of saving
    reduction on all repeat styles
    $240K
    60%
    Based on current benefits, we should change the traffic
    light to GREEN

    11
    Next steps

    • Change repeat styles FOB 2% start from May 1

    2014
    • Continuously support and monitor Lean at
    Harvest, and update result every 3 months

    12

    You might also like