Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 89 views

    Flexible Cell: The Future of Manufacturing Is Here TODAY

    Uploaded by

    rakibul sagor
    The document discusses the future of flexible cell manufacturing for small batch customized orders. [1] It introduces flexible cell working which allows for smaller order quantities to be produced more efficiently through specialized product family lines and cells within lines. [2] Each cell is dedicated to a specific process like front, back, or sleeve production and workers are cross-trained across cells. [3] Real-time data capture allows for maximizing output and minimizing defects. With this approach, the company was able to increase efficiency from 18% to over 50% while increasing capacity over time.

    Copyright:

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

    Flexible Cell: The Future of Manufacturing Is Here TODAY

    Uploaded by

    rakibul sagor
    89 views20 pages
    The document discusses the future of flexible cell manufacturing for small batch customized orders. [1] It introduces flexible cell working which allows for smaller order quantities to be produced more efficiently through specialized product family lines and cells within lines. [2] Each cell is dedicated to a specific process like front, back, or sleeve production and workers are cross-trained across cells. [3] Real-time data capture allows for maximizing output and minimizing defects. With this approach, the company was able to increase efficiency from 18% to over 50% while increasing capacity over time.

    Original Title

    Adidas+ +Flexible+Cell+Apparel

    Copyright

    © © All Rights Reserved

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses the future of flexible cell manufacturing for small batch customized orders. [1] It introduces flexible cell working which allows for smaller order quantities to be produced more efficiently through specialized product family lines and cells within lines. [2] Each cell is dedicated to a specific process like front, back, or sleeve production and workers are cross-trained across cells. [3] Real-time data capture allows for maximizing output and minimizing defects. With this approach, the company was able to increase efficiency from 18% to over 50% while increasing capacity over time.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    89 views20 pages

    Flexible Cell: The Future of Manufacturing Is Here TODAY

    Uploaded by

    rakibul sagor
    The document discusses the future of flexible cell manufacturing for small batch customized orders. [1] It introduces flexible cell working which allows for smaller order quantities to be produced more efficiently through specialized product family lines and cells within lines. [2] Each cell is dedicated to a specific process like front, back, or sleeve production and workers are cross-trained across cells. [3] Real-time data capture allows for maximizing output and minimizing defects. With this approach, the company was able to increase efficiency from 18% to over 50% while increasing capacity over time.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 20

    FLEXIBLE CELL

    The Future of Manufacturing is here TODAY


    24/07/2012
    FLEXIBLE
    CELL WORKING – NICE APPAREL

    NICE APPAREL IN PARTNERSHIP WITH M.E.


    24/07/2012
    1. Suppliers and Customization
    2. Introduction to Flex Cell

    AGENDA 3. Flex Cell set up and Strategy


    4. The Journey
    5. Capacity and Growth…
    1. Suppliers & Customisation
    Characteristics of order
    1. Small Lot Size
    2. High Complexity
    3. Short Lead Time
    4. mi adidas order frequency (Daily)
    5. High discrepancy between planned and actual order quantities
    ALL of the above are reasons for Varieties of C/O and Efficiency loss

    Need Flexibility
    Customisation
    FCW Order is aQty
    Unique Business Unit, in terms Order Quantity and Manufacturing Technique
    Analysis

    FCW Order Qty Analysis

    Based on PO’s Order Quantity Lot sizes 36.45%


    is averaging just 10 pieces per PO
    While the full range of Orders is averaging just
    42 pieces per PO.

    Normal Manufacturing processes could not


    perform Efficiently using normal Manufacturing
    techniques and needed a different concept
    …………
    THAT CONCEPT IS !
    2. Introduction to Flexcell
    Smaller Order Quantities can be made in a more Efficient
    Manner.
    Lines are set up with less , more multi skilled Operators,
    who work on specific product groups and styles at all times.
    Lines are split into “Cells” that produce specific parts of
    the Product.
    Operator skills are designed around the Cell they are
    assigned too , and movement is minimal within the cell only.
    All Machines needed to produce any of the specified styles to the
    relevant line are already set up and in place , thus the minimal
    C/O time.
    All BU’s can be made in the Flex Cell Method, offering the
    Supplier and Customer 100% Flexibility within the Product
    Group range
    Continuity of style and working within the Cell set up gives higher
    Efficiency and higher RFT.
    FCW Room - Opening Ceremony 18th July, 2012
    Flexcell Working Room
    3. FCW Strategy

    Product Family Grouping


    Specific Cell Design
    Multi-Skill Workers
    Real Time Information System to:
    • Maximum Output
    • Minimum Defect
    Zero Changeover
    Product Family Grouping

    100% Fabric
    80% Machine
    Product Family Line Criteria:
    80% Feature
    +10% SMV

    Criteria: 100% Fabric


    80% Machine
    80% Feature
    +10% SMV
    FCW Factory Layout
    - With Product Types Grouped to Specific Lines & Areas
    Cell Design

    Cell 1 Front
    Cell 2 Back
    Cell 3 Collar
    Cell 4 Sleeve
    Cell 5 Assembly
    Multi Skilling of Workers
    Operator Skill Matrix

    Skill
    Training

    4. Availabilities at station
    Real Time Data Capture System

    (1). Hardware

    Efficiency & D/T Tackle QC : Defect Data Pack : Production Output Sup. visor : Production data
    Template By : Touch screen By : Scan Barcode By : LCD Monitor

    (2).Software
    Daily plan

    Production
    Planning
    Program NGIS Data Defect Data Packing All Status
    Zero Changeover Time

    Style : MTS10BBW311

    Style : MTF10BBM311
    4. The Journey
    Av Eff 18% mi adidas
    Cell Design ( non C/O ) FCW ( Flexible Cell working )
    mi adidas Complete non C/O for
    Standing Modular Aug’11-Feb’12 Customize order
    Sep’08-July’11 Jun’12-Present

    2008-2012

    Cell Design - mi adidas

    Regular Line- NBA

    May’10-Feb’12 Feb’12-May’12 Av Eff 45%


    NBA Consolidate mi adidas &
    Regular Line NBA in one room
    5. Capacity & Potential

    Month Sewer Wkh Minute EFF SMV Target Avg.min Pcs. offer

    August 2011 300 8.5 633,420 18% (actual) 26 24,362


    August 2012 300 8.5 1,583,550 45% (actual) 26 60,000
    December 2012 300 8.5 1,829,880 52% 26 70,380
    March 2013 300 8.5 1,900,260 54% 26 73,086
    June 2013 300 8.5 1,970,640 56% 26 75,793
    THANK YOU!

    adidas Apparel, Manufacturing Excellence

    You might also like