NEW BALANCE LEAN ASSESSMENT 06/2021

5. Work Cells
SCORING CRITERIA
4 - Level 3 plus positive trend result for LLER%. Implement MTM time study method to build IE data base. All stitching cells follow 1 pair flow.
3 - All work cells (C2B + SF + Offline) follow design principles and use of visual documentation of production boards, Takt time, Line Balance tool, job instructions, standard process flow, water spider
system. IE system is in place and IE data used for target setting (target output vs manpower). Some stitching cells follow 1 pair flow principle

2 - All C2B and some work cells in SF & Offline follow design principles and use of visual documentation of production boards, Takt time, Line Balance tool, job instructions, standard process flow,
water spider system. IE system is in place and IE data used for target setting (target output vs manpower)

1 - There are some work cells follow design principles. Some use of visual documentation of production boards, Takt time, Line Balance tool, job instructions, standard process flow, water spider
system.
0 - There are no work cells to follow design principles. All operations are islands with undefined quantities of inventory between them.
GUIDELINES

+ Minimum Participations:
FTY - LEAN Sr Manger; 2nd Sr management; 3rd Sr management
NB - LEAN; Operation Manager; QA manager
+ Location: Meeting room and Walk through the selected VSM

+ Principles: A work cell should be circular or U-shaped if at all possible, using job combination concept and standing operation (C2B mini cell (EOLR: 45-100 prs/hour, (Stitching : Assembly - 2:1 ratio
as max), SF mini cell, Offline mini cell).
Designed capacity by C2B line with metric PPH/output by hour pairs.

+ Workers should be on the inside of the cell, and parts supplied from the outside of the cell / water spider system (structure standard work documentation)
+ IE capability (Methods-Time Measurement (MTM), time study method) to build IE data base (Satra TimeLine). The cell should be well balanced to Takt time and a line balance chart should be
posted near the line.

+ There should be a dedicated conveyance person that services the cells on a schedule and route (hourly or less), or is called in some automatic way. Finished parts should be picked up from the
cell on a regular interval.
+ Finished parts should be put into the appropriate container for the next process.
+ Progress to the production plan should be posted clearly at the work cell (hourly). Production board preferably with automatic system and plant wide monitor
+ LLER% (Lean Line Efficiency Rate) = IE manpower/Actual manpower
+ Cells should be re-balanced to accommodate changing demand.
Average Rating C2B SF
2.5 N/A N/A
 NEW BALANCE LEAN ASSESSMENT 06/2021
COMMENTS SUGGESTIONS
+ Execute the offline flow cell project (Continuous flow).
+ Painting cell design & painting innovative application.
+ Improve big assembly line (Upper from SA2) - convert the big line to the mini cell design.
+ EOL output tracking by digital system + Reaction example on the low-performance status (base on real-time info in production line).
+ Cell design & IE time application to design the + Classification of the water spider level (payment structure).
cell (man power) + Summary of Improvement projects (eg. water spider) - benefit analysis.
+ Target is variable base on TCT + IE data version comparison (by the way different stages).
+ Create the database (for the standard process as reference).
+ Bryan to check the efficiency and make the comparison by the way 3 types of lines.
+ Standard minute estimation system for whole shoes.
+ Line balancing to remove 1 buffing worker in the loading station.

Last Score Self Score New update

- Painting cell design & painting innovative application.
- Improvement for work cell: convert from target 2000prs to 1500prs; reduce operators arrange sole to
2.5 3 the head Top UV lines.
- Building IE Database System (Sharing docs internal teams).
NEW BALANCE LEAN ASSESSMENT 06/2021

Building IE Database System (Sharing docs internal teams) NEW UPDATES

NEW BALANCE LEAN ASSESSMENT 06/2021

Improvement for work cell NEW UPDATES

Big assembly line: convert from target 2000 to 1500

Factor Unit Before After Difference
2000
Target pair 2000 1500 25%
Standard Worker OP 61 45 26%
Standard Machine MC 38 20 47%
PPH pair/ OP/ hour 4.1 4.2 2%

Compare between taget (2000) and (1500)

PPH Target
4.2 2200

2000
1500
PPH (pair//OP/hour)

1800

Target (Pair)
4.1 1600

1400

1200

4.0 1000
2000 1500
Condition
 NEW BALANCE LEAN ASSESSMENT 06/2021

Improvement for work cell NEW UPDATE

Reduce operators arrange sole to the head Top UV lines
Before After

Compare
 NEW BALANCE LEAN ASSESSMENT 06/2021

Painting cell design & painting innovative application. NEW UPDATE

NEW BALANCE - PROCESS ANALYSIS OF PAINTING
BASE ON THE DRYING TIME IN THE BPFC
WORKING
BRAND PROCESS MODEL PART TARGET TAKT TIME DIRECT OP INDIRECT OP TOTAL OP LBR(%) PPH P.I.C UPDATE DATE
TIME
Thời gian làm Thời gian yêu Tỉ lệ cân bằng Sản lượng/
Nhãn hiệu Công đoạn Mã hàng Chi tiết Mục tiêu CN trực tiếp CN gián tiếp Tổng số CN Pure IE PPH Người lập Ngày cập nhật
việc cầu chuyền người/giờ

Phylon 1152 prs 23.75 sec 12 Op 1 Op 13 Op 93% 12 Prs/Op/Hour 15 Prs/Op/Hour

NEW BALANCE PAINTING MWFCPR V2 28800 sec LEAN-BAO 18/05/2021
520 5.42 Op 0.45

1. Layout
17.5 M

Spray Box
65 x 55
TABLE
100x50

Component TABLE NIR Chamber NIR Chamber

CONVEYOR NIR Chamber TABLE

3 M
120x70
rack 200x60 120x70
120x120 1240x100 cm
250x120 250x120

Spray Box
65 x 55

Microsoft Excel
2. Condition standard Worksheet
Time Cycle Production/
Standard Worker Average Time
Thời gian Time Shift
Establish No. Process Name Chemical
VA NVAN NVA M/C CT
Thời gian Sản Lượng/ Số người tiêu Thời gian
Remark

công đoạn Shift chuẩn trung bình

LOB for STT Tên Công Đoạn Hóa chất (sec/prs) (sec/prs) (sec/prs) (sec/prs) (sec/prs) (prs/shift) (Op/line) (sec/prs) Ghi chú

SET UP STANDARD TIME FOR CHAMBER Microsoft Excel

Worksheet
paint line PART: PHYLON
Arange sole & input
1
Sắp đế và thả hàng đầu chuyền
10 10.0 2,736
2.00 20.00
Cleaning sole by chemical
2
Vệ sinh đế bằng hóa chất
LB-2218TF 30 30.0 912
Attach tape on around sole
3
Dán keo xung quanh đế
95 95.0 288 4.00 23.75
CHAMBER (150X135 cm) Time: 2-2.5min ==> Capacity= 3648-4560 prs/shift
-
Buồng sấy Temperature: 45~50ºC
Spray
4
Xịt sơn
818 45 45.0 608 2.00 22.50
CHAMBER (250x135 cm) Time: 2-2.5min ==> Capacity= 6080-7600 prs/shift
-
Buồng sấy Temperature: 45~50ºC
Remove sticker & Cleaning sole
5
Bóc keo & Vệ sinh đế
42 42.0 651 2.00 21.00
CHAMBER (250x135 cm) Time: 2-2.5min ==> Capacity= 6080-7600 prs/shift
Buồng sấy
-
Temperature: 45~50ºC
Packing
6
Đóng gói
22 22.0 1,244 1.00 22.00
TOTAL 244 0 0 0 244 288 11.00 23.75
 NEW BALANCE LEAN ASSESSMENT 06/2021

Standard work for Water Spider (Cutting, STT, ASS, STF) Q2-2020
B18 반 공정별 물류 프로세스 세부사항
Thông tin chi tiết quy trình vận chuyển hàng từng công đoạn chuyền B18
부서 공정명 담당자 성명 ID 인수자 성명 ID 인계자 성명 ID 이동시간 이동수량
Bộ phận Công đoạn Phụ trách Họ tên - ID Người tiếp nhận Họ tên - ID Người bàn giao Họ tên - ID Thời gian vận chuyển Số lượng vận chuyển

자재담당 물류맨
자재입고 재단 조장 재단 조장 오전 9시, 오후 2시 4시간재고 5,000족
Trần Thị Oanh - 13100109 Thí công phụ trách Nguyễn Thị Thanh Xuân - 13032904 Trần Thị Oanh - 13100109
Nhập nguyên liệu Tổ trưởng cắt Tổ trưởng cắt 9 giờ sáng, 2 giờ chiều Tồn 4 tiếng 5,000đôi
nguyên liệu
설비별 계획서 부착
재단계획서 발부 재단 서무 재단비서 재단 조장 전일오후 3시
Lê Thị Hồng - 17042501 Nguyễn Thị Kim Nhung - 15060807 Trần Thị Oanh - 13100109 Gắn bảng kế hoạch
Giao kế hoạch cắt Quản lý cắt Thư ký cắt Tổ trưởng cắt 3 giờ chiều ngày hôm trước
lên từng máy cắt
출고 담당 물류맨 외주담당 관리자
재단 외주출고 B동 외주가공 세트메칭 관리자 Trần Thị Ngọc Huyền - 1205211 오전 9시, 오후 2시 4시간 재고 5,000족
Nguyễn Bích Phượng - 15120103 Thí công phụ trách xuất Quản lý phụ trách hàng Lê Dũng Sĩ - 06099790
Cắt Hàng đi gia công Quản lý phối hàng gia công nhà B Nguyễn Thị Bé - 99052120 9 giờ sáng, 2 giờ chiều Tồn 4 tiếng 5,000đôi
hàng gia công gia công
자재담당 물류맨
직재단자재입고 재단 조장 Trần Huy Vũ - 10041939 재단 조장 오전 9시, 오후 2시 4시간 재고 5,000족
Trần Thị Oanh - 13100109 Thí công phụ trách Trần Thị Oanh - 13100109
Đầu vào liệu không dán Tổ trưởng cắt Nguyễn Anh Vững - 18051419 Tổ trưởng cắt 9 giờ sáng, 2 giờ chiều Tồn 4 tiếng 5,000đôi
nguyên liệu
재봉준비물 출고
Xuất hàng chuẩn bị cho
재단 조장
Trần Thị Oanh - 13100109
재단 작업자
Công Nhân Cắt
재봉 물류맨
Trần Thị Ngọc Diện - 20021105
2시간 144족 Water Spider information of
Tổ trưởng cắt Công nhân cắt Thí công chuyền may 2 tiếng 144 đôi
STT
STT line

Video standard work for Water

spider showed at shop floor
 NEW BALANCE LEAN ASSESSMENT 06/2021

Standard work for Water Spider – STT A18 (MW880 V11) Q2-2020
 Standardize work for water spider – Receive & delivery procedure for input component in STT line.

The water spider arrange Delivery card Set (1 hours – Hourly water spider will delivery The water spider put
component in rack (1 hour – 72 prs) components to each station components into basket
72prs)

The input components rack The input components rack

(max : 24prs) for each process in STT line
NEW BALANCE LEAN ASSESSMENT 06/2021

Standard work for Water Spider - Benefit Q2-2020

Average BTS: 76%
A18 - 2019 Average Mix: 77 % Downtime Q1 2019
Average Vol: 98 %
120% 95.1% 100.0%
100.0%
86.5%
80% 6,000 73.8% 80.0%
6,185
40% 60.0%
4,000
0% 40.0%
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 2,000
/2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 1,065 720 20.0%
8 8 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 415
/0 /0 3 / 4 / 5 / 6 / 7 / 9 / 1 0 / 1 1 / 1 2 / 3 /0 4 /0 6 /0 7 /0 8 /0 9 /0 0 /0 1 /0 3 /0 4 /0 5 /0 6 /0 7 /0 8 /0 0 /0
30 31 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 - 0.0%
Set balance Changeover Machine Quality issues
breakdown
Line A18 Vol% Line A18 Mix% Line A18 BTS% Downtime Q1
2019

Downtime (min) Accum (%)

Average BTS: 89%
A18 - 2020 Average Mix: 95 %
Average Vol: 98 % Downtime Q3 2020
120%
96.8% 100.0%
80% 8,000 84.7% 100.0%
6,000 67.6% 80.0%
40%
3,750 60.0%
0% 4,000
40.0%
20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
/2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 /2 0 2,000 950 20.0%
9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 675 175
3 / 4 / 7 / 8 / 9 / 1 0 / 1 1 / 1 2 / 4 /0 5 /0 6 /0 7 /0 8 /0 9 /0 1 /0 2 /0 3 /0 4 /0 5 /0 6 /0 8 /0 9 /0 0 /0
1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 - 0.0%
BTS Line A18 Vol% Line A18 Mix% Line A18 BTS%
Downtime (min) Accum (%) Downtime Q3

Benefit of water spider:

2020

Benefit of water spider:

• Ensuring Set Input Rate BTS MIX • Decreasing downtime cause of Set balance –
• Increasing BTS %
13% 18 % 39%
 NEW BALANCE LEAN ASSESSMENT 06/2021

IE capability (MTM, time study method) to build data base. Q2-2020

IE Database Procedure

Time Study Method

NEW BALANCE - PROCESS ANALYSIS OF STOCKFIT
BRAND PROCESS MODEL WORKING TIME PROCESS TARGET TAKT TIME STANDARD TIME DIRECT OP INDIRECT OP TOTAL OP LBR(%) LLER(%) PPH P.I.C UPDATE DATE

Thời gian làm Thời gian tiêu Tỉ lệ cân bằng Tỉ lệ cân bằng Sản lượng/
Nhãn hiệu Công đoạn Mã hàng Công đoạn Mục tiêu Thời gian yêu cầu CN trực tiếp CN gián tiếp Tổng số CN Pure IE PPH Người lập Ngày cập nhật
việc chuẩn chuyền chuyền người/giờ
STF 1st 1900 prs 14.4 sec 5.36 min 24 Op 3 Op 27 Op 93% 93% 10 Prs/Op/Hour 11 Prs/Op/Hour
NEW BALANCE STOCKFIT MW880 V10 28800 sec IE 3/20/2020
STF 2nd 1900 prs 14.4 sec 6.03 min 28 Op 3 Op 31 Op 89% 90% 8 Prs/Op/Hour 10 Prs/Op/Hour

1. Condition standard
Cycle time Man Power Standard Actual Cycle time
Standard Worker Total
Sequent No. PFC Thời gian công đoạn (CT/TT) Machine Thời gian thực tế
Process Name Equipment Remark
Worker Công nhân Số người tiêu Số máy tiêu Thời gian
ACTUAL VA NVAN NVA M/C CT
cần thiết chuẩn chuẩn công đoạn
STT CN #PFC Tên Công Đoạn Loại máy (sec/prs) (Op) (Op) (Mc) (sec/prs) (sec/prs) (sec/prs) (sec/prs) (sec/prs) Ghi chú
PROCESS: STF 1st
Đặt phylon top + bot lên băng tải
1 1
Put phylon top +bot to conveyor
- 13.5 0.9 1.0 - 13.5 - - 13.5
Quét xử lý Shank và đăt lên băng tải
2+3 2
Primer shank and put in conveyor
- 23.0 1.6 2.0 11.5 - - - 11.5
Heating chamber (1'30' ~ 2')
Buồng sấy
-
Quét keo lót Phylon top
3
Primer Phylon top
- 18.0 1.3
4+5
Quét keo lót shank
4
Primer Shank
- 12.5 0.9 4.0 13.6 - - - 13.6
Quét keo lót phylon bottom
6+7 5
Primer phylon bottom
- 24.0 1.7
Heating chamber (1'30' ~ 2')
Buồng sấy
-
Quét keo Phylon top
8+9 6
Cement Phylon top
- 27.0 1.9 2.0 13.5 - - - 13.5
Quét keo shank
7
Cement Shank
- 17.5 1.2
10+11+12+13 4.0 14.4 - - - 14.4
Quét keo phylon bottom
8
Cement phylon bottom
- 40.0 2.8
Heating chamber (1'30' ~ 2')
Buồng sấy
-
Dán shank với phylon bottom
9
Attach Shank vs phylon bottom
- 41.0 2.9
14+15+16+1
7+18+19
6.0 13.7 - - - 13.7
Dán Phylon top vs phylon bottom
10
Attach Phylon top + phylon bottom
- 41.0 2.9
Ép tổng lực
20+21 11
Deep well pressing
DWP 25.0 1.7 2.0 2 12.5 - - - 12.5
Cooling (1'30")
Bồn lạnh
-
Ckecking by jig
22 12
Kiểm đế bằng rập
- 13.0 0.9 1.0 - 13.0 - - 13.0
Vệ sinh
23 13
Cleaning
- 14.0 1.0 1.0 - 14.0 - - 14.0
QC
Kiểm hàng
-
Đóng gói
24 14
Packing
TB100x50 12.0 0.8 1.0 - 12.0 - - 12.0
TOTAL 321.5 22.4 24.0 2 79.2 52.5 - - 14.4

2. Other Worker
2.1. Support Worker
No. Process Process Name Worker Remark
1
2
3
Total 0

2.2. Indirect
No. Process Process Name Worker Remark
1
2 STF 1st Water spider 2
3 STF 1st Team leader 1
4
5 STF 2nd Water spider 2
6 STF 2nd Team leader 1
Total 6

Target: 1900 prs Takt time: 14.4 sec

Time (sec)
20 Yamazumi Chart
15
- - - -
14
- - - - - - - - - - - - -
-
10 - -

14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14
12 12 13
5

0 -
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Operator

Checking Cycle time Analysis Process Analysis (PA) PA Template Confirm with T/L & G/L
 NEW BALANCE LEAN ASSESSMENT 06/2021

Tracking history all new model by each stage Q2-2020

• Set up the IE Standard database to comparison between each stage (EXT, FSR, SS, Production…)
• Monitoring improvement from each stage about Total Cycle time, Manpower, Capacity, PPH…
 NEW BALANCE LEAN ASSESSMENT 06/2021

IE Database – All model tracking at mass production Q2-2020

• All model at mass production will follow in Database about Target, Direct, Indirect Op
• This data will use to monthly Capacity analysis.
 NEW BALANCE LEAN ASSESSMENT 06/2021

Establish Standard Cycle time Database for Cutting, STT & ASS Q2-2020

• Set up the IE Standard time for Cutting process ( Manual, Atom, Semi,…)
• Base on the PFC (size, layer, material, cutting perimeter, kind of M/c…) to set up the IE standard time
 NEW BALANCE LEAN ASSESSMENT 06/2021

Establish Standard Cycle time Database for Cutting, STT & ASS Q2-2020

• Set standard time for each process which have same common process
• Base on the gender size to set up standard time ( MW, TD Kid, PS Kid, GS Kid)
 NEW BALANCE LEAN ASSESSMENT 06/2021

Offline Cell Layout Q2-2020

SUMMARY
Model MWSOLV V3
Target/day 1000 prs (2 line)
Working time 7.5 h
Takt time 53.44 s
Direct Op 28 Op (2 line)
 NEW BALANCE LEAN ASSESSMENT 06/2021

Traditional Production and Offline Cell Comparison Q2-2020

TRADITIONAL PRODUCTION MATERIAL FLOW OFFLINE-CELL MATERIAL FLOW

VS.

• Lots of inventory between stages • Setup WIP standard ( Max: 12 prs)

• Difficult to control line balancing • Rate of line balancing is high (90%)
• MLT: Min 2 days • MLT: Max 2 days
• Work with multi-models & single process. • Work with Top models ( high order quantity &
multi processes)
• Quality control at each stages. • Quality control at the end of the line