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