Stage 1 - Design• Create Product Concept
● Baby product ● Preemie and Newborn ● Incorporate Cal Poly 75th Anniversary
• Kimono Baby Booties • Draw Sketch • Make Patterns • Sew Samples • Select Fabric • Challenges
• Construction • Fabric Selection • Bulky Seams
Stage 2 – Tech Pack• Finalize Pattern • Grade Pattern • Sew two samples ▫ Final Fabric ▫ 75th Logo
• Tech Pack ▫ Summary ▫ BOM ▫ Fit Spec ▫ Ops Breakdown Summary
Stage 3 – Marker Making• Cutting Room Constraints • Cut Order Plan ▫ 2 Pattern Sets, 6 Plys
• Layout Fabric • Measure Fabric Width • Decide on Layout • Marker Making
• Edge Allowances ▫ Block cutting
• Marker Efficiency - 65%
Stage 4 – Cutting
• Spreading • Cutting ▫ Circular Knife
• Preparation for Sewing ▫ Progressive Bundle System ▫ 12 Bundles, 6 Pieces ▫ Modular Production System ▫ 12 Bundles, 12 Pieces
• Challenges ▫ Pitch - deep Notches ▫ All left sides, no right sides
Stage 5 – Production• Overview
• Complex construction and small team size • No Line Supervisor • All team members were sewing operators and checked for quality
• Progressive Bundle System ▫ Multiple operators, Single Operations ▫ Bottlenecks ▫ 6 hours to complete ▫ Fusing should have occurred in preparation for sewing
• Modular Production System ▫ Multiple operators, Multiple functions ▫ Shared sewing operations when bottlenecks occurred ▫ 2 hours to complete
Stage 6 - Quality Control• Evaluated 5 baby shoes
• 2 preemie • 3 newborn
• Quality Measured • Standards in Tech Pak • 5 POM
• All within tolerance except 2 shoes • Preemie • Across Top of Toes
• Too Small (2 1/2” +/- 1/2”) • 1 3/4”, 1 7/8”
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