Lean implementation Project

Folding department - arc

Project tEAM
Project Sponsors: Mian Atiq Mian Nadeem Team Leader: Ishtiaq (Folding) Consultant: Qadeer Bhatti

Team Members: Saleem (PPC) Khalil (Logistics) Imran (Quality) Razwan (IT) Afzal (Electrical) Usman (HR) Asad (Lab) Shahab (Mech)

Objectives
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Segregation of Products according to acceptable quality. On the spot defect removal. Accurately measurement and recording of products. Packing to customers required parameters piece length, packaging material etc. Accurately Marking and numbering. Convenient and safe storage, access and movement of goods. Accurate, efficient and safe loading for dispatching of goods. Preparation, issuance and controlling products for rework. To facilitate internal and external quality audit. Selection of efficient and effective men, materials, machines, and methods. Maintenance of machines and facilities for overall effectiveness. Efficient and safe Packaging material receiving, storage and issuance. To create a safer, more productive and organized workplace.

Training 5S & other Lean Tools

Training Folding staff

tpm training for all sections

Kaizen newspaper
Kaizen Newspaper
Project: ________Folding____________
Complete Under process Did Not Work Not Started

No Action Required
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Color Coding Trollies Estimated Time for Reprocess Customer Complaint relevant to Folding of one year. Safety Guard installation on Folding Machine Last Six month data of all happened accident in folding Six month data of all work orders relevant to Electrical Six month data of all work orders relevant to Mechanical To install Andon Board on all machines To install signaling system for Quality Section. To fix the loading trollies problem To standardized weight for Trollies To convert hard copies data in to soft copies. Work Flow Diagram of Folding Folding Machines Layout

Person Responsible
Shahab Saleem Ishtiaq Shahab Usman Afzal Shahab Afzal Ishtiaq Shahab Ishtiaq+Usman Rizwan Ishtiaq Ishtiaq

Status

Due Date
31/10/2012 31/10/2012 04/10/2012 03/11/2012 13/10/2012 03/10/2012 13/10/2012 10/11/2012 10/11/2012

Comments

31/10/2012 10 trolleys are complete 17/10/2012 31/10/2012 02/10/2012 02/10/2012

Current State VSM of Folding Department

Finishing Dept (Supplier)

PPC/Marketing

Customer (Export/Commercial)

Folding Manager

Receiving

Inspection

Folding

Segregation

Rolling

Packing

QC

Dispatch

I
12762

I
24295

I
0

I
4000

I
4000

I
6199

I
724084

VA

4h, 45m

10 m

1h, 50m

15 m

30 m

20 m

NVA

1h, 55m

15 m

8d

Improvement Opportunity

Objectives 1. Segregation of Products according to acceptable quality. 2. On the spot defect removal.

Segregation of products
Added two extra inspection tables. Took color blindness test of 81 people from printing, Finishing, Lab, Design Studio, Quality and Folding to check the checkers/operators ability to distinguish between different colors. 10 people out of 81 failed the color blindness test. Took 4 point system test for quality inspection of all the checkers and operators from grey to Folding. Delivered 4 point system training to all the operators and the checkers to fill their skill gap.

On the spot Defects removal

Reprocessing is a slow process. Reprocessing table has been moved to Finishing area. On the spot defects removal process has become faster and more efficient as Finishing manager can directly supervise the process. It has also helped to release more space for Folding.

Objective: 3. Accurately measurement and recording of products.

Accurately measurement
Counter meters are now being calibrated one a month. Wheels made of Tufnol material will be used instead of plastic which are long lasting. Work is being carried out to upgrade the counting meters using electric proximity sensor with mechanical fitting.

Accurate measurements
A program is in place to regularly calibrate the weighing scales. Due to unbalanced movement of weighing scales from one place to another, scale load cell stop working properly and the scale gets out of calibration. A new dollie with locked wheels has been developed in house. Scale movement with dollie will eliminate the problem of malfunction and also save one person during scale movement.

Accurate measurements
Before

After

Unbalanced movement can damage scale's load cell.

Objectives: 4. Packing to customers required parameters piece length, packaging material etc. 5. Accurately Marking and numbering.

Packing to Customer Requirements Online system

Currently there is no online information available regarding daily machine wise and shift wise production details. Online system provides these information along with eliminates any manual entry errors. It eliminates extra work with manual processing The system will be linked with barcode scanner in future.

Objectives: 6. Convenient and safe storage, access and movement of goods. 7. Accurate, efficient and safe loading for dispatching of goods.

Safe Storage of goods

Storage areas for commercial party, Export, ARC and B grade have been designated. It has been decided that all the finished fabrics will be placed on wooden pallets. The height of each pile of fabric rolls MUST not exceed 6 feet for safety.

Safe Storage of goods

Before After

Wooden Pallets for safe storage

Safe Storage of goods

Before After

Palette height should not more than 6 feet

6 Feet

Safe Movement of goods

All the Folding trolleys have been repaired for easy and safe movement of goods. All the Folding trolleys have been standardized i.e. there is a maximum loading capacity of 1500 kg for each trolley. Two people can easily move a 1500 kg trolley. Complete specifications of a mobile scissor lift were developed and a quote from local manufacturer was obtained.

Safe Movement of goods

Current Proposed

Objective: 8. Preparation, issuance and controlling products for rework.

Rework Time frame

A time frame has been agreed between Folding and Finishing as well as bleaching department for all kinds of rework completion. All the rework will be completed within 24 hours. The rework request time is mentioned on the PO by the issuing party.

Objective 9: To facilitate internal and external quality audit.

Audit Facilitation
A comprehensive checklist has been developed. There are 41 questions in the checklist. The checklist contains all the knowledge areas e.g. social policy, quality policy, health and safety policy and other benefits provided to the employees. Checklist is currently under final review by the management and will be operational once approved.

Objectives: 10. Selection of efficient and effective men, materials, machines, and methods. 11. Maintenance of machines and facilities for overall effectiveness.

Effective Methods
Before After

Effective Methods
Before After

Effective Methods
Before After

effective methods Illuminance Values

Default Value = 1075 LUX
Sr#
1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26

Machine Name Left

Rolling#1 Rolling#2 Rolling#3 Rolling#4 Rolling#5 Inspection#1 Inspection#2 Inspection#3 Inspection#4 Inspection#5 Folding Table#1 Folding Table#2 Cheking Table Folding Machine#1 Folding Machine#2 Folding Machine#3 Soaper Machine Drying Machine#1 Stanter#1 Stanter#2 Stanter#3 Rotary Curing Calender#1 Calender#2 314/1075 850/1080 880/1100 1000/1050 740/1080 710/1080 700/1140 440/1010 460/1030 550/1010 325/1070 330/1070 375/1050 460/1080 340/1080 360/1050 420/910 210/820 330/900 340/1030 210/1040 420/680 240/570 420/830 560/1010

Centre
270/950 800/1090 820/1040 950/1020 780/1070 760/1095 740/1120 470/990 450/1050 450/1040 350/1050 320/1090 400/1010 350/1070 320/1070 300/1020 530/900 200/710 400/1020 280/920 250/1070 510/780 300/530 460/790 610/1100

Right
Before/ After
318/1040 880/1080 780/1090 1160/1070 680/1090 740/1065 760/1090 470/1030 480/1120 550/1000 350/1030 320/1040 370/1040 360/1090 335/1090 330/1090 410/720 300/750 350/950 300/870 340/800 420/720 280/400 430/730 580/1040

Before/ After Before/ After

Effective Methods
Responsibility Assignment Matrix (RACI) for Commercial Party Fabric Processing
Department Activity/Process Order Taking Planning Quality Grey Bleaching Dyeing Design Studio Printing Finishing Lab Folding Logistics sub-process Print Dye White Marketing A/R A/R A/R C I I I C C C C C PPC C C C A/R I C C C C C C C C C Grey I I I C I A/R C Quality I I I C A/R C C C I C C C C C Bleaching I I I C I I A/R C C C C I Design Studio I Printing I I C I I C I I C C A/R C C I C I I C A/R Dyeing Finishing I I I C I I C C C A/R C I Lab I I I C I C C C C C A/R C C Folding I I I C I I I I I C C A/R C

A/R C

C C I

R = Responsible: Those who do the work to achieve the task. There is typically one role with a participation type of Responsible, although others can also assist in the work required. A = Accountable: The one ultomately answerable for the correct and thorough completion of the deliverables. In other words, an Accountable MUST approve on work that Responsible p C = Consult: Those whose opinions are required with two way communication. I = Informed: Those who are kept up-to-date on progress with only one way communication.

effective men Operator training for autonomous maintenance

effective men 4 point system - inspection training

effective machines - OEE

TPM (Total Productive Maintenance) training was delivered to all HODs. Autonomous training was delivered to all operators to reduce the machine downtime. Data Analysis training was delivered to all HODs about how to gather and analyze machine data. Overall Equipment Effectiveness (OEE) of Rolling machine as well as Rotary was calculated. Rolling machines 4 and 5 have been rotated by 90 o to make their use more effective. Andon lights have been installed on Rolling1 machine to alert the staff in the event of a machine breakdown.

Objective: 12. Efficient and safe Packaging material receiving, storage and issuance.

Safe packaging material All the storage racks have been repaired for safe packaging material storage. A new rack has been made for all kinds of polythene bags, Twin jute etc. More frequently used material and supplies have been placed closer to the point of use. All the racks have been labeled with the material name and size etc.

packaging material
Before

After

Objective: 13. To create a safer, more productive and organized workplace

Before 5S Workplace Organization

Before 5S

1s - sort

2s - Set in order

3s - Sweep & shine

4s - Standardize

4s - Standardize

5s - Sustain
Regular 5S inspection by supervisors and the Folding manager. Celebration of monthly 5S day. Weekly meetings of all Folding employees and the manager to discuss different ways to create a culture of continuous improvement. 5S training for all new starters. Regular audit by compliance officer.

6s - Safety
Before After

6s - Safety
Before After

6s - Safety
Before After

Visual management

Continuous improvement

Be better today than you were yesterday and better tomorrow than you are today.