Indonesia Factory

LEAN.ncpark@gmail.com

Ei- SMART SEWING SYSTEM

PROJECT
December 16 th , 2021

 Objectives
 Team / Resources
 Condition - BEFORE
 Procedures
 Condition – AFTER
 KAIZEN Metrics
 Benefit Summary
 Project Roadmap
 Appendix
- Supported Data (Pictures, Videos, Graphs, etc)
 OBJECTIVES

• Stitching the highest labor content

Stitching consistently the biggest portion in Direct Labor count

Stitching portion / quarter

• Ensure most effective learning

New Stitching Operators was hired Monthly Turn-Over rate is also
starting Q2’21 INCREASING
Monthly Turn-over

Ei-Smart Sewing System builds in more STABILITY

• Real-Time Output & Defect

Cell leader recognize the problem on sewing line more faster and solve it immediately.
These can increase Output, Productivity & RFT
 WHY we did this project in PWI ?

1. Reporting Data 3. Balancing Process

• Collect data with Paper report • Actual output calculation by each operator
• Using Visual boards as result information in order to Increase productivity.
• Report only available for Input/Output only

2. Time to Analyze Process/ Issues 4. Ei- Smart Sewing System

• CT data collection by Manual , Process by Process • Real-time data
to calculate & Analyze Process • Devices with IoT System
• Action plan from analysis • Fast Feedback Analysis with Real Time Data
(add Machine, MP or Review Process).

Project Timelines

1 Pilot Cell Installation (Electrical & device) - Pilot Project :

2 Stitching
2 Training User - 1 Regular Cell
(Lean/Mechanic/Prod./QIP/IT) - 1 Automation Cell

3 Monitoring System In Pilot Cell

4 Review Project
- 1 Regular Cell
5 Next Project For Other Cell - 4 Automation Cell
 TEAM / RESOURCES

I.T. teams
Production & QIP teams • Program & devices installation
• Especially related with IoT things
• Control WIP & Project Implementation
PRODUCTION • User training
• Review process (prod. leaders)
• CTQ process review ( QIP teams) &QIP I.T. • Communication w/ vendor
teams

LEAN Mechanics/
Engineering

LEAN teams Mechanics/ Engineering

• Follow up project implementation • Support during installation & set-up
• Tracing a result and analyze devices if necessary
• Control & re-setting
• Review project periodically
 CONDITION - BEFORE

Time Study Bottleneck Process

• Check Process By Process
• Average Time Process Operator By Process

Sewing Area
Visual Board

Stitching Automation
Collect Output
• Manual report Output on Visual boards
Stitching Regular • Collect Per Hours
 PROCEDURES

User Control

Dashboard Display User Control

• Actual Production Qty Set-Up Model Information
• Production Rate Setting Dashboard
• Work Detail Setting Target
• Completed Qty Per Line Process Allocation
 Line Of Balancing - Sewing
# Cell Automation 31 – LOB Calculate

Process Sewing
TT 37.50 MP 15
LOB – Before TCT 470.89 % LOB 83.7%
Pitch Time 36.85

# Cell Automation 31 – Real-Time IoT System LOB – After Process Sewing

TT 37.50 MP 15
TCT 510.87 % LOB 95.4%
Pitch Time 35.69
 CONDITION – AFTER INSTALL

Output
275 Prs

Change Over
519v2 to 608v5

Daily Performance EOL Sewing

without Ei-Smart Stitching

768 prs/day

Ramp Up CO
608v5

Output
219 Prs
 KAIZEN METRICS

Metrics Before After % Change

PPH (Sewing/ C2B) 6.4 (PPH Sewing) 6.86 (PPH Sewing) 7.2 %
1.67 (PPH C2B) 1.74 (PPH C2B) 4.1%
RFT  Next step Implementation

Lead Time 13.02 days 11.73 days 9.9%  e.g 10K order

Inventory 352 prs 292 prs (17%)

Part Path n/a n/a n/a

 RFT system not implemented yet, due to we will upgrade from Barcode system to Touch Pad Monitor
 BENEFIT SUMMARY
Desc. By Cell By Factory
Investment

Impact Increase Output : 768 prs/ day  852 prs/day Increase Output : 6480 prs/ day  7186 prs/day
(+10.9%) (+10.9%) (Base On Capacity Dec’21)
MLT reduce ± 9.9% MLT reduce ± 9.9%
Innovative Focus in biggest portion in C2B Labor count. (sewing in the biggest)
Stability & effective learning in stitching (covered : turnover & new workers training )
Applicable For all model in stitching line (pilot project in 2 different type of cell)
Effort Collaboration dept. : LEAN, Production, QIP, IT & Mechanics
Duration : 5 month plus (still on progress) since July 12th ,2021

 Calculate benefit by converting to $$$ per month or accumulation per year

 PROJECT ROADMAP
SUPPLIER PROLIFERATION PLAN
PROJECT NAME PICTURE REMARK
Web / EMAIL July Oct Nov Dec 2022 2023
- Pilot Project :
2 stitching cell

Ei- Smart EI SYSTEM - 1 Regular cell

1 Automation cell
www.eisystem.co.kr 2 4 12 29
Sewing System otrs@naver.com - Next to Project For RFT
System

 Estimate Payback Period (per cell investment) = 5.26 months (based-on Indo’s Labor cost)

 PPH Stitching IMPACT : Increased 8.2% from Current Stitching PPH

 MLT IMPACT : Reduced 1.291 days (9.9%) * with assumption for 10K’s PO
T HANK Y OU
APPENDIX
APPENDIX
 CHALLENGES
FINDING Suggestion
Issue
• Button install use a • Cable power installation
cable (not simple) (battery/wireless power suggestion)
• Disadvantages of battery
1. users could not know when they need to change battery
2. Dry cell battery : too expensive for factory
3. If use rechargeable Li-ion battery, concern on safety &
stability problem (due to can cause fire)

FINDING • If use
Issue Suggestion
• Inconsistent • Make a signal or “Alert/ Andon”
Operator use a
Bottom button.
Not Used
RFID + Andon +
color display
 CHALLENGES
FINDING Suggestion
Issue
• Unstable • Discuss with factory (IT division) for upgrade
Connection spec connection device needed
Code of
Error
Upgrade RFID +
color display +
Andon (M/C, Quality,
Mt’l)
FINDING Suggestion
Issue
• Need manual • Remote ‘Change-over’ button
installation button
• Long time on
change button
position at change
over model
 CHALLENGES
FINDING Suggestion
MT 510v3 Issue
• Show only one • Show data mix model running on the Visual
model data on the Data Report
Running
Mix Model
ML 574v2
Visual Data Report