Start: June 16th 2011

Update :August 1st 2011

TEAM 3
DFM/ DFP Kaizen Workshop – SS12
Product name: WORKOUT PLUS
Team Members:

UJANG Y M.Taufik
Lili Saptaji Suherlan
Yusuf Dwi
Silvi
Rani F
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 Plus
Baseline
Total part : 39 parts
Upper : 37 parts
Bottom : 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 Style name: WORK OUT PLUS M'S
Color: WHITE/BLUE
SRF: 29-111101A
Factory: PYI
Gender: M”S
First Mount Production: SS'!2
FE Product Leader: MAPLE
USA Representative: BERES FORD JESSICA
PGSC# : 2-J84948
Last# : RBK-943L
Bottom Picture Size Run: 6.5-15
Project Overview
PQ Chart Product Plan

Style

06/15/2011
Team Charter

Program Sponsor - Approve program

KS Shih - Provide resources
Jeftha W - Assure commitment from the teams
- Provide updates to business P. Owner

Facilitator - Program responsible

Agustiono Tugeno - Lead Kaizen events
- Share lessons learn & current best practice
- Review & set measurable
Project Manager - Visit PYI regularly
Ujang Y - Provide Monthly update to PS

- Facilitate and consult kaizen teams (Daily)

Project Core Member
- Support and follow up on Kaizen events & monitor
- M.Taufik -Silvi measurable
- Lili saptaji -Dwi - Visit shop floor 1 X week
- Suherlan -Rani F - Provide 2X month updates to Project Manager
- Yusuf
CEDAC
Critical Problem
CEDAC (Fishbone)
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 simplified
1. Change nylon eyelet to common eyelet
2. Change treatment of Quarter logo with another technique (emboss) and joining quarter overlay
and quarter
3. Match color between sock liner, tongue lining and collar lining
4. Provide mold for bottom part to reduce stitching process\
5. Remove decoration stitching
6. Reduce punching process in tounge 3
1
5
6

4
RACI Chart
Gantt Chart

Gant Chart
Workout plus
Activities Progress

Propose : Brainstorming Session

Propose : Presentation of waste identified Attendance : Team 3
Attendance : Team 3 Location : Training room
Location : Training room Date/Time : June 15th , 2011
Date/Time : June 14th , 2011 Description : Brainstorming idea to improve the current
Description : Explain Cause and Effect of waste design
according 8 waste principles in daily job
Activities Progress

Propose : Presentation to PYI senior managers Propose : Project review meeting with Mark Ma
Attendance : Team 3 Attendance : Team 3
Location : Training room Location : Meeting Room 1st floor
Date/Time : June 15th , 2011 Date/Time : June 24h , 2011
Description : Explain Cause and Effect idea Description : Review Project and Brainstorming season 2
implementation
Activities Progress (Best Practice)
Before After

Tongue Lining

Match color between element

Collar Lining

Sockliner

-Change nylon eyelet to common

eyelet
-Change treatment for quarter logo
Quarter Lateral with printing technique

Quarter backer Eliminate

Activities Progress (Best Practice)
Before After
Eliminate join stitching between
Bottom Part bottom and upper, provide
mold for treatment change

Before After
Eliminate Decoration Stitching
Decoration Stitching

Before After
Eliminate Pounching
Pounching
Activities Progress (Best Practice)
1. Change nylon eyelet with common eyelet (we suggest blue or white color)

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

- 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)
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
Best Practice Statement
Reduce Complexity of Part ,Material and Process:
a. Manpower saving: b. Overhead:
idea#1 : -1 person by stitching process of joining nylon eyelet idea#1 : 0
idea#2 : -1 person by stitching process of joining quarter logo idea#2 : reduce one number of supplier
idea#3 : 0 idea#3 : reduce shipping cost, streamline the material needs,
Idea#4 : 1 person by stitching process of joining bottom and upper part idea#4 : total TT and CT reduce in C2B
idea#5 : 1 person by decoration stitching idea#5 : material saving for quarter backer
idea#6 : 0
minor reduce : reduce stitching machine maintenance,
Calculation : Total Manpower Saving : 4 MP electricity,
Labor cost 1 operator/month =100USD save place to storage,
100USD x 4 = 400 USD/month save lab test and confirmation time
= 2000 USD/SS may reduce total number of defect

Total CT and TT Reduce = joining nylon eyelet = 30”/Pair

joining quarter logo = 04”/Pair Calculation Not Included (On Going Phase)
joining bottom and upper part = 15”/Pair
joining quarter backer and lateral = 08”/Pair

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 section Cutting Dies = 17.64 USD x 2 Cutting dies
idea#3 : 0 = 35.28 USD
idea#4 : 0 Tool for Decoration Stitching Process = 9.2 USD
Approx for minor reducement = 28 USD
idea#5 : eliminate one tool and process reduce
Total CT reduce = 22”/Pair
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
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