7. Before/After – WIP on Slides
7
• Work in Progress on each of the 5 slides
• Large bins to collect wipers and resorting
• Work in progress minimized
• Small barrels used for resorting and wipers
• Work in progress minimized
• Small barrels used for resorting and wipers
Before AfterAfter
8. Before/After – Finished Goods Boxes
8
• An average of 16 finished goods boxes
used around workstations by each operator
• An average of 6 finished goods boxes used by
each operator
• An average of 6 finished goods boxes used by
each operator
Before AfterAfter
10. Before/After – Work instruction
10
• Verbal, informal training
• Standardized work developed
• Improved from sorters feedback
• Posted on workstations, easy to be reviewed
• Standardized work developed
• Improved from sorters feedback
• Posted on workstations, easy to be reviewed
Before AfterAfter
11. 11
• All 15 products sent on 5 slides • 3 slides dedicated for Polos:
• Products divided by: T‐Shirts, Long
Sleeves and Baby items
Workflow Process
AfterAfterBefore
12. 12
• Just finished goods recorded • Daily production report developed
• Visual board for Measure of performance to
communicate progress will be soon ready
Production Report
AfterAfterBefore
Daily Production Report:
Date: 16-Jun-10
Area: Polo
Name: Meeta Balwinder Bhamna Daljit Vally
Finished Goods
Adult T-Shirt 641.5 640.5
Ladies T-Shirt 217.5 227.5
Sexy top SS 127.5 210
Children T-Shirt 100 206.5
Sport T-Shirt 199.5 104.5
Ladies LS 438.5
Sexy Top LS 298
Mens LS 501.5
Polo Pants
Children Turtleneck
Light Baby 633.5 378.5
Heavy Baby 642.5 387.5
Sleepers 30 71.5
Sexy Top SS 261.5 279
Children Turtleneck
Total: 1,286 1,389 1,238 1,568 1,117
FG %: 53.4% 68.3% 50.3% 62.7% 58.4%
White Wipers 397 124 171.5
Coloured Wipers 366.5 247.5 772
Dirty Baby Cloths 89.5 59.5
Total: 763.5 371.5 943.5 89.5 59.5
Whipers % 31.7% 18.3% 38.3% 3.6% 3.1%
Resorting: 357.75 274.25 279.5 842 735
Resort %: 14.9% 13.5% 11.4% 33.7% 38.5%
Processed (lbs): 2,407 2,035 2,461 2,499 1,911
13. Team Results After One Week
Support Metric Before After Difference
%
Improvement
Increase Safety and morale
Huge WIP on slides;
Difficult to handle;
Complex boxes
layout
Minimum WIP,
easier to
handle; easier
boxes layout
Workplace is a safer and
nicer to work TBD
Simplify the process flow – less
types of products to be inspected
15 products on 15
slides;
16 boxes needed for
each sorter
6 products on
each slide
3 slides needed
Reduce cost of parts,
improve stock accuracy,
minimize unexpected
shortages
60% boxes
reduction;
40% slides
reduction
Labour required to sort Polo 10 people
5 people + part
of Mika’s job
5 people are working on
different areas 50%
Main Metric Before After Difference
%
Improvement
Polo Area Performance
Average of 800 lbs
per sorter daily
Average of 1,250
lbs per sorter daily
Better productivity 56%
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14. Lessons Learned
• “It makes you aware of the severity of the problem”
• “The new process is much more easier than before”
• “It’s nice to work in this area now.”
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