1. HOP Yick BD Ltd
Hop Lun Ltd 1
• Case Study
• Strategy
• Offsets
2. General Info
o Sewing Line: A2
o Buyer: Debenhams
o Style: 087-H-00255
o First M/C previous style finished time : 3.30pm, 16-March-13
o Previous style last output time : 3.10pm, 18-March-13
o New Style start time : 8.45am, 18-March-13
o New style first output time : 2.00pm, 20-March-13
CASE-01
Hop Lun Ltd 2
3. Feeding Analysis-01
ITEM : MOULD PADDED BRA
Date
TIME Elapsed time
REMARKS Root Causes
Expected
Standard Time
SL#
Operations/Activities Type of
M/c or
equipment
Job responsibility START END Minutes
Name Repeatability
1 Open electrical line Do Electrician 18-Mar-13 8.45am,4/16 9.00am 15
Ok
15
2 M/C arrangement ( first 10 m/c) Do Mechanic 18-Mar-13 9.00Aam 11.00 am 60
inventory status is not accurate
30
3 Waiting for electrician Do Electrician 18-Mar-13 10.30am 11.00am 30
delay to come
4 Attach electrical line ( first 10 m/c) Do Electrician 18-Mar-13 11.00am 11.30am 30
change plug/new plug setup
20
5 Line feeding meeting Do Management 18-Mar-13 11.20am 11.45am 25
Delay of meeting
15
6 S/n l/s attach water-proof fabric on foam (for light color) Do 1/N Technician & QC 18-Mar-13 11.15am 1.30pm 75 Lunch 1 hr
(12.15 am-1.15
pm)
Gathering learning curve, need training of process control
15
7
Cut excess water-proof fabric seam allowance with knife
machine (for light color)
Do O/L Technician & QC 18-Mar-13 1.20pm 2.00pm 40
Gathering learning curve, need training of process control
10
8 S/n l/s join cup shell and mould cup on frt neckline Do 1/N Technician & QC 18-Mar-13 1.45pm 2.40pm 55
Gathering learning curve, need training of process control
25
9 3th o/l neaten upper foam edge
Do
O/L
Mechanic 18-Mar-13 2.30pm 2.45pm 15
ok
10
Do Technician & QC 19-Mar-13 2.45pm 7.40am 115
Gathering learning curve, need training of process control
20
10 S/n l/s baste cup shell on mould cup Do 1/N Technician & QC 19-Mar-13 7.30am 8.30am 60
Gathering learning curve, need training of process control
20
11 Extra shell fabric cut by knife machine on cup btm Do E/C Technician & QC 19-Mar-13 8.20am 8.40pm 20
ok
10
12 S/n l/s join cups with wings and cradle and gore Do 1/N Technician & QC 19-Mar-13 8.30am 9.20am 50
Gathering learning curve, need training of process control
10
13 3/16d/n l/s sew wire casing on cup bottom Do 2/N Technician & QC 19-Mar-13 9.00 am 10.15am 75
Gathering learning curve, need training of process control
30
14 S/n l/s baste double layer thread on wing Do 1/N Technician & QC 19-Mar-13 10.00am 10.30am 30
Gathering learning curve, need training of process control
10
15 S/n l/s join wings with cups Do 1/N Technician & QC 19-Mar-13 10.20am 10.40am 20
Gathering learning curve, need training of process control
10
16 5/16d/n l/s attach binding to side seam Do 2/N Technician & QC 19-Mar-13 10.40am 11.00am 20
Gathering learning curve, need training of process control
20
17 Bt lock side binding end *4 Do B/T Technician & QC 19-Mar-13 10.50am 11.15am 25
Gathering learning curve, need training of process control
15
18 Shoulder strap wrong supply Do Material 19-Mar-13 11.00am 1.30pm 90 Lunch 1 hr
(12.15 am-1.15
pm)
Gathering learning curve, need training of process control
0
19 S/n l/s fix shoulder strap at back wing Do 1/N Technician & QC 19-Mar-13 1.30pm 2.30pm 60
Gathering learning curve, need training of process control
15
20 C/s sew under bust Do F/L Technician & QC 19-Mar-13 2.20pm 8.20am 120
Gathering learning curve, need training of process control
40
21 S/n l/s fix fixed net in front shoulder strap Do 1/N Technician & QC 20-Mar-13 3.40pm 8.30am 50
Gathering learning curve, need training of process control
15
22 C/s wrap upper wing through underarm to front shoulder strap Do F/L Technician & QC 20-Mar-13 8.15am 9.15am 60
Gathering learning curve, need training of process control
15
23 ZZ l/s lock H&E(with compensating foot) Do 1/ZZ Technician & QC 20-Mar-13 9.10am 9.50am 40
Gathering learning curve, need training of process control
15
24
S/n l/s fold sew front shoulder strap with ring inserted and
fix back shoulder strap
Do 1/N Technician & QC 20-Mar-13 9.20am 10.00am 40
Gathering learning curve, need training of process control
15
25
Bt lock frt shoulder strap end and be shoulder strap *4,
armhole end *2
Do B/T Technician & QC 20-Mar-13 9.50am 10.10am 20
Lunch 1 hr.
(12.15am-1.15pm
Ok
20
26 M/c arrangement & adjustment (B/A) Do Mechanic 20-Mar-13 10.00am 1.15am 135
inventory status is not accurate
10
27 Attach 1 bow, 1 button and 1 tag Do B/A Technician & QC 20-Mar-13 1.15am 1.40am 25
OK
30
Hop Lun Ltd 3
4. Summary -01
Activities
Actual Expected
Minutes
Percentag
e Minutes Percentage
Technician & QC 1000 72% 350 74%
Mechanic 210 15% 70 15%
Electrician 60 4% 35 7%
Material 90 6% 0 0%
Management 25 2% 15 3%
Total 1385 100% 470 100%
Total Operations/Process 20 20
Hop Lun Ltd 4
7. Root Causes-01
Root Causes
Consum
ed Time Percentage
LC & T 935 72%
M/c Inventory
check 195
15%
Change/Replace 30 2%
Waiting 30 2%
Material 90 7%
MD 25 2%
Total 1305 100%
Note:
LC & T – Gather Knowledge through Trial & Error and build upward
learning curve thus needs proper training of process control
MD – Management Decision
Material - shortage/wrong LC&T
M/cInventorycheck
Change/Replace
Waiting
Material
MD
0%
20%
40%
60%
80%
100%
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Pareto Analysis 01 - Root Cause
Time Cumulative % Cut off %
Hop Lun Ltd 7
8. Root Causes-01
Root Causes
Consum
ed Time Percentage
LC & T 935 72%
M/c Inventory
check 195
15%
Change/Replace 30 2%
Waiting 30 2%
Material 90 7%
MD 25 2%
Total 1305 100%
Note:
LC & T – Gather Knowledge through Trial & Error and build upward
learning curve thus needs proper training of process control
MD – Management Decision
Material - shortage/wrong LC&T
M/cInventorycheck
Change/Replace
Waiting
Material
MD
0%
20%
40%
60%
80%
100%
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Pareto Analysis 01 - Root Cause
Time Cumulative % Cut off %
Hop Lun Ltd 8
9. General Info
o Sewing Line: A22
o Buyer: George
o Style: 018-k-00653
o First M/C previous style finished time : 10.00 am, 30-March-13
o Previous style last output time : 3.20 pm, 01-April-13
o New Style start time : 8.50 am, 01-April-13
o New style first output time : 12.55 pm 4-April-13
CASE-02
Hop Lun Ltd 9
10. Feeding Analysis-02
ITEM : MOULD PADDED BRA
Date
TIME Elapsed time
REMARKS Root Causes
Expected
Standard Time
SL#
Operations/Activities Type of
M/c or
Equipme
nt
Job
responsibility
START END Minutes
Name Repeatability
1 Open electrical line Do Electrician 1-Apr-13 8.50am 9:10am 20 15
2 M/C arrangement Do Mechanic 1-Apr-13 9:15am 9:55am 40 delay to check inventory status 30
3 Attach electrical line Do Electrician 1-Apr-13 9:50am 10:10am 20 20
4 Waiting & for PP meeting Quality 1-Apr-13 10:10am 11:00am 50 Busy with other management activities 15
5 Bring accessories Do Line feeder 1-Apr-13 10:30am 11:00am 30 Material has not brought at due time 0
6 Baste lining net at r/l lower cup Do 1/N Technician & QC 1-Apr-13 11:00am 11:25am 25 15
7 Baste lining net at top cup Do 1/N Technician & QC 1-Apr-13 11:30am 1:30pm 60
Lunch 1 Hr.
(11:45am-12:45pm)
trial & error>gather Learning Curve> need Proper technical Training 15
8 Join lower cup seam
Do
1/N
Mechanic 1-Apr-13 1:00pm 2:10pm 70 Simultaneous
Activities
alignment & adjustment problem> variability of materials
usage>unavailability of SOP
5
Do Technician & QC 1-Apr-13 2:10pm 8:20am 130 trial & error>gather Learning Curve> need Proper technical Training 10
9 Topstitch open and sew lower cup seam
Do
2/N
Mechanic 1-Apr-13 9:00am 11:30am 90
alignment & adjustment problem> variability of materials
usage>unavailability of SOP
10
Do Technician & QC 1-Apr-13 3:00pm 8:50am 110 trial & error>gather Learning Curve> need Proper technical Training 20
10 Join top gore and turn over to baste r/l sides Do 1/N Technician & QC 1-Apr-13 3:10pm 9:20am 130
Simultaneous
Activities
trial & error>gather Learning Curve> need Proper technical Training 10
11 Side wing baste and join with back wing Do 1/N Technician & QC 1-Apr-13 3:40pm 9:40am 120
Simultaneous
Activities
trial & error>gather Learning Curve> need Proper technical Training 15
12 Attach elastic ton front neckline Do 1/ZZ Technician & QC 2-Apr-13 8:25am 11:35am 190
Technical took longer time for adjustment> Gather learning Curve > need
proper training of process control
40
13 Join cup seam Do 1/N Technician & QC 2-Apr-13 11:30am 1:30pm 60
Lunch 1 Hr.
(11:45am-12:45pm)
trial & error>gather Learning Curve> need Proper technical Training 20
14 Topstitch cup seam and fold Do 2/N Technician & QC 2-Apr-13 1:00pm 2:15pm 75 trial & error>gather Learning Curve> need Proper technical Training 30
15 Attach fixed net to cup bottom and armhole Do 1/N Technician & QC 2-Apr-13 2:00pm 3:00pm 60 trial & error>gather Learning Curve> need Proper technical Training 15
16 Attach elastic to underbast
Do
3/ZZ
Mechanic 2-Apr-13 9:30am 2:30pm 240 alignment & adjustment problem of feed dog > Change m/c> Decision 20
Do Technician & QC 2-Apr-13 2:30pm 3:50pm 80 trial & error>gather Learning Curve> need Proper technical Training 25
17 join cup with wings and gore and cradle together Do 1/N Technician & QC 2-Apr-13 3:50pm 8:15am 85
Simultaneous
Activities
trial & error>gather Learning Curve> need Proper technical Training 20
18 Attach elastic to top wing through armhole Do 3/ZZ Technician & QC 2-Apr-13 4:10pm 8:50am 100 trial & error>gather Learning Curve> need Proper technical Training 45
19 Attach wire casing on side seam Do 2/N Technician & QC 2-Apr-13 4:20pm 9:15am 115 trial & error>gather Learning Curve> need Proper technical Training 30
20 Sew wire casing on cup bottom Do 2/N Technician & QC 2-Apr-13 4:40pm 9:30am 110 trial & error>gather Learning Curve> need Proper technical Training 40
21 Attach elastic to back scoop Do 1/ZZ Technician & QC 2-Apr-13 4:50pm 9:40am 110 trial & error>gather Learning Curve> need Proper technical Training 20
22 Lock hook and eye Do 1/ZZ Technician & QC 3-Apr-13 8:20am 10:00am 100 trial & error>gather Learning Curve> need Proper technical Training 15
23
Overlap and sew shoulder strap and fold & fix elastic end at
be scoop with ring inserted
Do O/L Technician & QC 3-Apr-13 8:55am 10:30am 95 trial & error>gather Learning Curve> need Proper technical Training 15
24
Bt lock shoulder strap opening*4, elastic end at be scoop *2,
lock wire & side seam end*8
Do B/T Technician & QC 3-Apr-13 9:40am 11:00am 80 trial & error>gather Learning Curve> need Proper technical Training 20
25 Attach Bow *3 Do B/A Technician & QC 3-Apr-13 9:55am 11:20am 85 trial & error>gather Learning Curve> need Proper technical Training 30
Hop Lun Ltd 10
11. Summary-02
Activities
Actual Expected
Minutes Percentage Minutes Percentage
Technician & QC 1920 78% 450 80%
Mechanic 440 18% 65 12%
Electrician 20 1% 35 6%
Quality 50 2% 15 3%
Line feeder 30 1% 0 0%
Total 2460 100% 565 100%
Total Operations/Process 20 20
Hop Lun Ltd 11
14. Root Causes-02
Note:
LC & T - Gather Knowledge through Trial & Error and build upward
learning curve thus needs proper training of process control
M-MD - Maintenance of Management Decision
Material - shortage/wrong
U-SOP – Unavailability of SOP
Root Causes
Consumed
Time
Percentage
LC & T 1895 78%
M/c Inventory
check
40 2%
U-SOP 160 7%
Waiting 50 2%
Material 30 1%
M-MD 240 10%
Total 2415 100%
LC&T
M/cInventorycheck
Change/Replace
Waiting
Material
MD
0%
20%
40%
60%
80%
100%
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Pareto Analysis 02 - Root Cause
Time Cumulative % Cut off %
Hop Lun Ltd 14
15. General Info
o Sewing Line: A22
o Buyer: Debenhams
o Style: 087-G-00636
o First M/C previous style finished time : 5.00 pm, 16-Sep
o Previous style last output time : 4:45:00 PM,17 Sep
o New Style start time : 11:20:00 AM,17 Sep
o New style first output time : 3:20:00 PM,18 Sep
CASE-03
Hop Lun Ltd 15
16. Feeding Analysis-03
ITEM : MOULD PADDED BRA
Date
TIME Elapsed time
Root Causes
Expected
Standard TimeSL#
Operations/Activities Type of M/c or
equipment
Job responsibility START END Minutes
Name Repeatability
1 Attach water-proof fabric on foam Do 1/N
Mechanic
17-Sep-12 11.20 11.35
5 ok 5
Technician & QC 10 ok 10
2 Cut excess water-proof fabric seam allowance Do E/C Technician & QC 17-Sep-12 11.35 11.40 5 ok 5
3 attach lace at upper cup Do 1/ZZ Technician & QC 17-Sep-12 11.40 12.50 10 ok 15
4 Check swatch card Do Technician & QC 17-Sep-12 12.50 1.16 36 wrong Sample given>Sample Dept. given wrong sample 10
5 3th o/l neaten cup edge, cup btm, armhole foam edge Do O/L
Mechanic
17-Sep-12 1.17 1.30
6 ok 5
Technician & QC 7 ok 10
6 Give above operation standard Do Technician & QC 17-Sep-12 1.30 2.10 40 ok 10
7 Correction lay-out paper Do IE 17-Sep-12 2.10 2.45 35 lay-out paper need correction>Job Description 0
8 wrap upper cup foam edge Do 1/N
Mechanic
17-Sep-12 2.45 3.25
10 ok 10
Technician & QC 20 Trial & Error> Gather Learning Curve>need training 10
9 attach cup shell on foam Do 1/N Technician & QC 17-Sep-12 3.25 3.35 10 ok 10
10 join top gore and gore bottom then turn over to sew both sides Do 1/N Technician & QC 17-Sep-12 3.35 3.45 10 ok 10
11 attach net to side wing Do 1/N Technician & QC 17-Sep-12 3.45 3.50 5 ok 10
12 Align M/C according to lay-out paper & Add electric power Do
Mechanic
17-Sep-12 3.50 4.30
30
No available space to keep M/C which manage from another line &
communication gap> M/c inventory status check
10
Electrician 10 20
13 join side wings with cups Do 1/N Technician & QC 17-Sep-12 4.30 4.35 5 ok 10
14 attach elastic to lower wing Do 1/ZZ
Mechanic
17-Sep-12 4.35 5.00
15 ok 10
Technician & QC 10 ok 10
15 topstitch elastic on lower wing Do 1/ZZ
Mechanic
18-Sep-12 8.05 9.00
20 Adjustment & Alignment Problem>Unviability of SOP 10
Technician & QC 35 Trial & Error> Gather Learning Curve>need training 25
16 Waiting for Technician Do Technician & QC 18-Sep-12 9.00 9.30 30 Technician engage in meeting>job Description 0
17 insert cup Do 1/N Technician & QC 18-Sep-12 9.30 10.10 40 operator engage in another sewing line> incorrect Man-Hour planning 15
18 attach elastic to upper wing through underarm Do 3/ZZ
Mechanic
18-Sep-12 10.10 11.05
10 ok 10
Technician & QC 45 previous style accessories shortage & recut problem> Replenishment problem 25
19 attach binding to side seam Do 2/N
Mechanic
18-Sep-12 11.05 11.30
10 ok 5
Technician & QC 15 ok 15
20 sew wire casing on cup bottom Do 2/N
Mechanic
18-Sep-12 11.30 1.10
18 ok 10
Technician & QC 22 Trial & Error> Gather Learning Curve>need training 15
21 attach elastic to be scoop Do 1/ZZ
Mechanic
18-Sep-12 1.10 1.45
10 ok 10
Technician & QC 25 ok 20
22 lock H&E Do 1/ZZ Technician & QC 18-Sep-12 1.45 2.15 30 Trial & Error> Gather Learning Curve>need training 20
23 overlap&sew shoulder strap with slider Do 1/N
Mechanic
18-Sep-12 2.15 2.30
5 ok 5
Technician & QC 10 ok 10
24 bt lock shoulder strap Do B/T
Mechanic
18-Sep-12 2.30 2.40
5 ok 5
Technician & QC 5 ok 10
25 attach 1 bow and 1 gore tag Do 1/ZZ
Mechanic
18-Sep-12 2.40 3.20
10 ok 10
Technician & QC 30 Trial & Error> Gather Learning Curve>need training 20
Hop Lun Ltd 16
19. Actual vs. Expected-03 Actual
Expected
455
154
10
35
295
105
20
00
50
100
150
200
250
300
350
400
450
500
Technician & QC Mechanic Electrician IE
Series1 Series2
Hop Lun Ltd 19
20. Root Causes-03
Note:
LC & T - Gather Knowledge through Trial & Error and build upward
learning curve thus needs proper training of process control
M-MD - Maintenance of Management Decision
Material - shortage/wrong
U-SOP – Unavailability of SOP
Root Causes Consumed Time
Percenta
ge
LC & T 137 44%
M/c
Inventory
check
10 3%
JD 65 21%
SOP 36 12%
U-SOP 20 6%
Replenish 45 14%
Total 313 100%
LC&T
JD
Replenish
SOP
U-SOP
M/cInventoryCheck
0%
20%
40%
60%
80%
100%
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
Pareto Analysis 03 - Root Cause
Time Cumulative % Cut off %
Hop Lun Ltd 20
21. Consolidation
Hop Lun Ltd 21
Root Causes -1
LC & T
M/c Inventory check
Change/Replace
Waiting
Material
MD
Root Causes - 2
LC & T
M-MD
U-SOP
Waiting
M/c Inventory Check
Material
Root Causes - 3
LC & T
JD
Replenish
SOP
U-SOP
M/c Inventory Check
LC & T
M/c Inventory check
Material
MD
M-MD
U-SOP
JD
Waiting
Replenish
SOP
22. Consolidation
Hop Lun Ltd 22
LC&T
M/cInventorycheck
M-MD
U-SOP
Material
Waiting
JD
Replenish
SOP
Change/Replace
MD
0%
20%
40%
60%
80%
100%
0
500
1000
1500
2000
2500
3000
Axis Title
80/20 Analysis
Time Cum % Cut Off
73%
6%
6%
4%
3%
2% 2% 1% 1%
1% 1%
Pie Chart- Proportion of
Causes
LC & T
M/c Inventory check
M-MD
U-SOP
Material
Waiting
JD
20 % Root
Causes
consume 80%
time
23. Goal(s)
Hop Lun Ltd 23
By making setup times/Change over times quicker
and simpler to enables Hoplun produces smaller
lots with higher flexibility. This means company can
meet their customers’ needs for high quality, low
cost products that are delivered quickly and
without the expense of excess inventory.
24. Objective(s)
Hop Lun Ltd 24
1. The setup time for every operation
should be made or ready for bulk
production in less than 10 minutes.
2. There will be no interruption in hourly
production during change over
29. Hop Lun Ltd 29
Correlation Between Internal Activities & Root Causes
• M/C
Inventory
MACHINE SEARCHING/MACHINE
READYNESS AS PER LAY OUT
•Change/Repl
aceATTACHMENT OF GUIDES & FOLDERS
•MD, JDFEEDING MEETING
•M/C
InventoryMACHINE SETUP AS PER LAYOUT
• U-SOPLINE FEEDING & STITCHING STANDARD
FIX
•U-SOP,
M-MD
GUIDE & FOLDERS ADJUSTMENT AS PER
STANDARD
•LC & TENSURE BUYER MEASUREMENT
STANDARD & GET UP
Possible to make
external Activities
Trial & tune it as
external activities
Possible to make
external Activities
Perform Parallel as
internal activities
Perform Parallel as
internal activities
Perform Parallel as
internal activities
Perform Parallel as
internal activities
30. Hop Lun Ltd 30
Corrective Action Plan
Root Causes
Short Term Plan Mid Term Plan Long Term Plan
Code Elaboration
LC & T
Gather Knowledge through Trial & Error and
build upward learning curve thus needs
proper training of process control
1. Standardize HC of QC
& Technician.
2. Ensure attendance of
Tec & QC
Standardize the process
wise setup time
1. Ensure proper training
of process control to
Technician & QC
personnel.
2. Ensure proper training
to operator to know how
to fix required SPI.
M/c Inventory
check
No visual inventory system & current
Inventory status is not updated continuously
Visualize & Update
Inventory & Define Roles
Display Inventory at
Floor, Retrieval system
Implement TPM
Material Shortage or send wrong material
Visualize the material
replenishment
Practice the Kaizen
Board to visualize the
problem
Need to develop mistake
proofing techniques at
cutting & W/H
MD Management Decision
Practice Kaizen board to
visualize problem
Perform weekly kaizen meeting & take corrective
action on weekly basis
M-MD Maintenance -Management Decision
Review the job reporting
system during
changeover
Standardize time limit to
maintenance/solve a job
Train and Visualize the
next level decision to
solve a problem
U-SOP Unavailability of SOP
List down and review
SOP of machine
maintenance
Standardize SOP Sustain SOP
JD Job Description Review Job description
Standardize Job
description
Sustain JD
Replenish Input material not receive at due time
Standardize
Replenishment SOP
Standardize the place & visualize inventory
SOP SOP not followed
Review operating
Procedure
Standardize the operating procedure
31. Change Over Off Sets
Hop Lun Ltd 31
Need Discussion, Grooming &
Then……..
