1. WHERE ARE MY SHOES???
Old
Router
Cobbler travels to Desk, SMOH, Cabinet, and custom cells to gauge need, travels back
to cut, then returns to said areas with shoes, and finally returns to GRL. Night shift has a
water spider route. Shoes are made on demand without a standard process creating
enormous waste in the process.
Old miter
saw
4. Create a standard, let human ingenuity
refine it
No standard to process
Pieces are cut randomly as needed
Inventory depletes rapidly as demand of SMOH,
Cabinet, Custom, and Desking cells is sporadic and hard
to predict.
No forecast of demand
Incredibly wasteful misuse of raw material
5. MAKE CUTS COUNT
90" 2x43+ 2"
scrap
3x30 4x21"+ 6"
scrap
4x23"+1"
scrap
72"+18"
72" 1x66"+6"
scrap
49"+23" 42"+30" 2x31"+10" 3x24"
36" 26"+10"
Largest scrap piece 6”
Drastically reduces scrap, saving space and $$$
Wood costs approximately:$744 per load for 3/4x3 1/2x108
Total est. annual material cost, $78,000
Tasks minimized, saving time.
By cutting pre-routed 90”, 72”, 36” inch shoes, portions of the
routing is complete for subsequent shoes production.
Time savings equates to 2/3 current rate 0r 10 man-hours per
day @ $20 and 75% less material waste
Cost savings= (material )$58,500 + (manpower)
$73,000=$131,000 annual cost savings.
Every new formula is an easily implemented EE
Suggestion and added savings!
6.
7.
8. Router
Mobile cart
same height
as router
Hand off
order/pickup
Found Them!!!
By cutting the area in half and standardizing the process waste is greatly reduced. A
water Spider route ensures Cobblers no longer have to walk back and forth constantly. A
kanban system attached to the new cart ensures the correct shoes are delivered and in
a timely manner. By creating a standard for cutting from existing pre-cut sized waste is
reduced by 90%
9. CONCLUSION
Cost savings equate to $131,000 annually
Overproduction and excess inventory
reduced to zero
Floor space reduced to 40% of previous
footprint.
Success!!
