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Improve Warping OE
- 4. OUTLINE How Does OE Accurately Describe Our Goals? What Is The Value Of Improved OE? What Are The Limiting Factors? What Can Be Done To Improve OE? Back-Bar Waste Analysis Warping Optimization Project Labor Cost-Benefit Analysis LEAN Initiative – Case Yarn Management Future Projects OPERATIONAL EFFICIENCY (OE)
- 5. How Does OE Accurately Describe Our Goals?
- 7. What Is The Value Of Improved OE?
- 8. PRODUCTION VALUE OF OE REFERENCE: Michael Franklin Cost Analyst CURRENT ESTIMATED OUTPUT 45% $13,936,972
- 9. PRODUCTION SAVINGS OF OE REFERENCE: Angie Houston Purchasing/Planning CURRENT ESTIMATED OUTPUT 45% $1,369,437
- 10. What Are The Limiting Factors?
- 11. REFERENCE: Planning/Purchasing Angie Houston Bonnie Kennedy July 21 st ,2010 OPPORTUNITY
- 12. REFERENCE: Planning/Purchasing Angie Houston Bonnie Kennedy July 21 st ,2010 INTERNAL OPPORTUNITY
- 13. What Can Be Done To Improve OE?
- 14. CURRENT OE Reduce Waste Improve Labor Efficiency Improve Machine Efficiency Increase Labor Purchase Efficient Machinery IMPROVED OE
- 15. Warping Optimization Project MONITOR, TRACK, IMPROVE
- 18. PLC & OPC “WARP PLANNING” APPLICATION IMAGE A IMAGE B REFERENCE: Andrey Veshchev Programmer Analyst ISR 22482-1
- 20. MACHINE ANALYSIS>> zoom + zoom + EXAMPLE ONLY
- 21. SHIFT ANALYSIS>> zoom + zoom + EXAMPLE ONLY
- 22. TRACK OE PROGRESS>> EXAMPLE ONLY
- 23. LEAN Initiative – Case Yarn Management IMPROVE BY EFFICIENT MOTION ALLOCATION
- 25. zoom +
- 26. AFTER INITIATIVE Tasks are performed by separate associate AFTER INITIATIVE Tasks plus Tying In are performed by Yarn Handler
- 27. Warehouse (Receiving) Purchasing Supplier Warehouse (Balances) Planning Warehouse (Case Yarn Inventory) Warping Department Repack Yarn + Case Yarn (IN) Repack Yarn (OUT) Waste (OUT) Beam Yarn (OUT) Knitting Department Action Information Purchasing/Planning Warehouse/Shipping Warping Department Knitting Department Neutral Staging Areas Supplier LEAN INITIATIVE – CASE YARN MANAGEMENT Warehouse CASE YARN IN Warping Department REPACKS OUT NEUTRAL SITE NEUTRAL SITE
- 28. GUILFORD EAST FLOOR PLAN SEPARATING/STAGING/LOADING REFERENCE: Guilford East S Drive Common Directory
- 29. BEFORE DISTANCE TRACKER Outside Staging & Loading Area 2.83 miles 3.41 miles 1.93 miles 2.25 miles 1.86 miles Total (Over 5 Days) = 12.29 miles
- 30. AFTER DISTANCE TRACKER Outside Staging & Loading Area 0 miles 0 miles 0 miles 0 miles 0 miles Total (Over 5 Days) = 0 miles
Editor's Notes
- How Does OE Accurately Describe Our Goals? OE describes the amount we are able to produce on any given day, week, month, or year based on consistently producing certain styles. This production has a value. What Is The Value Of Improved OE? If improvement of OE occurs, it should, and based upon all available data, does correlate to increased production of beam yarn. This beam yarn has a value based upon the purchase value of the case yarn and the resources to produce the beam yarn. Considering that we can improve OE through a larger workforce, better processes, and better machines, the limiting factors that put a ceiling on the usefulness of OE need to be considered. What Are The Limiting Factors? The amount of machines, the amount of space available, the beam set requirements for knitting, the beam yarn need for knitting, and all upstream productivity are the limiting factors that are being considered. If we can improve OE by 10%, will the Knitting Department be able to use this increased amount of beam yarn produced? Yes…and no. As long as the knitting machines are in demand of the styles of beam yarn we can produce, then there should be no diminishing returns from investing in improved OE. At the moment, there is plenty of demand, but the investment in providing that demand must be justified by the value of our marginal returns. What Can Be Done To Improve OE? By priority order, reduced physical and downtime waste, improved labor efficiency, increased labor, and improved machine efficiency will all improve OE. Keep in mind that adding another machine does not necessarily improve the OE as a whole unless the machine was high efficiency and high production. It would however increase our production values which indicates the OE is a fluid variable dependent upon the machines and styles we use.
- How Does OE Accurately Describe Our Goals? OE describes the amount we are able to produce on any given day, week, month, or year based on consistently producing certain styles. This production has a value.
- What Is The Value Of Improved OE? If improvement of OE occurs, it should, and based upon all available data, does correlate to increased production of beam yarn. This beam yarn has a value based upon the purchase value of the case yarn and the resources to produce the beam yarn. Considering that we can improve OE through a larger workforce, better processes, and better machines, the limiting factors that put a ceiling on the usefulness of OE need to be considered.
- What Are The Limiting Factors? The amount of machines, the amount of space available, the beam set requirements for knitting, the beam yarn need for knitting, and all upstream productivity are the limiting factors that are being considered. If we can improve OE by 10%, will the Knitting Department be able to use this increased amount of beam yarn produced? Yes…and no. As long as the knitting machines are in demand of the styles of beam yarn we can produce, then there should be no diminishing returns from investing in improved OE. At the moment, there is plenty of demand, but the investment in providing that demand must be justified by the value of our marginal returns.
- What Can Be Done To Improve OE? By priority order, reduced physical and downtime waste, improved labor efficiency, increased labor, and improved machine efficiency will all improve OE. Keep in mind that adding another machine does not necessarily improve the OE as a whole unless the machine was high efficiency and high production. It would however increase our production values which indicates the OE is a fluid variable dependent upon the machines and styles we use.