This document outlines efficiency improvements made through the ME methodology at a Walmart plant. Key metrics like efficiency, production, and people ratio were measured against targets. Process flows, layouts, and balancing were analyzed. Methods were improved for several processes, increasing capacities and reducing cycle times. As a result, production increased by 200 pieces and efficiency improved by 17%. Line balancing efficiency also increased by 12%.

1. EFFICIENCY IMPROVEMENT
THROUGH
ME METHODOLOGY
Style: FG36T380
Buyer: Walmart
Line: 01
Unit: Unit-2

2. DEFINE

3. DEFINE
Training & Development
• Training with Line chief, Supervisor& Line IE about ME Methodology .
• After that completed simulation exercise

4. MEASURE

5. MEASURE…CONTINUE
Category Current Target
Efficiency 76% 91%
Production 1000 pcs 1200 pcs
People Ratio 77:5:18 79:5:16
SMV 24.3 23.3
Line Balancing 74% 86%

6. Category Attachment
Base data
Current OB
Process flow chart
People Ratio
Capacity Graph
Lay out
Base data
Current OB
People Ratio
Capacity Graph
Process flow chart
MEASURE…CONTINUE
Lay out

7. ANALYSIS

8. IMPROVE
Benefits:
 Line 1 & 2 both line production increase
 200 pcs production increase
 17% efficiency improved
Benefits:
 12% balancing efficiency improved
1. Method analysis
2. Line balancing analysis

9. LINE BALANCING
Before
After

10. IMPLEMENT
Line Balancing
Category Before After
Line Balancing 74% 86%

11. METHOD IMPROVEMENT…….
Cuff Turn
Before
After

12. METHOD IMPROVEMENT…….
Cuff Press
Before After

13. METHOD IMPROVEMENT…
Cuff Attach Category Before Method
Improve
After Method
Improve
Capacity 48 pcs 59 pcs
Cycle time 62 sec 51 sec
Result 110 pcs/day increase

14. METHOD IMPROVEMENT…
Box & cross stitch
Category Before
Method
Improve
After Method
Improve
Capacity 90 pcs 125 pcs
Cycle time 33 sec 24 sec
Result 350 pcs/day increase

15. METHOD IMPROVEMENT…
Att. sleeve tap 2 gamble
Category Before
Method
Improve
After
Method
Improve
Capacity 111 pcs 130 pcs
Cycle time 27 sec 23 sec
Result 190 pcs/day increase

16. METHOD IMPROVEMENT…….
Sticker Remove

17. METHOD IMPROVEMENT

18. ACHIEVEMENT
Production