This document outlines Greentex Indonesia's efforts to reduce potential losses from changeovers and production ramp up times through their quick changeover (QCO) process. It shows that implementing QCO activities like preparing layouts, checklists, and changeover records helped reduce average first output time from 3.44 hours in 2012 to 45 minutes in 2014. Ramp up time also decreased from an average of 79.8 hours in 2012 to a target of 30 hours in 2014 for repeat styles. This led to projected annual potential losses dropping from over Rp33 billion in 2012 to a target of Rp11 billion in 2014. Visual tools were also created to track changeover information for different departments. The document demonstrates how focusing on Q

1. QUICK CHANGE OVER
PROCESS_LEAN DEPT
PT. GREENTEX INDONESIA
UTAMA

2. ONTARGET
CHANGEOVER/LAYOUT PROGRESS

3. 2012

4. 2013

5. ONTARGET
CHANGEOVER LOSS SCHEME 2012

6. ONTARGET

7. Potential Changeover Loss 2012
• Huge Potential Loss From 1st Ouput
– Average first output GREENTEX = 3.44 Hours
– Average Changeover per Line = 1.3 Times
– Average Output GREENTEX per Hours = 105 pcs
– Total Line = 16 Line
– Average CM 2012 = $ 1.56
– Loss pcs because NO OUTPUT for 3.44 Hours (3.44 Hours x 105 pcs)
= 361 pcs
– Total Loss per year from 1st output :
• = 361 pcs x 1.3 times C/O x 16 Line x 12 Months x $ 1.56
• = $ 140,565x Rp 12,000
•= Rp 1,686,780,000

8. Potential Changeover Loss 2012
• Huge Potential Loss from Ramp Up (Average Ramp Up = 79.8 hrs = 10 Days)
 TOTAL PRODUCTION 1 DAY = 105 pcs X 8Hrs = 840 pcs
 Production rate 1st day 25% from normal target = 210 pcs ~ Loss Pcs 1st day = 840-210 = 630
 Production rate 2nd day 35% from normal target = 294 pcs ~ Loss Pcs 2nd day = 840-294 = 546
 Production rate 3rd day 45% from normal target = 378pcs ~ Loss Pcs 3rd day = 840-378 = 462
 Production rate 4th day 55% from normal target = 462pcs ~ Loss Pcs 4th day = 840-462 = 378
 Production rate 5th day 60% from normal target = 504 pcs ~ Loss Pcs 5th day = 840-504 = 336
 Production rate 6th day 65% from normal target = 546 pcs ~ Loss Pcs 6th day = 840-546 = 294
 Production rate 7th day 75% from normal target = 630 pcs ~ Loss Pcs 7th day = 840-630 = 210
 Production rate 8th day 85% from normal target = 714 pcs ~ Loss Pcs 8th day = 840-714 = 126
 Production rate 9th day 90% from normal target = 756 pcs ~ Loss Pcs 9th day = 840-756 = 84
 Total Loss pcs for Ramp Up = 630+546+462+378+336+294+210+126+84 = 3,066 pcs
 Total Loss per year from Ramp Up :
• = 1680 pcs x 1.3 times C/O x 16Line x 12Months x $ 1.56
• = $ 654,152 x Rp 12,000
• = Rp 7,849,824,000

9. POTENTIAL LOSS BECAUSE OF
CHANGEOVER/ LAYOUT =
1. 1ST OUTPUT = Rp 3,493,324,800
2. RAMP UP = Rp 29,669,068,800
3. TOTAL = Rp 33,162,393,600

10. ONTARGET
CHANGEOVER LOSS SCHEME 2013

11. ONTARGET

12. Potential Changeover Loss 2013
• Huge Potential Loss From 1st Ouput
– Average first output GREENTEX = 1.1 Hours
– Average Changeover per Line = 2 Times
– Average Output GREENTEX per Hours = 120 pcs
– Total Line = 16 Line
– Average CM 2013 = $ 2.55
– Loss pcs because NO OUTPUT for 1.1 Hours (1.1 Hours x 120 pcs)
= 132 pcs
– Total Loss per year from 1st output :
• = 132 pcs x 2times C/O x 16 Line x 12 Months x $ 2.55
• = $ 129,254 x Rp 12,000
•= Rp. 1,551,052,800

13. Potential Changeover Loss 2013
• Huge Potential Loss from Ramp Up (Average Ramp Up = 34.6 hrs = 4.4 Days)
 TOTAL PRODUCTION 1 DAY = 120 pcs X 8Hrs = 960 pcs
 Production rate 1st day 35% from normal target = 336 pcs ~ Loss Pcs 1st day = 960-336 = 624
 Production rate 2nd day 55% from normal target = 528 pcs ~ Loss Pcs 2nd day = 960-528 = 432
 Production rate 3rd day 75% from normal target = 720pcs ~ Loss Pcs 3rd day = 960-720 = 240
 Production rate 4th day 90% from normal target = 864 pcs ~ Loss Pcs 4th day = 960-864 = 96
 Total Loss pcs for Ramp Up = 624+432+240+96 = 1,392 pcs
 Total Loss per year from Ramp Up :
• = 1392 pcs x 2times C/O x 16Line x 12Months x $ 2,55
• = $ 1,363,046 x Rp 12,000
• = Rp 16,356,552,000

14. POTENTIAL LOSS BECAUSE OF
CHANGEOVER/ LAYOUT =
1. 1ST OUTPUT = Rp 1,551,052,800
2. RAMP UP = Rp 16,356,552,000
3. TOTAL = Rp 17,907,604,800

15. ONTARGET

16. TEAMLEADER
(MR.CSRYU/FACTMGR)
MS.LEE
(SEWING MGR)
IDA/SYARIF/TONI/KOMAR
(SEWING CHIEF)
SEWING SPV
ACHMAD
(CUTTING CHIEF)
TAMI
(LOADING SPV)
RIRIS
(QC CHIEF)
BUDI
(MECHANIC SPV)
NETI/YATI
(FCA)
SEWING ADM
Teach & lead sewing process w. high
difficulties together w/ Chief
1. Make layout
2. Teach & lead sewing process
1. Meeting w/ all operator on new style
2. Operator plan position
3. Calculate machine requirement based on layout
4. 1st output ,meeting
1. Reject replacement on cutting panel, reject mati
2. Prepare real fabric for machine setting
1. Update changeover board
2. Prepare complete material to load to sewing
1. Make sure inline QC/QA standby during changeover
2. Make sure inline make mock up on critical process
3. Held 1st output meeting
1. Prepare machine based on layout
2. All machine have can be used directly
3. Instruct mechanic helper & mechanic standby during layout
1. Set critical to quality point
1. Prepare loading accs & thread
2. Supply panel for 1st process
3. Collecting unused thread & accs
1. Inform changeover
schedule to TAMI,
SEWING CHIEF,
MECHANIC
2. Held meeting
before layout
3. Evaluate QCO
procedure
effectiveness

17. FACTORY
MGR
Preparing
layout
SEWING
CHIEF
Update
changeover
visual board
& ACCS
LOADING
SPV & ACCS
Preparing
complete
panel/set
CUTTING
CHIEF
Complete all
reject
replacement
Preparing real
fabric to
mechanic
MECHANIC
SPV
Prepare
machine need
based on
layout
Machine
setting before
layout
SEWING
SPV
Prepare
operators
planning
Finished all
reject
garment
Meeting w/
all operators
INLINE
QC/QA/FCA
Standby in
sewing line
during
changeover
Make sure every
process OK
before go to
next process
Teach & lead
sewing
process
SEWING
MGR
Standby during
changeover for
machine
arrangement
First Output
Meeting &
Comment
Mock up for
critical point
based on FCA &
1st output
FCA
Evaluate
CHANGEOVER/LAYOUT
PERFORMANCE :
1. CHANGEOVER TIME
2. 1ST OUTPUT
3. RAMP UP
Inform
changeover
schedule &
MEETING
BEFORE
LAYOUT

18. Quick Changeover Activities
Focus On
Preparation

19. Quick Changeover Form
Line Balancing & Layout
QCO Checklist
QC File
First Output Comment
Changeover Record Form

20. QCO/LAYOUT TARGET
• CHANGEOVER TIME =
– REPEAT STYLE = 2 HRS
– NEW STYLE = 3 HRS
• FIRST OUTPUT
– REPEAT STYLE = 30 MIN
– NEW STYLE = 1 HRS
• RAMP UP
– REPEAT STYLE = 30 HRS
– NEW STYLE = 60 HRS

21. ONTARGET
CHANGEOVER TARGET 2014

22. ONTARGET

23. • Huge Potential Loss From 1st Ouput
– Average first output GREENTEX = 45 Minute = 0.75 Hours
– Average Changeover per Line = 2 Times
– Average Output GREENTEX per Hours = 120 pcs
– Total Line = 16 Line
– Average CM 2013 = $ 2.55
– Loss pcs because NO OUTPUT for 0.5 Hours (0.75 Hours x 120 pcs)
= 90 pcs
– Total Loss per year from 1st output :
• = 90 pcs x 2times C/O x 16 Line x 12 Months x $ 2.55
• = $ 88,128 x Rp 12,000
•= Rp 1,057,536,000
Target Potential Changeover Loss 2014

24. Target Potential Changeover Loss 2014
• Huge Potential Loss from Ramp Up (Average Ramp Up = 30 hrs = 3.75 Days)
 TOTAL PRODUCTION 1 DAY = 120 pcs X 8Hrs = 960 pcs
 Production rate 1st day 45% from normal target = 432 pcs ~ Loss Pcs 1st day = 960-432 = 528
 Production rate 2nd day 75% from normal target = 720 pcs ~ Loss Pcs 2nd day = 960-720 = 240
 Production rate 3rd day 90% from normal target = 864 pcs ~ Loss Pcs 3rd day = 960-864 = 96
 Total Loss pcs for Ramp Up = 528+240+96 = 864 pcs
 Total Loss per year from Ramp Up :
• = 864 pcs x 2times C/O x 16Line x 12Months x $ 2,55
• = $ 846,029 x Rp 12,000
• = Rp 10,152,345,600

25. TARGET POTENTIAL LOSS BECAUSE
OF CHANGEOVER/ LAYOUT 2014 =
1. 1ST OUTPUT = Rp 1,057,536,000
2. RAMP UP = Rp 10,152,345,600
3. TOTAL = Rp 11,209,881,600

26. ONTARGET

27. ONTARGET
PROCESS PIC VISUAL
Update visual changeover
board
LOADING SPV,
because she is
the one who
know actual
sewing
schedule
Update changeover
information (style, date
and layout) IN MECHANIC
LAYOUT PLAN
MECHANIC ADM
Update changover
information (style, date, &
trimcard/accessories
status) in ACCESSORIES
ROOM to prepare all
accessories need
ACCESSORIES
ADM
Update CHANGEOVER
TARGET (CHANGEOVER
TIME, 1ST OUTPUT and
RAMP UP) in sewing line as
REMINDER
SEWING CHIEF
Trimcard Label Drawcord Logo Piping
Neck
tape
2 24-Feb
5 25-Feb
6 26-Feb
OK
NOT OK
Sewing Line
Accessories Status
Layout date
STYLE
CHANGEOVER
TIME
FIRST
OUTPUT
RAMP UP
REPEAT 2HOURS 30MIN 30HOURS ~3.75DAYS
CHANGEOVER TARGET