10. Stage 3 – Marker Making
• Cutting Room Constraints
• Cut Order Plan
▫ 2 Pattern Sets, 6 Plys
• Layout Fabric
• Measure Fabric Width
• Decide on Layout
• Marker Making
• Edge Allowances
▫ Block cutting
• Marker Efficiency - 65%
11. Stage 4 – Cutting
• Spreading
• Cutting
▫ Circular Knife
• Preparation for Sewing
▫ Progressive Bundle System
▫ 12 Bundles, 6 Pieces
▫ Modular Production System
▫ 12 Bundles, 12 Pieces
• Challenges
▫ Pitch - deep Notches
▫ All left sides, no right sides
12. Stage 5 – Production
• Overview
• Complex construction and small team size
• No Line Supervisor
• All team members were sewing operators and checked for quality
• Progressive Bundle System
▫ Multiple operators, Single Operations
▫ Bottlenecks
▫ 6 hours to complete
▫ Fusing should have occurred in preparation for sewing
• Modular Production System
▫ Multiple operators, Multiple functions
▫ Shared sewing operations when bottlenecks occurred
▫ 2 hours to complete
13. Stage 6 - Quality Control
• Evaluated 5 baby shoes
• 2 preemie
• 3 newborn
• Quality Measured
• Standards in Tech Pak
• 5 POM
• All within tolerance except 2 shoes
• Preemie
• Across Top of Toes
• Too Small (2 1/2” +/- 1/2”)
• 1 3/4”, 1 7/8”
13
14. Stage 7 - Packaging & Delivery
• Packaging
• Organza Drawstring Bags
• Shredded Filler
• Die-cut Tag
• Delivery
• Pomona Valley Hospital
• NICU
