Factory Analysis

VAUDE VIETNAM CO. LTD.

04-07/03/2019
Line No 3 & 4

2
RESULT OF INVESTIGATION (ACTUAL)

A CONDITION OF SEWING LINE EXISTING

DAILY WORK HOURS(sec.) 36000

STANDARD TOTAL PROCESS TIME (sec.) 4180.4

NUMBER OF OPERATOR 46

BOTTLENECK PROCESSING TIME (sec.) 123.7

ALLOWANCE RATE(%) 22.4

ACTUAL ORGANIZATION EFFICIENCY(%) 60

PLAN DAILY QUANTITY(pcs.) 237.7

PRODUCTIVITY/OP 5.2

3
Routine performance
Touch the next material

Dispose Pick up
Routine
performance

Machine SEW Machine

Stops Starts

Routine performance = Net processing time

Irregular performance

Open bundle Transport

Dispose Move
Pick up
Record Routine
performance
Wait

SEW
Correct Talk

Irregular performance = Allowance

INVESTIGATION RESULT:
ALLOWANCE RATE 22.4 %

4.5 %
70.0 %
4.0 %
60.0 %
3.5 %

50.0 % 3.0 %

40.0 % 2.5 %

2.0 %
30.0 %
1.5 %
20.0 %
1.0 %

10.0 % 0.5 %

0.0 % 0.0 %

Your factory Japan Average *Average of investigation of 333 factory by JUKI

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Đường Chuyền thực tế
Lắp Ráp

Thân Lưới Quai

Sau Đệm thân Hông
sau

Đầu
Đầu
ra
vào

Table
QC
Đường Chuyền thực tế
Top pkt Top pkt
outer inner
JUKI Consultation- Ideas

Actual motion: Right hand pick-up

Fabric

Fabric
Fabric
Left hand pick-up Fabric
Left hand Dispose

• Activity:
• Rotate the workstation 180
degree
JUKI Consultation- Ideas

Pickup Right Hand Existing Pickup Left hand Kaizen

(17s) (13s)

10
PROCESS DISTRIBUTION – EXISTING
Line Balancing Efficiency 60%
150

U.C.L=8
Over utilized
Process Time (sec.)
100

B.P.T=74
L.C.L=61
50

Under utilized
0

Process Name (Operator No.)

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Decision:
Process Name Proces Video State Action
s Time

Run stitch back lining red Velcro 7 Sec Under utilized

Reduce
Run stitch Hip belt stabilizers straps 32 Sec 1 Op 1 Op.
Attach hip belt net with hip belt outer 47 Sec Under utilized

1 Op.
SHARE
Sew front & Back 173.4 Over utilized Allocate
Sec Reduce
2 Op. Op
Attach mouth to Backpack 74 Sec

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PROCESS DISTRIBUTION – KAIZEN
150

Line Balance Efficiency 60 %

U.C.L=8
100
Process Time (sec.)

B.P.T=7
L.C.L=61
50
0

Process Name (Operator No.)

100
80

U.C.L=8
Process Time (sec.)

B.P.T=7
60

L.C.L=6
40

Line Balance Efficiency 78.1 %

20
0

13
Process Name (Operator No.)
RESULT COMPERISION

A CONDITION OF SEWING LINE EXISTING KAIZEN Effect

DAILY WORK HOURS(sec.) 36000 36000

STANDARD TOTAL PROCESS TIME (sec.) 4180.4 4180.4

NUMBER OF OPERATOR 46 46

BOTTLENECK PROCESSING TIME (sec.) 123.7 95

ALLOWANCE RATE(%) 22.4 22.4 Increased

ACTUAL ORGANIZATION EFFICIENCY(%) 60 78.1
Productivity
28.8 %
PLAN DAILY QUANTITY(pcs.) 237.7 309 71

PRODUCTIVITY/OP 5.2 6.7 1.5

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Motion Improvement

Your Factory(Trim Thread) Minimum Motion

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Motion Improvement

Your Factory(Pickup) Simultaneous Motion

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Motion Improvement

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KAIZEN

Scissor Position Use magnet to keep scissor

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Kaizen Table Kaizen Table

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Visual Management

Your Factory Other Factory

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AMS Machine

Your Factory Other Factory

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 Sewing performance optimum for stepped sections
Intermediate presser height and Needle thread tension (Active-tension) can be set to
different material thickness and height easily from the operation panel.

Improve irregular tension on the

No damage on sewing products! seams!

＜VIDEO 4.＞ ＜VIDEO 5.＞

Active-tension
（Our original technology）
OJT Program & Set up Model Line Innovation With our Best Global Support

We implemented our idea 0n 20th Feb

Theory Section

Practical Section Consequences After OJT

THANK YOU