015

Line
Layout
 Layout / Manpower
Prep Assembly
aTA
Hanger line
Cell design
OPTIMIZE Workstation Engineering
Production Material handling – Obtain & aside

Methodology
Workstation Engineering
MC Attachment & Fixture
Roller Folder & Guides
Template / Semi automation
Fully Automation
Objective:

To create the OPTIMIZE production

methodology base on the product type
and order volume to MAXIMIZE
efficiency performance
 OPTIMIZE Production Methodology
✓ Maximize production life cycle
✓ Less material handling
✓ Minimum material transportation
✓ High efficiency & Good quality
✓ Low skill requirement from operator
✓ The best management system
✓ Space optimization
 Layout / Manpower
Prep Assembly
aTA
Hanger line
Cell design
OPTIMIZE Workstation Engineering
Production Material handling – Obtain & aside

Methodology
Workstation Engineering
MC Attachment & Fixture
Roller Folder & Guides
Template / Semi automation
Fully Automation
HOW PRODUCTION CYCLE RELATE TO
EFFICIENCY PERFORMANCE

85.00%

75.00%

65.00%

55.00%

45.00%
DAY1 DAY4 DAY7 DAY10 DAY13 DAY16
EFFICIENCY IMPACT BY ORDER VOLUME (TTL SMV)
USE 20 MINUTES PRODUCT AS EXAMPLE, TO ACHIEVE HIGHEST
EFF BY BUILDING RIGHT PRODUCTION LIFE CYCLE AND TARGET MANPOWER
85%
81%
79%
80%
76%
73%
75%

70%

65%

60%
56%
55%
0-2000 2000-5000 5000-10000 10000-20000 40000-50000
Production 4.4 days 8.3 days 12.1 days 16.8 days 13.2 days
life cycle
PRODUCTION METHODOLOGY
Difference Prep Assembly Hangerline aTA Modular Flexcel Cell adidas Cell

Working Posture Sitting/Standing Sitting Standing Standing/ Sitting Sitting

Order Volume High Medium to High Medium to low Small Order Lot Medium to high
Multi Skilled
Low or none skill Low to Medium Multi skill/ High skill Multi skill Medium
Req’t

Layers block & Piece flow WIP

Work Flow Piece flow WIP control Piece Flow Bump back Bundle Flow by Cell
centralized control

Machine
High High Low Low Medium
utilization

Balancing Normal Auto controlled NO balance loss Normal Normal

Very High 85% to

Efficiency level High 80% above High 80% above Medium 60%~ High 70%~
100%
PREP ASSEMBLY Production floor layout
W&H PPA Sewing
AA Pressing
Final Assembly line 1 Pressing

Cutting PPA

Final Assembly line 2

PREP ASSEMBLY-PRINCIPLE
• Prep assembly – P1 Centralized for the whole factory in cutting room or warehouse, eg label assembly
• P2 Centralized for multiply lines before assembly for the same features, eg small part assembly
• Prep Assembly manpower and output should be managed centralized section base on P1/P2
• PPA Production schedule should be arranged according to assembly schedule
• Start managing the Quality and efficiency from the beginning.
• Component and small parts should be included to PPA before assembly no matter automation operations or not.
•
PREP ASSEMBLY- BENEFIT

• Minimize the Change over in assembly

• Better line balancing in assembly line
• High efficiency in PPA by repeating the same operation.
• Better quality controlling
• Enable automation and semi automation after centralization
• Maximize utilization of machinery
HANGER LINE LAYOUT
HANGER LINE- PRINCIPLE
• Always apply Prep Assembly before hanger line
• Line layout and line balance pre design base on the historical worker’s efficiency
• Apply middle and high volume orders to hanger line base on minimum production life cycle
• Design work station properly to ensure worker obtain and assign the panel easily or
sew the panel without taking it off.
• Combine short SMV operations into one station to• reduce manual handling
• Traffic line system install in each station for quality control.

Photo of combine two Photo of Traffic line system

operations together in hangerline
HANGER LINE-PRINCIPLE
1st priority:
• Order size: > 3days production lifecycle
• Jacket
• Flat layers after cutting
• Pants
• Training: direct & indirect
2nd priority:
• Combine short SMV operations
• 30% more space • Sweatshirt
• Design each workstation and panel hanging position • Polo
• Tight
 HANGER LINE- BENEFIT

• Management -Control WIP by computer, individual performance including quality output and efficiency. Machine
breakdown could be recorded in each station.

• Quick change over– Predesign the line layout and line balance by using historical worker’s skill and efficiency.
• Flexibility– Production line can be split and combined easily according to ttl SMV to achieve target production life
cycle and target efficiency

• Material transportation automatically from station to station and from line to line.
 HANGER LINE- BENEFIT

• Improved Quality – Avoid any shading issue as all the panels are loaded together and avoid any spot marks as
the handling is much better than an conventional line .

• Better Material Handling – there is no bundling and dispose time and even pickup time is comparatively very
less than the conventional line.
HANGER LINE- CAUTION

• Management skill set training before hanger line start

• Hanger line feeding speed will create pressure for new worker
• Enough Space to prepare for hanger line
• Role of line leader. Need to be more aggressive and quick in problem solving
HANGER LINE IN ADIDAS SUPPLIERS
2018 HANGERLINE ADOPTION 8 %-200 LINES

1000 2390
800 589
558
600 392
400
101 189
63 57 92 131 211
200 55 49 0 2
0 1 43 17 73
0 1 7 50 37 224
2 41
2 50 0 1 0 200
0 T…
0
0 T…
A…

Actual Target Total Lines

HANGER LINE IN ADIDAS SUPPLIERS
8% OF CONVENTIONAL LINE TO HANGER LINE IN 2018

15% 15%

8%

5%
3%

2016 2017 2018 2019 2020

aTA Sewing System layout

• Not just about sewing lines in a ‘U’ shape…

• Based on a clear set of principles
• Principles need to be followed to realise benefits
aTA Sewing System
Basic Polo
Op # Operation SMV In Mod
1 Hem 0.98
2 Attach Placket 0.15
3 Make placket 1.58 1.58 Questions ?:
4 Join Shoulders 0.38 0.38 • Which operations can be done most
5 T/S Shoulders 0.36 0.36 effectively in ‘preparation’ or ‘small
6 Set Collar 0.98 0.98 parts pre-assembly’?
7 Set Sleeves 0.78 0.78
• Which operations can be done most
8 T/S Sleeves 0.72 0.72
9 3-stripes 0.68 0.68 effectively within the assembly
10 Join Sides 0.57 0.57 module?
11 Hem Sleeves 0.25 0.25
12 Make Vents 1.13 1.13
13 B/Hole B/sew 0.60 0.60
14 B/Tack 0.58 0.58
15 Inspect 0.98 0.98
16 Press 0.58 0.58
Basic Polo 17 Pack 0.38 0.38
Total 11.68 10.55
aTA Sewing System
Basic Polo
Op # Operation SMV In Mod Operations that:
1 Hem 0.98 • Can be performed with a lower SMV when
2 Attach Placket 0.15 handled in bulk
3 Make placket 1.58 1.58 • Utilize auto/semi-auto machinery that should
4 Join Shoulders 0.38 0.38
be centralized for optimum utilization
5 T/S Shoulders 0.36 0.36
6 Set Collar 0.98 0.98
7 Set Sleeves 0.78 0.78
8 T/S Sleeves 0.72 0.72
9 3-stripes 0.68 0.68
10 Join Sides 0.57 0.57
11 Hem Sleeves 0.25 0.25
12 Make Vents 1.13 1.13
13 B/Hole B/sew 0.60 0.60
14 B/Tack 0.58 0.58
15 Inspect 0.98 0.98
16 Press 0.58 0.58
Basic Polo 17 Pack 0.38 0.38
Total 11.68 10.55
aTA Sewing System
Basic Polo
Based on total ‘in-module’ time and
Op # Operation SMV In Mod
1 Hem 0.98
number of operators planned, operator
2 Attach Placket 0.15 ‘multi-skilling’ needs can be identified:
3 Make placket 1.58 1.58
4 Join Shoulders 0.38 0.38 Example:
5 T/S Shoulders 0.36 0.36
6 Set Collar 0.98 0.98 10.55mins = 2.63 average/operator
7 Set Sleeves 0.78 0.78 4 operators
8 T/S Sleeves 0.72 0.72
9 3-stripes 0.68 0.68
10 Join Sides 0.57 0.57
11 Hem Sleeves 0.25 0.25 But for stand-up, single pc flow to work
12 Make Vents 1.13 1.13 with zero balance loss, operators must
13 B/Hole B/sew 0.60 0.60
14 B/Tack 0.58 0.58
be able to complete a minimum of 2-
15 Inspect 0.98 0.98 operations either side of hand-over
16 Press 0.58 0.58 point…
Basic Polo 17 Pack 0.38 0.38
Total 11.68 10.55
aTA Sewing System
Make Join T/S Set Set T/S
Placket Shoulders Shoulders Collar Sleeves Sleeves

Sides
Join
Sleeves
Hem
Btn Btn
Pack Press Inspection B/Tack
Sew Hole
aTA Sewing System Principle
Make Join T/S Set Set T/S
Placket Shoulders Shoulders Collar Sleeves Sleeves

Principles:
• U-shape configuration

Sides
• Minimize handling

Join
• 1-piece per operator
• Stand-up sewing
• ‘Bump-back’ garment hand-over

Sleeves
Hem
Btn Btn
Pack Press Inspection B/Tack
Sew Hole
aTA Sewing System Principles & Benefits
Make Join T/S Set Set T/S
Placket Shoulders Shoulders Collar Sleeves Sleeves

Principles:
• U-shape configuration U-layout supports:

Sides
• Minimize handling

Join
• Ease in communication
• 1-piece per operator • Passing of work for repairs etc.
• Stand-up sewing • Reduces movement when skipping
• ‘Bump-back’ garment hand-over machines to avoid downtime etc.

Sleeves
Hem
Btn Btn
Pack Press Inspection B/Tack
Sew Hole
aTA Sewing System Back panels delivered to 2nd Collar delivered to Sleeves delivered
operation 4th operation to 5th

Fronts only delivered to 1st Make Join T/S Set Set T/S
operation Placket Shoulders Shoulders Collar Sleeves Sleeves

Principles:
• U-shape configuration • ‘Line feeder’ delivers only the components

Sides
• Minimize handling required to the operation

Join
• 1-piece per operator • Delivered in ‘bundles’ – sew in singles
• Stand-up sewing • This minimizes operator handling
• ‘Bump-back’ garment hand-over • Removes non-value added elements from skilled

Sleeves
Hem
operator
• Increase needle time of skilled operators

Btn Btn
Pack Press Inspection B/Tack
Sew Hole
aTA Sewing System Back panels delivered to 2nd
operation
Collar delivered to
4th operation
Sleeves delivered
to 5th

Fronts only delivered to 1st Make Join T/S Set Set T/S
operation Placket Shoulders Shoulders Collar Sleeves Sleeves

Principles:
• U-shape configuration • Prevents WIP
•

Sides
• Minimize handling Essential to achieve 100% operator utilization/

Join
• 1-piece per operator ‘zero’ balance loss
• Stand-up sewing • Ensures all efforts are utilized towards output vs.
• ‘Bump-back’ garment hand-over WIP or waiting for work

Sleeves
•

Hem
Minimum stock effected by quality issues
• Enable fast style/colour change

Btn Btn
Pack Press Inspection B/Tack
Sew Hole
aTA Sewing System Back panels delivered to 2nd Collar delivered to Sleeves delivered
operation 4th operation to 5th

Fronts only delivered to 1st Make Join T/S Set Set T/S
operation Placket Shoulders Shoulders Collar Sleeves Sleeves

Principles: Essential to support:

• U-shape configuration • Single pc flow

Sides
Join
• Minimize handling • 100% utilization/ ‘zero’ balance loss
• 1-piece per operator
• Stand-up sewing

Sleeves
• ‘Bump-back’ garment hand-over

Hem
Btn Btn
Pack Press Inspection B/Tack
Sew Hole
aTA Sewing System Back panels delivered to 2nd
operation
Collar delivered to
4th operation
Sleeves delivered
to 5th

Fronts only delivered to 1st Make Join T/S Set Set T/S
operation Placket Shoulders Shoulders Collar Sleeves Sleeves

When final operator completes final operator they

walk back to next operator and ‘bumps back’ the next
Principles: operator, taking over the garment. The ‘bumped’

Sides
Join
• U-shape configuration operator does the same until the first operator
• Minimize handling begins a new garment.
• 1-piece per operator
Again, essential to support:

Sleeves
• Stand-up sewing

Hem
• ‘Bump-back’ garment hand-over • Single pc flow
• 100% operator utilization/’zero’ balance loss

Btn Btn
Pack Press Inspection B/Tack
Sew Hole
 aTA Sewing System
Make Join T/S Set Set T/S
Placket Shoulders Shoulders Collar Sleeves Sleeves

• Self balancing/self managing

• 100% operator utilization

Sides
•

Join
‘Zero’ balance loss
What are the advantages? • Effective on all order sizes
• Better ‘RFT’/faster rectification of mistakes
• ‘Short runs’ become longer…

Sleeves
Hem
• Increased operator engagement = LTO/Absenteeism
• Operator earnings…

Btn Btn
Pack Press Inspection B/Tack
Sew Hole
 FLEX CELL
• Developed and designed to deal with small quantities of multiple styles without disruption
for machine change or adjustment
• ‘Skill’ or ‘feature’ cells within a ‘Flexcell’ unit
• Established as the most effective solution for this business model

Style : MTS10BBW311

Style : MTF10BBM311
FLEX CELL
Characteristics of Orders
1. Small Lot Size
2. High Complexity
3. Short Lead Time
4. mi adidas order frequency (Daily)
5. Samples (Presell/SMS)

ALL of the above are reasons for Varieties of C/O and Efficiency loss

Need Flexibility
 FLEX CELL
INTRODUCTION
✓ Smaller Order Quantities can be made in a more Efficient Manner.

✓ Lines are set up with less , more multi skilled Operators,

who work on specific product groups and styles at all times.

✓ Lines are split into “Cells” that produce specific parts of

the Product.

✓ Operator skills are designed around the Cell they are

assigned too , and movement is minimal within the cell only.

✓ All Machines needed to produce any of the specified styles to the relevant line are
already set up and in place , thus the minimal C/O time.

✓ Continuity of style and working within the Cell set up gives higher Efficiency and
Lower WFT.
FLEX CELL
STRATEGIES & GUIDELINES

Strategies:
✓ Specific Cell Design
✓ Multi-Skill Workers
✓ Zero Changeover

Guidelines:
✓ Product Type is the Same
✓ Fabrics is the Same
✓ Features (80% the Same)
✓ Machines (80% the Same)
✓ SMV (+/- 10% Variance)
FLEX CELL
CELL PREPARATIONS

Multi skilling of operators Availabilities at station

FLEX CELL
CELL DESIGN : JACKETS

Normal Line : 28-30 sewers

1:1 ratio sewer vs machine

Small Cell Line: 8-10 sewers

1:2-3 ratio sewer vs. machines
FLEX CELL
CELL DESIGN : T-SHIRTS
FLEX CELL
CELL DESIGN : PANTS /SHORTS
ADIDAS CELL SET UP
ADIDAS CELL FOR T-SHIRT

Priority product
• T-Shirt
10 9
• Shorts
8 7 4 3
6 2 1
• Tights
12 11
• Polo
5
• Sweatshirt

No. of operator:- 12-24

• <35 SMV
Line balancing > than 85%
Facile pick up and dispose
Single pc flow
ADIDAS CELL FOR SWEATSHIRT

Hood Join Hood

Front Panel

Join Front & Back Panel Join Cuff rib, Bartack,

Principal:
➢ Follow first in first out
➢ Good Line balance
➢ Follow max 5 pcs WIP
ADIDAS STANDARD CELL TARGET 1
0 9
32% OF CONVENTIONAL LINE TO SMALL CELL IN 2018 1 1
8 7
6
4 3
2 1
2 1
5

65%

50%

32%

2% 3%

2016 2017 2018 2019 2020

ADIDAS CELL COVERAGE – 1
0 9
2018 CONVERT 32%- 766 LINES 1 1
2 1
8 7
6
4 3
2 1
5

1000 2390
800 589
558 865
600
392 766
400 218
142 101 220 189
141 170 92 211
200 50 216 131
40 38
27 17 73
0 20 16 50 37
27 9 73
8 50 22
10 64 T…
20 T…
A…

Actual Target Total Lines