SOP

Contents
1. Overview.................................................................................................................................2
2. Working Arrangement............................................................................................................4
2.1 Att elastic to top wing, Att btm wing elastic overlay (1ZZ)................................................4
2.2 Make CF (Join cf btm w/ stabilizer, T/S btm of c/frt, Join top opf c/frt & bagout,
Runstitch c/frt sides)..............................................................................................................6
2.3 Att btm wing elastic overlay..................................................................................................8
2.4 Tack open hook & eye to gmt x 2 + Att hook & eye tapes w label.................................10
2.5 Make strap 1 Stitchn hook/slide & ring..............................................................................12
2.6 Cut Wing Lace (Manual)......................................................................................................14
3. Optimizing Processes..........................................................................................................16
3.1 Att elastic to top wing+ T/S top wing elastic.....................................................................16
3.2 Make CF (Join cf btm w/ stabilizer, T/S btm of c/frt, Join top opf c/frt & bagout,
Runstitch c/frt sides)............................................................................................................19
3.3 Att btm wing elastic overlay................................................................................................21
3.4 Tack open hook & eye to gmt x 2 and Att hook & eye tapes w label.............................22
3.5 Cut Wing Lace (Manual)......................................................................................................26
1. Overview
a. Purpose
The purposes of this project are to standardize the working arrangement of the
process of the bra making process and optimize the operating procedure by
eliminating the ineffective motion using the left-hand and right-hand motion
method to reduce the cycle time of the processes.
b. Scope
The scope of this project is only limited to the processes of wing area, centre
front, strap and hook and eye.
c. Prerequisites
The information required before proceeding with the procedure is Yamazumi
Chart and GSD.
d. Responsibilities
The project made by James William and under supervision by Rizka. Contact
information:
a. James William Silalahi
Email : jameswilliamsilalahi@student.undip.ac.id
Phone : +6285277497135
b. Rizka Septy Wulan
Email : rizkas@masholdings.com
Phone : +6281390000928
e. Procedure
Steps required to perform this procedure

1) Optimizing Working Procedure
Research to study the timing of methods done by conducting an experiment
by a respondent. Furthermore, data retrieval is done by analysing video.
Through video playback in slow motion can be analysed the movement
elements that occur and the time of each element of the movement. Some of
the combination movements that change very quickly as a movement. Data
collection was carried out on November - December 2018 at PT MAS Sumbiri
with respondents.
2) Working Arrangement
Research to study the better placement of the materials and tools with regard
to ergonomic aspects. Data collection including measurement of the working
area of the bra making processes.
2. Working Arrangement
2.1 Att elastic to top wing, Att btm wing elastic overlay (1ZZ)
Current State
Analysis:
Name of the Process:

Future State
Analysis:
Working Arrangement
2.2 Make CF (Join cf btm w/ stabilizer, T/S btm of c/frt, Join top opf c/frt &
bagout, Runstitch c/frt sides)
Current State
Analysis:

Future State
Analysis:
Working Arrangement
2.3 Att btm wing elastic overlay
Current State
Analysis:

Future State
Analysis:
Working Arrangement
2.4 Tack open hook & eye to gmt x 2 + Att hook & eye tapes w label
Current State
Analysis:

Future State
Analysis:
Working Arrangement
2.5 Make strap 1 Stitchn hook/slide & ring
Current State
Analysis:

Future State
Analysis:
Working Arrangement
2.6 Cut Wing Lace (Manual)
Current State
Analysis:
Working arrangement: The tools (pattern, ballast and cutter) are not arranged
well in the table work. The impact of this state is waste movement and both hands
were not used.
Kaizen improvement: By simplifying pattern and ballast using metal piece and
small magnets into one piece of tools. The benefit of this kaizen is to minimize
picking time of the tools and increase productivity of the cutting lace process.

Future State
Analysis:
Working arrangement: The tools (pattern, ballast and cutter) were arranged well
in the table work. The yellow tape was used to standardize the position of the
tools. The impact of this future state is both hands are used and no additional
movement waste occurs
Kaizen improvement: By simplifying pattern and ballast using metal piece and
small magnets into one piece of tools. The benefit of this kaizen is to minimize
picking time of the tools and increase productivity of the cutting lace process. See
px for the time saving efficiency
3. Optimizing Processes
3.1 Att elastic to top wing+ T/S top wing elastic
[CURRENT STATE] The left-hand and right-hand motion
Process: Att elastic to top wing + T/S top wing elastic
Style: QP2013-Small/10/B
Made by: James William Silalahi
Date of Mapping: 20 December 2018
Left Hand Time (s) Symbols Time (s) Right Hand
R, G,
Reach, grasp and move the panel 2.1 UD 2.1 Idle
M
Positioning the panel* 0.7 P UD 0.7 Positioning the panel*
Move the panel below the foot 1.2 M M 1.2 Move the panel below the foot
Stitch 4.84 U U 4.84 Stitch
R, G,
Reach, grasp and move the panel 3 UD 3 Idle
M
The process repeats for 2 more pairs
Reach, grasp and move the
Idle 3.33 UD R, G, M 3.33
trimmer
Hold the elastics 0.5 H U, R 0.5 Cut and Release
R, G, Reach, grasp and move the
Reach, grasp and move the panel** 1.04 R, G, M 1.04
M trimmer**
Positioning the panel 1.73 P P 1.73 Positioning the panel
Hold the panel 1.7 H R, G, M 1.7
trimmer
Hold the panel 0.5 H U 0.5 Cut
R, G,
Reach, grasp and move the panel 0.87 H 0.87 Hold the trimmer
M
Fold the panel 3.1 P P 3.1 Fold the panel
Hold the panel 1.63 H U 1.63 Cut per pairs
Move and release the panel 2.14 M, R M, R 2.14 Move and release the panel
TOTAL 184.14 184.14
TOTAL (minute) 3.069

SMV 1.023 0.6304
EFF 61.6%
Note
The operator flips the panel. This ineffective motion can be
*
eliminated by changing the pinch method for time saving
** (not giving
the operator does excessive work, she changes the position of the
additional time
tool again because there is no standardization of the location of
saving)
equipment placement
Name of the Process: Att elastic to top wing, Att btm wing elastic overlay (1ZZ)
[FUTURE STATE] The left-hand and right-hand motion
Process: Att elastic to top wing + T/S top wing elastic
Style: QP2013-Small/10/B
Date of Mapping: 20 December 2018
R, G,
Reach, grasp and move the panel 2.1 UD 2.1 Idle
M
R, G,
Reach, grasp and move the panel 3 UD 3 Idle
M
Idle 3.33 UD R, G, M 3.33
trimmer
Hold the elastics 0.5 H U, R 0.5 Cut and Release
R, G, Reach, grasp and move the
Reach, grasp and move the panel 1.04 R, G, M 1.04
M trimmer
Positioning the panel 1.73 P P 1.73 Positioning the panel
Hold the panel 1.7 H R, G, M 1.7
trimmer
Hold the panel 0.5 H U 0.5 Cut
R, G,
Reach, grasp and move the panel 0.87 H 0.87 Hold the trimmer
M
Fold the panel 3.1 P P 3.1 Fold the panel
Hold the panel 1.63 H U 1.63 Cut per pairs
Move and release the panel 2.14 M, R M, R 2.14 Move and release the panel
TOTAL 182.04 182.04

1.01133 0.630
SMV
3 4
EFF 62.3%
3.2 Make CF (Join cf btm w/ stabilizer, T/S btm of c/frt, Join top opf c/frt &
bagout, Runstitch c/frt sides)
Process: Join c/frt st btm w/stabi
Style: QP2013S/15/B
Date: 20 December 2018
Left Hand Waktu (s) Symbols Waktu (s) Right Hand
Reach, grasp, move and release Reach, grasp, move and
2 RGMRi RGMRi 2
the CF release the CF
Reach, grasp, move and
Idle 3.7 UD RGMRi 3.7
release the Stabilizer
Positing (Aligning CF
Idle 2.96 UD P 2.96
and Stabilizer)
Put under m/c foot 4.2 P P 4.2 Put under m/c foot
Stitch 6 U U 6 Stitch
Reach, grasp, move and release Reach, grasp, move and
3.37 RGMRi RGMRi 3.37
the CF release the CF
Reach, grasp, move and
Idle 4.67 UD RGMRi 4.67
release the Stabilizer
Positing (Aligning CF
Idle 6.2 UD P 6.2
and Stabilizer)
The process repeats up to 3 times
Reach, grasp and move
Idle 1.77 1.77
the scissors
Hold 5.73 H U 5.73 Cut chain
Move and release the
Move and release the bundle 3.07 MRi MRi 3.07
bundle
TOTAL 119.07 119.07

SMV 0.3969 0.176
EFF 44%
Not
e
* Can be used by both hands
The scissor is not in the best work zone. Change the position of the scissor to save
**
time
Process: Join c/frt st btm w/stabi
Style: QP2013S/15/B
Time Time
Left Hand Symbol Right Hand
(s) (s)
Reach, grasp, move and RGM Reach, grasp, move and
3.7 UD 3.7
release the CF Ri release the Stabilizer
Positing (Aligning CF and
Idle 2.96 UD P 2.96
Stabilizer)
Stitch 6 U U 6 Stitch
Reach, grasp, move and RGM Reach, grasp, move and
4.67 UD 4.67
release the CF Ri release the Stabilizer
Positing (Aligning CF and
Idle 6.2 UD P 6.2
Stabilizer)
Idle 1.77 1.77
scissors
Hold 5.73 H U 5.73 Cut chain
Move and release the M
3.07 MRi 3.07 Move and release the bundle
bundle Ri
TOTAL 105.645 105.645
1.7607
Total (minute)
5
0.3521
SMV 0.176
5
EFF 50%
Process: T/S btm of c/frt
Style: QP2013S/15/B
Time Time
Left Hand Symbols Right Hand
(s) (s)
Move the part 0.74 M UD 0.74 Idle
Unfold the part 0.53 A A 0.53 Unfold the part
Move the part under m/c foot 1.9 P P 1.9 Move the part under m/c foot
Sew 2.33 U U 2.33 Sew
Reach, grasp and move the RG
1.17 UD 1.17 Idle
part M
Unfold the part 1.2 A A 1.2 Unfold the part
Move the part under m/c foot 1.37 P P 1.37 Move the part under m/c foot
Sew 3 U U 3 Sew
RG Reach, grasp and move the
Hold the part 1.3 H 1.3
M scissor
Hold the part 0.43 H U 0.43 Use the scissor
Move the part 1.86 M MRi 1.86 Move and release the scissor
TOTAL 34.19 34.19

SMV 0.113967
EFF 141.4%
Not
e
* No action required
Process: Join top of c/frt &bagout
Style: QP2013S/15/B
Time Time
(s) (s)
P
Adjust the parts 3.2 PP 3.2 Adjust the parts
P
Sew 1.53 U U 1.53 Sew
P
Adjust the parts 6.13 PP 6.13 Adjust the parts
P
Sew 2 U U 2 Sew
The process repeats for 3 more units
RG
Hold the part 1.64 H 1.64 Reach, grasp and move the scissor
M
Hold the part 0.33 H U 0.33 Use scissor to cut the chain
Hold the part 6.1 H U 6.1 Use scissor to dechain
Hold the part 0.5 H MRi 0.5 Move and release the scissor
U RG
Idle 1.37 1.37 Reach, grasp and move the part
D M
P
Bagout 3.56 PP 3.56 Bagout
P
U RG
Idle 1.37 1.37 Reach, grasp and move the part
D M
P
Bagout 3.56 PP 3.56 Bagout
P
The process repeats for 3 more units
TOTAL 72.145 72.145
1.20241
TOTAL (minute)
7
0.24048 0.2037
SMV
3
EFF 84.7%
Not
e
* No action required
3.3 Att btm wing elastic overlay
Process: Att btm wing elas-overlay
Style: QP2013S/15/B
Time Symbol Time
Left Hand Right Hand
(s) s (s)
1.53 H 1.53 Hold
panel M
Put the panel under m/c foot 2.07 P P 2.07 Put the panel under m/c foot
2.84 H 2.84 Hold
panel M
Put the panel under m/c foot 1.7 P P 1.7 Put the panel under m/c foot
Hold 38.2 H U 38.2 Cut the chain
TOTAL 166 166
2.76666
Total (minute)
7
SMV 0.461111
EFF 106%
Note
* No optimization can be done
3.4 Tack open hook & eye to gmt x 2 and Att hook & eye tapes w label
Process: 1Z-Att hook & eye tapes w label, Tack open hook & eye to gmt x 2
Style: QP2013S/15/B
Time Time
(s) (s)
Idle* 0.97 UD 0.97
M wing*
Reach, grasp, move and RGM
1.03 UD 1.03 Idle*
release the eye* Ri
Idle 0.47 UD 0.47
M label
Combine label and eye 4.53 A A 4.53 Combine label and eye
Idle 2.33 UD 2.33
M wing
Hold and close eye 2.04 A A 2.04 Hold and close eye
Rotate the panel** 1.03 P P 1.03 Rotate the panel**
Put under m/c foot 2 M M 2 Put under m/c foot
Rotate the panel 1.5 P P 1.5 Rotate the panel
Move and release the panel 0.43 MRi UD 0.43 Idle
The process repeats for 5 more parts
Idle* 1 UD 1
M wing*
Positioning*, *** 0.67 P P 0.67 Positioning*, ***
2.8 UD 2.8 Idle
release the hook Ri
Idle 0.43 P P 0.43 Positioning**
Place hook to wing 1.73 A A 1.73 Place hook to wing
Put under m/c foot 3 P P 3 Put under m/c foot
Time Time
(s) (s)
Reach, Grasp and Move the RG Reach, Grasp and Move the
1.26 RGM 1.26
trimmer M trimmer
Hold the panel 18.24 H U 18.24 Use the trimmer
Move and release the
Hold the panel 0.3 H MRi 0.3
trimmer
Check size & appearance and Check size & appearance
9.36 IA I 9.36
assemble and assemble
Move to dispose 1.1 M M 1.1 Move to dispose
TOTAL 302.66 302.66
5.04433
TOTAL (minute)
3
0.84072
SMV
2
EFF 100.3%
Note
* The operator doesn’t use both hands
The operator rotates the panel. This ineffective motion can be eliminated by
**
changing the pinch method for time saving
The operator flips the panel. This ineffective motion can be eliminated by changing
***
the pinch method for time saving

Process: 1Z-Att hook & eye tapes w label, Tack open hook & eye to gmt x 2
Style: QP2013S/15/B
Time Time
(s) (s)
Reach, grasp, move and RGM RG Reach, grasp and move the
1.03 1.03
release the eye Ri M wing
Idle 0.47 UD 0.47
M label
Combine label and eye 4.53 A A 4.53 Combine label and eye
Idle 2.33 UD 2.33
M wing
Hold and close eye 2.04 A A 2.04 Hold and close eye
Put under m/c foot 2 M M 2 Put under m/c foot
Move and release the panel 0.43 MRi UD 0.43 Idle
Idle 1 UD 1
M wing
2.8 UD 2.8 Idle
release the hook Ri
Place hook to wing 1.73 A A 1.73 Place hook to wing
Put under m/c foot 3 P P 3 Put under m/c foot
Reach, Grasp and Move the RG Reach, Grasp and Move the
1.26 RGM 1.26
trimmer M trimmer
Hold the panel 18.24 H U 18.24 Use the trimmer
Hold the panel 0.3 H MRi 0.3 Move and release the trimmer
Check size & apperance and Check size & apperance and
9.36 IA IA 9.36
assemble assemble
Move to dispose 1.1 M M 1.1 Move to dispose
TOTAL 284.06 284.06
4.73433
TOTAL (minute)
3
0.78905
SMV
6
EFF 106.9%
3.5 Cut Wing Lace (Manual)
Process : Cut Lace Wing pair
Style: 193902-Large/P. U Lace/15/A
Date: 27 November 2018
Time Time
Left Hand Symbol Right Hand
(s) (s)
Menjangkau, memegang , Menjangkau, memegang
0.8 R, G, M R, G, M 0.8
membawa roll lace , membawa roll lace
Mensejajarkan roll lace 7.83 P P 7.83 Mensejajarkan roll lace
Menjangkau,
R, G, M,
Idle 1.53 UD 1.53 memegang, membawa
RI
dan menaruh pola
Memposisikan pola 2.1 P P 2.1 Memposisikan pola
Menjangkau,
R, G, M,
Idle 0.77 UD 0.77 memegang, membawa
RI
dan release pemberat
Menjangkau,
Diam 0.93 UD R, G, M 0.93 memegang, membawa
cutter
Hold 7 H U 7 Memotong Lace
Menjangkau, memegang ,
R, G, M, Membawa dan menaruh
membawa, menaruh lace 0.6 R, G, M 0.6
RI cutter
terpotong
Menjangkau,
Idle 1.3 UD R, G, M 1.3 memegang, membawa
pemberat
Menjangkau,
Idle 0.7 UD R, G, M 0.7 memegang, membawa
pola
Menjangkau,
Menjangkau, memegang,
0.27 R, H R, H 0.27 memegang, lace
lace terpotong
terpotong
Mempoposisikan lace Mempoposisikan lace
0.73 UD P 0.73
terpotong terpotong
Membawa dan menaruh Membawa dan menaruh
0.67 M, RI M, RI 0.67
lace terpotong lace terpotong
TOTAL 25.23 25.23
Process: Cut Lace Wing pair
Style: 193902-Large/P. U Lace/15/A
Date: 27 November 2018
Menjangkau,
Menjangkau, memegang ,
memegang , membawa 1.25 R, G, M R, G, M 1.25
membawa roll lace
roll lace
Mensejajarkan roll lace 3.7 P P 3.7 Mensejajarkan roll lace
Idle 2 UD R, G, M, RI 2 membawa dan menaruh
pola dan pemberat
Memposisikan pola dan Memposisikan pola dan
3.13 P P 3.13
pemberat pemberat
Idle 0.84 UD R, G, M 0.84
membawa cutter
Hold 7.93 H U 7.93 Memotong Lace
Idle 0.4 UD R, G, M, RI 0.4 membawa dan menaruh
lace terpotong
Membawa dan menaruh
membawa dan menaruh 1.53 R, G, M, RI M, RI 1.53
cutter
pola dan pemberat
Menjangkau, membawa Menjangkau, membawa
dan menaruh lace 1.17 R, H R, H 1.17 dan menaruh lace
terpotong terpotong
Mempoposisikan lace Mempoposisikan lace
0.27 P P 0.27
terpotong terpotong
Membawa dan menaruh Membawa dan menaruh
0.33 M, RI M, RI 0.33
lace terpotong lace terpotong
TOTAL 21.95 21.95

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Contents

Steps required to perform this procedure

Name of the Process:

Name of the Process:

Name of the Process:

Name of the Process:

Name of the Process:

Name of the Process:

TOTAL (minute) 3.069

TOTAL (minute) 3.034

TOTAL (minute) 1.9845

TOTAL (minute) 0.569833

[FUTURE STATE] The left-hand and right-hand motion

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