TRAINING PRESENTATION

Last Update : 24/09/2018 1

by Tarek AYEB
 SCHEDULE

- Training Opening
- SAM Discovery
- Operation Discovery
- Macro element Discovery

Break

- MTM MTM2 Discovery

- SAM & PACE
- What is SAM for( SENS )
- SOT Introduction
Summary & Closing

2
 TARGETS

1. Understand the content of a SAM in DECATHLON

2. Understand the “MTM2” method used to calculate the

DECATHLON SAM

3. Understand THE SENS of SAM in DECATHLON

4. Understand the SOT and the main differences with

the DECATHLON SAM

3
 WHAT IS A ?

STANDARD Allocated Minute

⇒ A Quantified Operation Breakdown

Analyse of product fabrication steps from cutting to

packaging + associated time
4
 THE SAM AT DECATHLON :

Cutting
Preparation
Marking
CONTAINS Assembling
Ironing
Finishing & Quality
control
Packing

5
 CUTTING

Operations included under « Cutting » section

are :

> Spreading
> Cutting
> Bundling &
labelling

There is a « piece » time which gathers those 3 elements. Just count the number
of pieces of each fabric and multiply it by defined time.

6
 PREPARATION

Operations under "PREPARATION“ section are :

Quilting for quilted products

Thermofusing

7
 MARKING

Operation under Marking section is:

Heat transfer labels

account

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 ASSEMBLING

Operations under Assembling section are :

Stitching Taping Thermobonding

Etc...
9
 QUALITY CONTROL

Operations included in Finishing & Quality

Control are :

FINISHING :
Cut and/or evacuate threads.

END OF LINE CONTROL :

• 100% of the pieces are controlled according to Decathlon
Standard
• With Measurement Chart : Only critical & fundamental
measurements
• Following DCS book
• Label control (matching RFID , size , etc.)

10
 IRONING

Operations under Ironing section are :

Etc.

Iron finished
clothes 11
 PACKING

Operations under Packing section are :

All folding works (put hood in collar,

etc.)
All labelling works (sticked or swifted)
Putting in bag (if necessary)
Putting on hanger (if necessary)
Packing in box
Etc….

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 HOWCAN
HOW CANWE
WEOBTAIN
OBTAINSAM’S
SAM’STIMES
TIMES??

⇒By splitting up all operations steps.

⇒With a predetermined evaluation time

system of body motion.

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EXERCISE

Kit SAM

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CORRECTION

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 WHAT IS INSIDE SAM ?

=> A SAM IS BUILT WITH SEVERAL …………………

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 WHAT IS INSIDE SAM ?

=> A SAM IS BUILT WITH SEVERAL OPERATIONS

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 APPLICATION

• Make a list of all motions made by worker

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 CORRECTION
⇒ OPERATION : Put elastic on waist
List of all motions needed to make the operation :
Code Description Type Repeat Time Default parameters
PICKUP AND POSITION 16-30
PP20 ELASTIC TO FRONT BELT Distance 1 0.041 cm
MA10 SINGLE FOLD Time 1 0.029 time
PICKUP AND POSITION
PP20 ELASTIC TO BACK BELT Distance 1 0.035 6-15 cm
MA10 SINGLE FOLD Time 1 0.029 time
16-30
MTPA STRETCH ELASTIC Distance 1 0.008 cm
16-30
PO10 POSITION UNDER FOOT Distance 1 0.02 cm
MTA0 GUIDE ACTION Time 1 0.009 time
L : 80 LR : 26,67
Length1 TOTAL LENGTH Loop 0.335 cm cm

16-30
MA30 ALIGN 2 FOLDS Distance 3 0.097 cm
Length 26.67
STAB SEWING FORMULAE Formulae 3 0.238 (cm) :

EndLength
1 EndLoop
MTA0 GUIDE ACTION Time 1 0.009 time
THREAD CUTTING WITH 19
CT70 FIXED CUTTER Time 1 0.011 time
16-30
DI20 DISPOSE(ONE HAND) Distance 1 0.025 cm
 WHAT IS INSIDE SAM ?

=> AN OPERATION IS BUILT WITH SEVERAL ……………...

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 WHAT IS INSIDE SAM ?

=> AN OPERATION IS BUILT WITH SEVERAL MACRO ELEMENTS

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 EXAMPLE OF DETAILS OF MACRO ELEMENT

PP35: TAKE & PLACE 2 ELEMENTS (L-R)

Left Hand Right Hand

Bring Hand near
Take 1st piece
2nd piece
Take 2nd piece

Bring1st piece Bring 2nd piece

Adjust piece
Regrasp

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 WHAT IS INSIDE SAM ?

=> A MACRO ELEMENT IS BUILT WITH SEVERAL ………………….

23
 WHAT IS INSIDE SAM ?

=> A MACRO ELEMENT IS BUILT WITH SEVERAL MTM2 ELEMENTS24

 MTM

(MTM = Methods Time Measurement)

MTM is a predetermined evaluation time system

of body motion created in 1948.

It combines :

Motions + Distances + Weight

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 MTM2

(MTM = Methods Time Measurement)

Have been created in 1965.

MTM2 is an abstract of MTM system.
Second global level of MTM data.

MTM 593 Values

MTM2 39 values
MTM2 is an abstract of MTM system.
Second global level of MTM data.

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MTM2 MOTIONS

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 MTM2 MOTIONS

G
Get = Obtain REACH + GRASP
(hand or finger) + RELEASE later.

GA = grasp contact or grasp very easily.

GB = 1 single grasp motion.

GC = several fingers motion.

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 MTM2 MOTIONS

P
PUT = PLACE Carry a piece (hand or
finger) to a destination
+ put in place.

PA = move + put in place without precision.

PB = move + put in place one direction

or fingers correction.

PC = move + put in place 2 directions

or several fingers correction. 29
MTM2 MOTIONS

G G

G
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 IN COMPLEMENT MOTIONS

A R C E
Apply Pressure Regrasp Crank Eye Action

F S B
Foot Motion Step Bend and Arise

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MTM2 DISTANCES

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MTM2 DISTANCES

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 W : WEIGHT CORRECTION

DEFINITION :
GET WEIGHT is the action asked to hand and arm
muscles to overcome resistance of object weight during
object taking.

When resistance is equal or

superior to 2 kg,
1 TMU is allowed
for each kilo,
including the 2 first kilos.

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 W : WEIGHT CORRECTION

DEFINITION :
PUT WEIGHT is an added extra to motion PUT,
depending on weight and carrying.

Between 2 kg and 5 kg,

1 TMU is allowed and
symbolized PW5

Between 5 kg and 10 kg,

2 TMU are allowed
and symbolized
PW10, etc….

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 MTM2 TIME UNIT
TMU = Time Measurement Unit

1 TMU* = 1/100000th of hour

Conversion rate of TMU is
hundred thousandth of an hour :
1 TMU = 0.0006 Min
Because
60/100000 = 0.0006
Secondes
X :
60 60
Minutes

X :
0,0006 TMU
0,0006
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MTM2 ELEMENT VALUES

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 APPLICATION

PP35: TAKE & PLACE 2 ELEMENTS (L-R)

Left Hand Codes Right Hand

Bring Hand near
Take 1st piece GC30 GA30
2nd piece
GC5 Take 2nd piece

Bring1st piece PA30 Bring 2nd piece

Adjust piece PC5

R Regrasp

PP35 = ...........TMU = ………. Min = ……. Scd

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 CORRECTION

PP35: TAKE & PLACE 2 ELEMENTS (L-R)

Left Hand Codes Right Hand

Bring Hand near
Take 1st piece GC30 GA30
2nd piece
GC5 Take 2nd piece

Bring1st piece PA30 Bring 2nd piece

Adjust piece PC5

R Regrasp

PP35 = 75 TMU = 0.045 Min = 2,7 Scd 39

 SAM UNIT

EXEMPLE
SAM for OWE 6.774

DETAILS SAM
Cutting 0.748
Marking 0.000
Assembling 5.223
QC 1.090
Packing 0.460
Preparation 0.000
Ironing 0.000
Other 0.000

Total SAM = 7,521 TOTAL SAM 7.521

12535 TMU
31 Scd = -------------
SAM = 7,521 Min = 7 Min & ---------

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 TO SUM UP

MTM2 Time= Combination of Motions time and distance time + Weight

time

OPERATION TIME =
MTM2 TIME (min) + MACHINE TIME (min) + ALLOWANCES (% )
( Motions + Distances + Weight )

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 MACHINE TIME

L= Sewing length (cm)

NP = Number of stitch per cm

TM = Speed reached during sewing section

(rotations per minute)

0.010 = machine time control

+ acceleration + deceleration
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 ALLOWANCES ( % )

HUMAN:
– Personal Time
– Tired

MACHINE: ( depending on machine typology and number of needles )

– Damages
– Spool changing
– Incidents

POSITION:
– Sit down (with or without reflexion)
– Standing (with or without reflexion)
– Lying (with or without reflexion)
– Etc …..

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 MTM 2 ADVANTAGES

Define a time

Determinate working methods

Do workstation improvements

Symbolised in the same way all around the world

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 TREE VIEW

• Several elements of
OPERATIONS MTM2 (and MTM)

MTM – MTM2 • Several macro

elements

• Several Micro
SAM
Elements Manual

MACRO ELEMENT • Several operations

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 TREE VIEW

1. SAM
⇒ Assemble several operations

2. OPERATIONS
=> Assemble several macro
elements

3. MACRO ELEMENTS
=> Assemble several elements
MTM 1&2

4. MTM-MTM2
=> Micro Elements Manuals

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EXAMPLE OF SAM

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 WHERE TO FIND IT ?

Intranet Decathlon => PACE

« Technical data » => « METHOD » => SAM tool

Request => Pattern Maker (90%)

Made by Methods Engineer / Sample Maker

Use only validated SAM not

in progress SAM
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 WHAT IS SAM FOR ?

During Conception Process

Help for decision during product development or improvement (design to cost).

During Costing Process

Negociation help tool with supplier SOT.

During Production Process

Line Balancing / supplier help or evaluation.

Encourage continuous improvement => improve productivity.

During Supply studies

Easy to evaluate the real capacity in advance.

Guiding for production planning for the factory & forecast the precise shipment date.
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 SOT INTRODUCTION

SOT ?
(Supplier Operating Time)

Quantified Operating Breakdown, adapted to

supplier equipment, to his technical skills, to his
assembling logic. Also without efficiency and
speed notion.

It can be made under supplier sofware’s choice.

If supplier is motivated to get trained, he can

access to SAMPACE software for a better
comparison. 50
DIFFERENCE SAM & SOT TIME

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 SAM vs SOT

– If gap < + or - 10% => OK

– If gap > + or - 10%

=> analyse possible reasons (parallel with SAM API,
unnecessary operation, over quality, …)

– In case value is still over range, contact API

(with video or pictures) .

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 SAM vs SOT

PAPER BOARD GAME + POST IT TO PUT ON

THE RIGHT PLACE

SAM SOT
standard sewing method ? Post it

? Post it based on supplier’s actual

machine quantity
standard allowance ?

? Post it based on supplier’s sewing flow

Post it… = (output * SAM) / Post it… = (output * SOT) /

working time working time

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 SAM vs SOT

CORRECTION

SAM SOT
Standard sewing method Based on supplier’s know-how &
experience

standard machine based on supplier’s actual

machine quantity

standard allowance based on supplier’s management

level

standard bundle time based on supplier’s sewing flow

OWE Efficiency
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