FLEXIBLE CELL

The Future of Manufacturing is here TODAY

24/07/2012
FLEXIBLE
CELL WORKING – NICE APPAREL

NICE APPAREL IN PARTNERSHIP WITH M.E.

24/07/2012
 1. Suppliers and Customization
2. Introduction to Flex Cell

AGENDA 3. Flex Cell set up and Strategy

4. The Journey
5. Capacity and Growth…
1. Suppliers & Customisation
Characteristics of order
1. Small Lot Size
2. High Complexity
3. Short Lead Time
4. mi adidas order frequency (Daily)
5. High discrepancy between planned and actual order quantities
ALL of the above are reasons for Varieties of C/O and Efficiency loss

Need Flexibility
 Customisation
FCW Order is aQty
Unique Business Unit, in terms Order Quantity and Manufacturing Technique
Analysis

FCW Order Qty Analysis

Based on PO’s Order Quantity Lot sizes 36.45%

is averaging just 10 pieces per PO
While the full range of Orders is averaging just
42 pieces per PO.

Normal Manufacturing processes could not

perform Efficiently using normal Manufacturing
techniques and needed a different concept
…………
THAT CONCEPT IS !
 2. Introduction to Flexcell
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.
All BU’s can be made in the Flex Cell Method, offering the
Supplier and Customer 100% Flexibility within the Product
Group range
Continuity of style and working within the Cell set up gives higher
Efficiency and higher RFT.
FCW Room - Opening Ceremony 18th July, 2012
Flexcell Working Room
3. FCW Strategy

Product Family Grouping

Specific Cell Design
Multi-Skill Workers
Real Time Information System to:
• Maximum Output
• Minimum Defect
Zero Changeover
Product Family Grouping

100% Fabric
80% Machine
Product Family Line Criteria:
80% Feature
+10% SMV

Criteria: 100% Fabric

80% Machine
80% Feature
+10% SMV
FCW Factory Layout
- With Product Types Grouped to Specific Lines & Areas
Cell Design

Cell 1 Front
Cell 2 Back
Cell 3 Collar
Cell 4 Sleeve
Cell 5 Assembly
 Multi Skilling of Workers
Operator Skill Matrix

Skill
Training

4. Availabilities at station
 Real Time Data Capture System

(1). Hardware

Efficiency & D/T Tackle QC : Defect Data Pack : Production Output Sup. visor : Production data
Template By : Touch screen By : Scan Barcode By : LCD Monitor

(2).Software
Daily plan

Production
Planning
Program NGIS Data Defect Data Packing All Status
Zero Changeover Time

Style : MTS10BBW311

Style : MTF10BBM311
4. The Journey
Av Eff 18% mi adidas
Cell Design ( non C/O ) FCW ( Flexible Cell working )
mi adidas Complete non C/O for
Standing Modular Aug’11-Feb’12 Customize order
Sep’08-July’11 Jun’12-Present

2008-2012

Cell Design - mi adidas

Regular Line- NBA

May’10-Feb’12 Feb’12-May’12 Av Eff 45%

NBA Consolidate mi adidas &
Regular Line NBA in one room
5. Capacity & Potential

Month Sewer Wkh Minute EFF SMV Target Avg.min Pcs. offer

August 2011 300 8.5 633,420 18% (actual) 26 24,362

August 2012 300 8.5 1,583,550 45% (actual) 26 60,000
December 2012 300 8.5 1,829,880 52% 26 70,380
March 2013 300 8.5 1,900,260 54% 26 73,086
June 2013 300 8.5 1,970,640 56% 26 75,793
THANK YOU!

adidas Apparel, Manufacturing Excellence