Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing
Abstract
Purpose: The research aims to design a performance improvement framework for a new model of sports shoes to increase the ramp-up process time.
Methodology/Approach: The approach used the problem-solving system of 8 disciplines, Single Minute Exchange Dies, Visual Management, and the Just In Time principle.
Findings: By using the methods described above, the research findings will have a positive impact on the company. Model changeover time was reduced from 600 minutes to 102 minutes, and ramp-up time was reduced from 20 days to 2 days.
Research Limitation/Implication: The limitation of this study was that only the CK2946 model was still done as a case study. The cost and other inhibiting factors were also not included in the discussion of this rump-up process.
Originality/Value of paper: By integrating SMED, Just In Time, visual management, and using 8-Dicipline, the researcher developed a framework for improved performance for ramping up a new model of sports shoes.
References
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Syafei, M.Y. and Lokadipati, T., 2018. Improving Work System by Reducing Setup Time Activity in Drying Room in Pharmaceutical Industry with Single Minutes Exchange Die (SMED). JIE Scientific Journal on Research and Application of Industrial System, [e-journal] 3(1), pp.50-58. DOI: 10.33021/jie.v3i1.497.
Talekar, A. A., Patil, S.Y., Shinde, P.S. and Waghmare, G.S., 2019. Setup time Reduction Using Single Minute Exchange of Dies (SMED) at A Forging Line. B.S. Babu, K. Kumar, T.V. Vardhan and S. S. Kumar, eds. 1st International Conference On Manufacturing, Material Science and Engineering. Telangana, India, 16-17 August 2019. AIP Conference Proceedings. DOI: 10.1063/1.5141188.
Trimarjoko, A., Saroso, D.S., Purba, H.H., Hasibuan, S. Jaqin, CH. and Aisyah, S., 2019. Integration of nominal group technique, Shainin system and DMAIC methods to reduce defective products: A case study of tire manufacturing industry in Indonesia. Management Science Letters, [e-journal] 9(13), pp.2421-2432. DOI: 10.5267/j.msl.2019.7.013.
Uzun Kocamiş, T., 2015. Lean Accounting Method for Reduction in Production Costs in Companies. International Journal of Business and Social Science, 6(91), pp.6-13.
Van Treeck, K., 2016. Wages and Productivity in The Garment Sector in Asia and the Pacific and The Arab States. International labor organization, 5(November), pp.1-8.
Zarghami, A. and Benbow, D., 2017. An Introduction to 8D Problem Solving. Milwaukee: ASQ Quality Press.
Zerin, N.H., Hossain, L. and Zannat, M., 2019. Manufacturing Lead Time Improvement by Reducing Changeover Time with The Application of SMED. International Journal of Scientific & Engineering Research, 10(7), pp.2088-2092.
APICCAPS (the Portuguese Footwear, Components and Leather Goods Manufacturers’ Association), 2020a. Footwear consumption to decline 22.5%, world footwear yearbook. [online] Available at: < https://www.worldfootwear.com/news/footwear-consumption-to-decline-225-in-2020/4746.html > [Accessed 20 August 2020].
APICCAPS (the Portuguese Footwear, Components and Leather Goods Manufacturers’ Association), 2020b. Footwear production with new record of 24.3 billion pairs, world footwear yearbook. [online] Available at: < https://www.worldfootwear.com/news/footwear-production-with-new-record-of-243-billion-pairs/5356.html > [Accessed 20 August 2020].
APRISINDO (Indonesian Footwear Association), 2018. Indonesian Footwear Industry Country Report 2018. [pdf] Indonesian Footwear Association. Available at: < http://www.hkfootwear.org/content/upload/1539063579.pdf > [Accessed 14 May 2020].
Arief, F.N. and Ikatrinasari, Z.F., 2018. Perbaikan Waktu Setup Dengan Menggunakan Metode SMED Pada Mesin Filling Krim. Operational Excellence, 6(1), pp.1-8.
Black, C. and Létis, M.T., 2018. Sectoral Report Footwear Industry Brazil 2018. Novo Hamburgo: Brazilian Footwear Industries Association.
Briciu, S. and Ofileanu, D., 2015. Value Stream Mapping in the Romanian Footwear Industry. SEA – Practical Application of Science, III(07), pp.121-127.
Cotton, D., 2016. The Smart Solution Book: 68 Tools for Brainstorming, Problem Solving, and Decision Making. United Kingdom: Financial Times.
Dombrowski, U., Wullbrandt, J. and Krenkel, P., 2018. Industrie 4.0 in production ramp-up management. Procedia Manufacturing, 17, pp.1015-1022. DOI: 10.1016/j.promfg.2018.10.085.
Esa, M.M., Rahman, N.A.A. and Jamaludin, M., 2015. Reducing High Setup Time in Assembly Line: A Case Study of Automotive Manufacturing Company in Malaysia. Procedia - Social and Behavioral Sciences, [e-journal] 211, pp.215-220. DOI: 10.1016/j.sbspro.2015.11.086.
Filla, J., 2016. The Single Minute Exchange of Die Methodology in a High-Mix Processing Line. Journal of Competitiveness, [e-journal] 8(2), pp.59-69. DOI: 10.7441/joc.2016.02.05.
Gavali, R., Chavan, S. and Dongre, G.G., 2016. Set-up Time Reduction of a Manufacturing Line Using SMED Technique. International Research Journal of Engineering and Technologhy, 3(7), pp.1748-1750.
Gemba Academy, 1998. Preparing for the Kaizen Event. [online] Available Available at: < https://www.gembaacademy.com/school-of-lean/the-kaizen-way-course/kaizen-overview > [Accessed 20 August 2020].
Huda, L., 2020. Kemenperin: Penjualan Alas Kaki Dalam Negeri Turun hingga 70 Persen. TEMPO.Co. Available at: < https://bisnis.tempo.co/read/1374456/kemenperin-penjualan-alas-kaki-dalam-negeri-turun-hingga-70-persen/full&view=ok > [Accessed 20 August 2020].
International Labour Organization, 2016. Wages and Productivity in The Garment Sector in Asia and the Pacific and The Arab States. International labor organization, 5(November), pp.1-8.
Jagtap, N.S., Ugale, V.D., Kadam, M.M., Kamble, S.S. and Salve, A.V., 2015. Setup Time Reduction of Machine Using SMED Technique and Lean Manufacturing. International Journal of Advances in Production and Mechanical Engineering, 1(2), pp.7-14.
Karam, A.A., Liviu, M., Veres, C. and Hore, R., 2018. The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project. Procedia Manufacturing, [e-journal] 22, pp.886-892. DOI: 10.1016/j.promfg.2018.03.125.
Kentli, A., Dal, V. and Alkaya, A.F., 2013. Minimizing machine changeover time in product line in an apparel industry. Tekstil ve Konfeksiyon, 23(2), pp.159-167.
Krishna, Y., 2020. Kemenperin Rancang Indonesia Footwear Network. Validnews.id, [online] 10 August. Available at: < https://www.validnews.id/Kemenperin-Rancang-Indonesia-Footwear-Network-BJV > [Accessed20 August 2020].
Maalouf, M.M. and Zaduminska, M., 2019. A Case Study of VSM and SMED in The Food Processing Industry. Management and Production Engineering Review, [e-journal] 10(2), pp.60-68. DOI: 10.24425/mper.2019.129569.
Mulyana, A. and Hasibuan, S., 2017. Implementasi Single Minute Exchange of Dies (SMED) Untuk Optimasi Waktu Changeover Model Pada Produksi Panel Telekomunikasi. Sinergi, [e-journal] 21(2), pp.107-114. DOI: 10.22441/sinergi.2017.2.005.
Pujiastuti, L., 2015. Pabrik Nike di Cianjur Mampu Produksi 1 Juta Pasang Sepatu/Bulan. detikFinance, [online] 27 October. Available at: < https://finance.detik.com/industri/d-3054661/pabrik-nike-di-cianjur-mampu-produksi-1-juta-pasang-sepatubulan > [Accessed 6 May 2020].
Setyawan, L., 2019. Increasing the production capacity of copper drawing machine in the cable industry using SMED method: A case study in Indonesia. Operational Excellence, 11(1), pp.217-227.
Singla, M. and Pal, S., 2017. Reduction of Changeover Time During Style. National Institut of Fashion Technilogy.
Sunadi, S., Purba, H.H. and Hasibuan, S., 2020. Implementation of statistical process control through pdca cycle to improve potential capability index of drop impact resistance: A case study at aluminum beverage and beer cans manufacturing industry in indonesia. Quality Innovation Prosperity, [e-journal] 24(1), pp.104-127. DOI: 10.12776/QIP.V24I1.1401.
Syafei, M.Y. and Lokadipati, T., 2018. Improving Work System by Reducing Setup Time Activity in Drying Room in Pharmaceutical Industry with Single Minutes Exchange Die (SMED). JIE Scientific Journal on Research and Application of Industrial System, [e-journal] 3(1), pp.50-58. DOI: 10.33021/jie.v3i1.497.
Talekar, A. A., Patil, S.Y., Shinde, P.S. and Waghmare, G.S., 2019. Setup time Reduction Using Single Minute Exchange of Dies (SMED) at A Forging Line. B.S. Babu, K. Kumar, T.V. Vardhan and S. S. Kumar, eds. 1st International Conference On Manufacturing, Material Science and Engineering. Telangana, India, 16-17 August 2019. AIP Conference Proceedings. DOI: 10.1063/1.5141188.
Trimarjoko, A., Saroso, D.S., Purba, H.H., Hasibuan, S. Jaqin, CH. and Aisyah, S., 2019. Integration of nominal group technique, Shainin system and DMAIC methods to reduce defective products: A case study of tire manufacturing industry in Indonesia. Management Science Letters, [e-journal] 9(13), pp.2421-2432. DOI: 10.5267/j.msl.2019.7.013.
Uzun Kocamiş, T., 2015. Lean Accounting Method for Reduction in Production Costs in Companies. International Journal of Business and Social Science, 6(91), pp.6-13.
Van Treeck, K., 2016. Wages and Productivity in The Garment Sector in Asia and the Pacific and The Arab States. International labor organization, 5(November), pp.1-8.
Zarghami, A. and Benbow, D., 2017. An Introduction to 8D Problem Solving. Milwaukee: ASQ Quality Press.
Zerin, N.H., Hossain, L. and Zannat, M., 2019. Manufacturing Lead Time Improvement by Reducing Changeover Time with The Application of SMED. International Journal of Scientific & Engineering Research, 10(7), pp.2088-2092.
Authors
Setiawan, L., & Hasibuan, S. . (2021). Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing. Quality Innovation Prosperity, 25(2), 19–36. https://doi.org/10.12776/qip.v25i2.1516
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