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Operations & Supply Chain ManagementGroup E F2IE Business School

Daria AleshinaJess MonzNicole PagnoniJoaqun A. Ramirez MongilRamn Schmitt

Operations & Supply Chain ManagementGroup E F2IE Business SchoolAGENDA


WHO ARE WE?

A Barcelona based shoe manufacturer whos vision is to create a footwear brand built on three key pillars: 100% handmade in Spain, Barceloneta Lifestyle and The Sole Revival.

Each pair of Maians is made strictly by hand, giving them a detailed craftsmanship feel that meets the urban beach style. About Process Competition Quality Improvement


About Process Competition Quality Improvement


PROCESS OVERVIEW


STOCKINGCUTTINGMAKINGVULCANIZINGCOOLINGPACKAGING

Operations & Supply Chain ManagementGroup E F2IE Business SchoolAbout Process Competition Quality Improvement

PROCESS DIAGRAM


Lower Variety Moderate VarietyHigh VarietyFLEXIBLE (JOB SHOP) PROCESS BATCH PROCESSASSEMBLY LINE

About Process Competition Quality ImprovementPRODUCT-PROCESS MATRIX



Worker-paced assembly process.Factory capable of handling production of around 28 models and 7 sizes each.Majority of the work depends on assembling unique parts into a single piece.Small production, hand-made process.

Outsources its manufacturing division to third parties. Main system adopted in their shoe production is molding.Allows them to use batch process.Provide a much greater variety of products.lower volumes. Job shop production process.Provide various different tailoring steps.capable of providing completely unique shoes. volume produced is exceptionally low (technically, one model = one pair).



HOW DO WE MAINTAIN QUALITY?

To maintain a certain level of quality, Maians shoes have to go through various tests conducted by the relative Quality Control employees.

These procedures are made to ensure that the products that leave the manufacturing plant are of top quality.

Operations & Supply Chain ManagementGroup E F2IE Business SchoolAbout Process Competition Quality Improvement

Vulcanization Test: made to assure that the vulcanization of the outer sole process has been correctly executed. Needle Test: detects if there is any hazardous metal object found in the shoe. Bonding and Rubbing Test: conducted to see if the shoes adhesives are capable of keeping their integrity throughout different environments. Size Measurement Check: ensures both shoes are of the same measurement.

Operations & Supply Chain ManagementGroup E F2IE Business SchoolHere we identify some of the processes or tests that Maians adopts in order to maintain quality throughout their various processes: 10


OPPORTUNITY FOR IMPROVEMENT IDENTIFYING THE BOTTLENECK

We identified the bottleneck to be found within the sole attaching stage - press and stocking.

This bottleneck arises as the vulcanized machine requires at least 600 seconds to attach the sole to the upper-part. Thus, system capacity is 110 pairs per hour.




Based on data analyzed we developed some suggestions that will improve the productivity of existing machinery & redistribute the resources available:

Tackle the bottleneck: improving existing machinery, decreasing process time by 33%.Redistribute the lasting process employees & machines from 8 to 2.Reallocate resources released from the lasting process to 6 new machines.To smooth and refine the process we suggest purchasing 3 more sole attaching machines and 1 more cotton cutting machine.

About Process Competition Quality ImprovementRECOMMENDATIONS


About Process Competition Quality ImprovementApplying these 4 recommendations we assume production will improve from 109 pairs/hour to 237 pairs/hour.

The process will look as illustrated in the graph.

109237


Daria AleshinaJess MonzNicole PagnoniJoaqun A. Ramirez MongilRamn Schmitt

Operations & Supply Chain ManagementGroup E F2IE Business SchoolBATCH*Batch/minService time (secs/pair)Capacity (pair/hour)N MachinesTotal capacityActivity

Cutting

Transportation1215720172015%

Cotton20180118061%

Transportation1215720172015%

Vulcanized sole10360136030%

Quality control15240124045%

Transportation120,510360136030%

Assembly (upper-part)4090436030%

Assembly (inner sole with upper-part)30120448023%

Lasting25144811529%

Sole attaching (preparation)30120448023%

Sole attaching (press & stocking)6605,4520109,09100%

Cooling9004100***40027%

Quality control15240124045%

Download - Handcrafting shoes, Maians

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