Morning Sun OP506

Morning SunMorning SunScreen Printing CompanyScreen Printing Company

Presented by:

George Holk

James Gemperle

& Kim Dubois

Morning Sun OP506

Company OverviewCompany Overview Founded in 1986 425 Employees, $52M Annual Sales Product: Custom Screen Printed T-Shirts Market: Primarily Department Stores,

and Some Smaller Retailers Batch Process, Make to Order

Morning Sun OP506

Competitive PrioritiesCompetitive Priorities

High Quality Flexibility Speed of Delivery

Morning Sun OP506

Plant Layout and Work Flow Plant Layout and Work Flow (Approximately 150,000 Square Feet)(Approximately 150,000 Square Feet)

WarehouseWarehouse

ScreenPrep

Art

Shipping

Sewing

Offices

Embroidery

Printing

Morning Sun OP506

Plant OperationsPlant Operations & Methods of Supporting the & Methods of Supporting the Competitive Priorities Competitive Priorities of:of:

QualityQuality, , Flexibility and Speed

Morning Sun OP506

Raw Materials InventoryRaw Materials Inventory

JIT System

Strong Supplier Relationships

Quality Inspections Performed

Orders Stacked by Design and Size Scale

Morning Sun OP506

Art and Screen PreparationArt and Screen Preparation

Designs by In-House Art Department 200 In Stock Designs (Down from 500)

Frames and Screens are Constructed

Design Image “Positive” is Burned onto Screen

Morning Sun OP506

Competitive Priorities Competitive Priorities

Quality

-Supplier Relationships

-Raw Material Inspection

-Design Engineering

Speed, Flexibility

-Reducing Inventories (JIT)

-Fewer Designs

Morning Sun OP506

Screen PrintingScreen Printing Two Types of Screen Press Machines Used

-Hand Press

-Auto Press Dryer Oven Belt Shirts Inspected for Quality Foiling, Embroidery To Sewing for Final Work

Morning Sun OP506

Screen Printing CP SupportScreen Printing CP SupportQuality

-Quality Inspections, Run Set-Up Testing and Fail SafingDelivery Speed

-Reduction of Set Up Times

-Combining Processes

-New Embroidery MachinesFlexibility “Mass Customization”

-All Machinery on Wheels

-Hand Presses for Special Orders

Morning Sun OP506

SewingSewing

Labels and Collars

-Formerly Outsourced

Capacity

-20 Machines /3 Shifts

Bottleneck

Morning Sun OP506

Sewing (cont.)Sewing (cont.)

Identified as “Herbie”

How to Move Herbie Upstream

-Collars

-Smaller Batches

-QC Runners

Morning Sun OP506

Sewing cont.Sewing cont.

Other Changes Made:

-Pay for Performance

-Purchase of 10 New Machines

-Limit Order to Size Scale

Morning Sun OP506

Sewing- Competive PrioritiesSewing- Competive Priorities

Quality

-QC Runners

Speed and Flexibility

-Additional Machines

-Improved Throughput

Morning Sun OP506

Summary - Operations Support Summary - Operations Support of Competitive Prioritiesof Competitive Priorities Quality

-Inspections, QA Dept.

Flexibility

-Mobile Production Equipment

-Order Size Variance

Speed

-JIT, Moving /Combining Processes