Your

Company

Logo

Dr. Gordon YenEnhancing Supply Chain Visibility in

Fountain Set with SCOR Model

Your

Company

Logo

Basic Information of FSHLBasic Information of FSHL• Knitted fabric mill founded in 1969

• One of the world’s largest with over

50k tons of monthly capacity

• Highly vertical-integrated operations - Spinning, Knitting, Dyeing, Printing, Finishing & Garment Production

• Ship fabric to over 40 countries for supply chain of internationally renowned brands

Your

Company

Logo

Multiple ChallengesMultiple Challenges• Fragmented supply chain

• Highly customized product quality and design requirements

• Large work-in-progress inventory

• Short lead-time High penalty on delay

Your

Company

Logo

Solution (SCOR) Solution (SCOR)

Collaborative project between GS1 and FSHL - To examine the entire ‘MAKE’ process

Your

Company

Logo

Objectives Objectives

• To find out how time is spent on value-added and non-value added processes

• To provide insights for improvement

* Increasing visibility in the ‘MAKE’ production process* Reducing production time and cost

Your

Company

Logo

• ‘MAKE’ process in FSHL

– Knitting– Dyeing – Finishing mills– Quality Control– Packaging and staging– Delivery

Your

Company

Logo

Value-stream analysisValue-stream analysisMeasure process performance with average length of time spent on each process

ValueAdded

ProcessKnitting

TheMAKE

Process Non-valueAdded

Process

QC&

PackagingDyeing Finishing

GreyFabric

Staging

DyedFabric

Staging

FinishedFabric

Staging

PackagedFabric

Staging

Delivery

Your

Company

Logo

Recommendations For Cycle Time Recommendations For Cycle Time ImprovementImprovement

Value Added Process

Process Time Without Affecting Product Quality

•Use additional facilities/resources to improve productivity

Non-value Added Process

Staging Time

•Eliminate unnecessary staging/delay or minimize staging through root cause analysis

TheMAKE

Process

Your

Company

Logo

• Potential Root CausePotential Root Cause

FabricStaging

ExternalProcess

InternalProcess

• Awaiting customers’ provision of color assortment information

• Awaiting customers’ approval of fabric swatch (on color, architecture, etc.)

• Awaiting instructions from production planning

• Awaiting availability of materials

• Awaiting availability of machinery

Your

Company

Logo

• Further break down steps through Work Breakdown Structure (WBS)

• Study each step and define a standard time

• Capacity can be obtained

• Prepare optimized production plan through staff experience or production scheduling software

• Compare the production plan with the actual output - Performance can be measured

Your

Company

Logo

DefineStandard

TimeFor

All StepsUnder the

WBS

IdentifyManufacturing

CapacityFrom theStandard

Time

Optimizationof

ProductionPlan

AchieveDefined

Performance

Your

Company

Logo

Set up Internal Benchmark & Model

Operation

Your

Company

Logo

• Standard knitting time by fabric architecture, material, and knitting machine type

• Standard dyeing time by material type, color or by volume

Your

Company

Logo

• Under the SCOR model, performance are measured by

– Fill rate – Cycle time

• In FS’s operation,

– Fill rate can be defined as• % of batch orders completed within standard time

– Cycle time can be defined as • Average cycle time of a batch order

Your

Company

Logo

• Set a target performance level for each, e.g.– % of batch orders completed within standard days

• As-Is: 80%, To-Be: 90%

– Average cycle Time• As-Is: 30 days, To-Be: 25 days

Your

Company

Logo

Improve Accuracy of Cycle Time Measurement

Your

Company

Logo

• Moving from manual record to barcode scanning system

• Also testing RFID for rapid and accurate measurement

Your

Company

Logo

Your

Company

Logo

Overall benefits of the projectOverall benefits of the project

Your

Company

Logo

• Performance quantification enhances supply chain visibility

• Eliminate wastes – stemming from over-production, transportation, over-

processing, waiting time, inventory, motion, and scrap

• Operational efficiency is enhanced in the overall supply chain

• Improve customer satisfaction

Your

Company

Logo

Thank You