Benneyan, James, Detellis, Frank, Keon, Brian, Blackwell, John, Truman, Chad, Harriman, Jeff, Johnstone, Bob, Bousquet, Greg, Malden Mills, Northeastern University, Department of Mechanical Industrial and Manufacturing Engineering
Malden Mills has determined that their waste produced is equal to 4.1 percept on a forecasted production of 14,500,000 yards. The company loses an estimated $7.24 for every yard lost in the process. Observations were taken of the manufacturing floor, and supervisors as well as operators and managers were interviewed to gain more insight into the problem. From there, Pareto charts of waste data revealed that the 3 largest contributors to wast are the finishing department, the quality cuts taken in all departments, and finally the knitting department. From interviews, it was hypothesized that the main cause of these defects was poor seem quality. We discovered an existing correlation between puckering of the seam (a large factor in seam quality) and waste, and then performed a design of the experiments to reduce puckering during the sewing process. We also tested whether a new type of sewing maching would reduce puckering, thus reducing waste.
Malden Mills, waste
Abed, Joseph; Kurowski, Alicia; Raposo, Isabel; Russo, Nicole; and Verano, Zulma, "Reducing and Monitoring Material Waste at Malden Mills" (2007). Capstone Design Program: Industrial Engineering. Paper 9. http://hdl.handle.net/2047/d10010440
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