straightline snowboards, wakeboards, kneeboards and tow lines n fearon brown n monte christensen n...
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STRAIGHTLINESnowboards, Wakeboards, Kneeboards and Tow Lines
STRAIGHTLINESnowboards, Wakeboards, Kneeboards and Tow Lines
Fearon BrownFearon Brown Monte ChristensenMonte Christensen Fred HolubikFred Holubik
MBA 518
Topics of Discussion
BackgroundBackground ManufacturingManufacturing PlanningPlanning QualityQuality
1. Background1. Background
Company HistoryCompany History
.. Founded 1986 as manufacturer of tow lines for Founded 1986 as manufacturer of tow lines for water sportswater sports
Late 1980’s branched out into distribution of Late 1980’s branched out into distribution of branded water recreational productsbranded water recreational products
Began manufacturing wake and knee boards in 1993Began manufacturing wake and knee boards in 1993 1994 limited production of snow boards1994 limited production of snow boards 1995 full production of snow boards1995 full production of snow boards Diminishing role of distribution of branded productsDiminishing role of distribution of branded products
2. Manufacturing2. Manufacturing
PRODUCTION FLOWPRODUCTION FLOW Batch shop Batch shop 75 unit lot size75 unit lot size Nov. - March production for water sportsNov. - March production for water sports Jan. - Sept. production for snowJan. - Sept. production for snow Oct. - Feb. cross over production - new design marketing, Oct. - Feb. cross over production - new design marketing,
special ordersspecial orders 11 of 14 manufacturing steps are generic to snow or water 11 of 14 manufacturing steps are generic to snow or water
boardsboards Rope production - year-round as needed (low volume, Rope production - year-round as needed (low volume,
assembly) assembly)
invcore assembly
snow board core assembly
water board core assembly
sand blastmold inject
(2)
water board core material (O/H)
water board core assembly
sand blastmold inject
(2) invcore assembly
snow board core assembly
presses (4)
water board core material (O/H)
water board core assembly
sand blastmold inject
(2) invcore assembly
snow board core assembly
presses (4)
tip/tail routingde-flashing
rough sanding3 stations
water board core material (O/H)
water board core assembly
sand blastmold inject
(2) invcore assembly
snow board core assembly
presses (4)
tip/tail routingde-flashing
rough sanding3 stations
drilling/inserting (2)
water board core material (O/H)
water board core assembly
sand blastmold inject
(2) invcore assembly
snow board core assembly
presses (4)
tip/tail routingde-flashing
rough sanding3 stations
drilling/inserting (2)
final sanding3 stations
rough/med/finewater board core material (O/H)
water board core assembly
sand blastmold inject
(2) invcore assembly
snow board core assembly
presses (4)
tip/tail routingde-flashing
rough sanding3 stations
drilling/inserting (2)
final sanding3 stations
rough/med/finewater board core material (O/H)
inspection/grading
water board core assembly
sand blastmold inject
(2) invcore assembly
snow board core assembly
presses (4)
tip/tail routingde-flashing
rough sanding3 stations
drilling/inserting (2)
final sanding3 stations
rough/med/finewater board core material (O/H)
inspection/gradingshrink wrap
water board core assembly
sand blastmold inject
(2) invcore assembly
snow board core assembly
presses (4)
tip/tail routingde-flashing
rough sanding3 stations
drilling/inserting (2)
final sanding3 stations
rough/med/finewater board core material (O/H)
inspection/gradingshrink wrappackagingshipping
3. Planning3. Planning
High Quality and InnovationHigh Quality and Innovation
Research & DevelopmentResearch & Development
Cross-functional teamsCross-functional teams Design by experimentationDesign by experimentation Industry standardsIndustry standards Custom laboratoryCustom laboratory
Competitor reviewCompetitor review
PlanningPlanning Seasonality - year round manufacturingSeasonality - year round manufacturing New product every 6 monthsNew product every 6 months Non-manufactured orders once a yearNon-manufactured orders once a year
Fall
Winter
Spring
Summer
Fall
Winter
Spring
Summer
Wakeboard
Snow board
Wakeboard
Snow board
Wakeboard
Snow board
Wakeboard
Snow board
Wakeboard
Snow board
Wakeboard
Snow board
Wakeboard
Snow board
Wakeboard
Snow board
Wakeboard
Snow board
Fall
Winter
Spring
Summer
Fall
Winter
Spring
Summer
Order FulfillmentOrder Fulfillment
Made to orderMade to order Pre-season / In-seasonPre-season / In-season Weekly work chartWeekly work chart Push quality on suppliersPush quality on suppliers
4. Quality4. Quality
SPCSPC Team orientedTeam oriented Process oriented Process oriented
SPC Procedures
Parado chartsParado charts Push SPC down to suppliersPush SPC down to suppliers Computer generated defect reportsComputer generated defect reports Results measured dailyResults measured daily Strive for only 10% defects was 35%Strive for only 10% defects was 35%
Team OrientedTeam Oriented
Daily meeting with Daily meeting with leads about problemsleads about problems
Feedback taken from Feedback taken from workersworkers
Teams get incentive Teams get incentive pay for qualitypay for quality
Each team the key to Each team the key to qualityquality
Process Oriented
Bar coding of raw Bar coding of raw materials and defectsmaterials and defects
Acceptance testing at Acceptance testing at start of runstart of run
Written procedures at Written procedures at each locationeach location
Check quality at each Check quality at each stagestage
No formal QA groupNo formal QA group
Bar CodedMaterials
AcceptanceTesting
Quality Checkeach Location
PassQuality
PassQuality
Completed Product
Bar CodedDefects
Yes
Yes
No No
Input into SPCdatabase
Next Location
Completed
Finished Goods
STRAIGHTLINESTRAIGHTLINE Questions?Questions?