straightline snowboards, wakeboards, kneeboards and tow lines n fearon brown n monte christensen n...

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?