Morning Sun Screen Printing Company Presented by: George Holk James Gemperle & Kim Dubois Morning Sun OP 506
Company Overview u. Founded in 1986 u 425 Employees, $52 M Annual Sales u. Product: Custom Screen Printed T-Shirts u. Market: Primarily Department Stores, and Some Smaller Retailers u. Batch Process, Make to Order Morning Sun OP 506
Competitive Priorities u. High Quality u. Flexibility u. Speed of Delivery Morning Sun OP 506
Plant Layout and Work Flow (Approximately 150, 000 Square Feet) Warehouse Sewing Screen Prep Printing Shipping Offices Art Morning Sun OP 506 Embroidery
Plant Operations & Methods of Supporting the Competitive Priorities of: Quality, Flexibility and Speed Morning Sun OP 506
Raw Materials Inventory u JIT System u Strong Supplier Relationships u Quality Inspections Performed u Orders Stacked by Design and Size Scale Morning Sun OP 506
Art and Screen Preparation u Designs -200 by In-House Art Department In Stock Designs (Down from 500) u Frames u Design Morning Sun OP 506 and Screens are Constructed Image “Positive” is Burned onto Screen
Competitive Priorities ð Quality -Supplier Relationships -Raw Material Inspection -Design Engineering ð Speed, Flexibility -Reducing Inventories (JIT) -Fewer Designs Morning Sun OP 506
Screen Printing u Two Types of Screen Press Machines Used -Hand Press -Auto Press u Dryer Oven Belt u Shirts Inspected for Quality u Foiling, Embroidery u To Sewing for Final Work Morning Sun OP 506
Screen Printing CP Support ð Quality -Quality Inspections, Run Set-Up Testing and Fail Safing ð Delivery Speed -Reduction of Set Up Times -Combining Processes -New Embroidery Machines ð Flexibility “Mass Customization” -All Machinery on Wheels -Hand Presses for Special Orders Morning Sun OP 506
Sewing u Labels and Collars -Formerly Outsourced u Capacity -20 Machines /3 Shifts u Bottleneck Morning Sun OP 506
Sewing (cont. ) u Identified u How as “Herbie” to Move Herbie Upstream -Collars -Smaller Batches -QC Runners Morning Sun OP 506
Sewing cont. u Other Changes Made: -Pay for Performance -Purchase of 10 New Machines -Limit Order to Size Scale Morning Sun OP 506
Sewing- Competive Priorities ð Quality -QC Runners ð Speed and Flexibility -Additional Machines -Improved Throughput Morning Sun OP 506
Summary - Operations Support of Competitive Priorities u Quality -Inspections, QA Dept. u Flexibility -Mobile Production Equipment -Order Size Variance u Speed -JIT, Moving /Combining Processes Morning Sun OP 506
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