Next, we will demonstrate step-by-step how we have turned our product development process around. But first, if you are not up to speed on what led us to change, click here and read part one.
How the layout for the new warehouse came to life
According to Elisa Tinoco from the MEGO team, “our main goal was to create a layout for the new warehouse that would allow the company to organize sections, such as the storage of the different materials, inbound and outbound, and quality control.” Plus, it was indispensable to be well set up, ergonomic, versatile, adaptable for growth.
Regarding the ergonomic problems detected in the former warehouse, the group carried out an ABC analysis to find out which materials should be in a more accessible position and which can be further back. It became easier and more visual to identify the areas and the location of each article.
Together, we put the project into practice by this the order of priorities:
- Create the layout of the warehouse floor in order to reduce displacements;
- Distribute the labeled materials on the shelves according to an ABC analysis;
- Create the layout of the production floor, especially the product development area;
- Propose the purchase of an interactive whiteboard for the product development process, so that all details and any possible changes can be noted and shared with the commercial department;
- Dimension workstations for the reception and dispatch of materials according to the results of an EWA assessment;
- Create an out-of-stock visual identification system.
Besides storage racks, as well as the materials within each rack, different work areas were also arranged, as the team helped us to rethink the distances walked daily by the staff. These upgrades have improved the distance covered by 48%, which went from 65 meters/task to 34 meters/task. Regarding the level of effort, it will decrease due to the approximation of the workspaces, but also due to the better dimensioning of the workspaces and tables.
The result will further help prevent employee fatigue, and reduce the risk of work injuries or even the incidence of occupational diseases, associated with the dorso lumbar region, for instance. For us, this is the viable way to assume ourselves as truly ethical activewear and swimwear specialists. The following are the five key aspects that led to our revised processes.
1. Research
Conducting research is crucial to understand best practices, consumer preferences, trends, and demand for specific processes. All proposals were based on actual research, and real-life metrics, so that we can measure them over time.
The students from the University of Minho went on several visits to our new facilities, where we had a tour of the previous clothing manufacturing, offices, break rooms, warehouse, and the new product development room.
2. Collaboration
Surveys and interviews with the staff were equally conducted, namely the commercial management and the sample management. It was valuable to understand what worked well prior to the move and should be carried to the future.
We foster cooperation: the proposal covered encouraged cross-functional teams to work together, from design to production and product development teams. This helps ensure all aspects of the product are considered and can improve the speed and efficiency of the development process.
3. Lean methodologies
It was decided to implement lean product development methods to streamline processes, reduce waste, and increase efficiency. On site, the students have simulated various layouts for a wider perception, measuring and signaling the spaces occupied by shelves and workstations.
Added to that, the tours were also important to detect that one of the pillars on the new premises was not well-designed in the building's plan. As the layout had been designed based on the blueprint, it would’ve ended up influencing the results negatively if this had not been verified.
In a nutshell, the new layout is aimed to facilitate the flow of materials and makes the overall space more intuitive, especially with the proposed signage and space organization solutions.
4. Textile sustainability
In the midst of all these shifts, one thing is clear: sustainability considerations, such as eco-friendly materials and energy-efficient manufacturing processes, has continued to be a priority.
Our new layout is structured in such a way that the processes of collecting materials, returning, reserving, and shipping are much more efficient. As we sort through all of the above, we were able to reduce plastic and waste. Also, the new facilities and processes minimize the amount of time spent on transportation.
5. Advanced technology
As we re-mapped processes, this project took into consideration advanced technology in the development process to speed up prototyping and product sampling.
These optimizations ensure we meet clients’ needs and preferences in an even more timely and cost-effective manner, thus creating value for brands who search for a trusted swim, sportswear manufacturer, or, for that matter, any other textile manufacturer. Whatever the case, it all starts with a supply chain strategy.
From here on, we are committed to regularly evaluating and reviewing our new product development process and making changes as needed. The lesson is continuously striving to improve and find new ways to endorse that it stays efficient and effective, to innovate, and stay ahead of the competition.
If you meet the criteria and are ready to start your project from conception to production, send us a quote now, and you will be directly connected to someone in charge.
