Masco Cottons – Engineering a Lean-Agile Transformation

1. Cutting System

• Integrated laying and cutting into structured team-based systems, eliminating redundancy and securing smoother coordination.
• Centralized auxiliary activities within a Cut Parts Kanban Zone, supported by Bump Jump teams to streamline material readiness.
• Introduced time-activity catalogs, visual boards, and Andon signals to reinforce flow control, visibility, and rapid response.
• Implemented a pull-based cut-job planning and allocation system, engineered to align cutting directly with sewing demand.
• Enforced strict WIP control (maintaining 0.5–1 day of sewing demand) and synchronized dispatch to secure continuity.
• Deployed the Bump Jump team system across auxiliary processes to eliminate idle time and balance workloads.

Scale-Up Highlights:

• Merged and simplified processes for smoother integration.
• Adjusted cutting tables and layouts to optimize space and utilization.
• Formulated team-based concepts anchored by engineered work methods.
• Deployed standardized layouts, master display boards, and monitoring systems for real-time alignment.
• Combined and streamlined work methods, ensuring simplified flows and maximum resource utilization.

2. Sewing System

• Transitioned to team-based micro-factory units (10–12 operators) for greater responsiveness and ownership.
• Introduced centralized Kanban zones connecting preparatory operations directly with sewing streams.
• Shifted skills into fixed-position work units, with clear allocation of responsibilities to team members.
• Implemented TPM routines to ensure machine reliability and prevent breakdowns.
• Deployed point-of-use systems that integrate trims and supplies into Kanban baskets, splitting bulk cut parts into ready-to-use units.
• Applied value engineering principles to drive production efficiency and enable systematic monitoring.
• Balanced work units through elemental time analysis and simulation trials to ensure stability.
• Reinforced workplace discipline with structured 5S checklists and audits.
• Maintained standards through daily SmartGemba routines at the functional base.
• Reduced order changeover time to 30 minutes with agile workforce deployment.
• Linked cutting and sewing flows via Andon triggers for real-time synchronization.
• Adopted SPEP order changeover strategies under the fixed-position concept to streamline product transitions.
• Integrated disruption-free strategies for ensuring maximum resource optimization

Scale-Up Highlights:

• Segmentation into structured product families.
• Standardization of work units and engineered layouts.
• Deployment of real-time dashboards for visibility.
• Comprehensive skill-gap analysis and targeted training.
• Finalization of engineered layouts supporting stability and agility.
• Elimination of product delays through disruption-free strategies
• Deployment of well-calibrated machinery

3. Finishing & Packing

• Restructured into cellular Bump Jump units, fully connected to a centralized Kanban system.
• Standardized carton preparation, labeling, and dispatch zones, aligned with the Bump Jump concept for smoother execution.
• Strengthened flow discipline through structured runner cycles, Andon signals, and real-time visual dashboards.
• Deployed point-of-use systems integrating trims, accessories, and supplies directly into Kanban baskets for seamless readiness.
• Integrated disruption-free strategies to ensure maximum resource utilization and flow stability.
• Piloted cross-functional collaboration and workforce adaptability, building multi-skill flexibility across teams.
• Reinforced workplace discipline with structured 5S checklists and audit routines.
• Adopted pull-based planning to dynamically match finishing and packing capacity with sewing demand.

Scale-Up Highlights:

• Expansion of centralized Kanban systems to factory-wide coverage, including sewn garments, trims, accessories, and carton preparation.
• Simulation of Bump Jump team capacity to determine optimal team numbers and workload balance.
• Disciplined runner cycles and fixed Kanban routes established across all finishing and packing teams.
• Visual management scaled through dashboards and loading displays for real-time tracking of WIP, throughput, and dispatch readiness.
• Final engineered layouts drafted, accommodating cellular manufacturing teams and centralized Kanban zones at full capacity.
• Manpower planning confirmed with supervisors and operators trained for adaptability and flexibility.
• System integration with the overall Factory Operating System to ensure synchronization with upstream sewing and downstream dispatch.
• Redefined roles and responsibilities of engineering, supervision, and team leaders to sustain evolved systems.
• Tools, equipment, and furniture lists finalized for full-scale deployment.

The End Goal – Masco Factory Operating System

The transformation embeds:

• Operational Stability – through point-of-use systems, SmartGemba routines, TPM, and 5S governance.
• Workforce Adaptability – with reskilled engineering teams, supervisors trained as real-time problem-solvers, and workers cross-trained for system adaptability.
• Digital Readiness – by phasing in real-time monitoring and AI/IoT support systems.