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Morning Sun Screen Printing Company

Morning Sun Screen Printing Company. Presented by: George Holk James Gemperle & Kim Dubois. Company Overview. Founded in 1986 425 Employees, $52M Annual Sales Product: Custom Screen Printed T-Shirts Market: Primarily Department Stores, and Some Smaller Retailers

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Morning Sun Screen Printing Company

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  1. Morning SunScreen Printing Company Presented by: George Holk James Gemperle & Kim Dubois

  2. Company Overview • Founded in 1986 • 425 Employees, $52M Annual Sales • Product: Custom Screen Printed T-Shirts • Market: Primarily Department Stores, and Some Smaller Retailers • Batch Process, Make to Order

  3. Competitive Priorities • High Quality • Flexibility • Speed of Delivery

  4. Plant Layout and Work Flow (Approximately 150,000 Square Feet) Warehouse Sewing Shipping Warehouse Screen Prep Printing Offices Art Embroidery

  5. Plant Operations& Methods of Supporting the Competitive Priorities of:Quality, Flexibility and Speed

  6. Raw Materials Inventory • JIT System • Strong Supplier Relationships • Quality Inspections Performed • Orders Stacked by Design and Size Scale

  7. Art and Screen Preparation • Designs by In-House Art Department • 200 In Stock Designs (Down from 500) • Frames and Screens are Constructed • Design Image “Positive” is Burned onto Screen

  8. Competitive Priorities • Quality -Supplier Relationships -Raw Material Inspection -Design Engineering • Speed, Flexibility -Reducing Inventories (JIT) -Fewer Designs

  9. Screen Printing • Two Types of Screen Press Machines Used -Hand Press -Auto Press • Dryer Oven Belt • Shirts Inspected for Quality • Foiling, Embroidery • To Sewing for Final Work

  10. Screen Printing CP Support • Quality -Quality Inspections, Run Set-Up Testing and Fail Safing • Delivery Speed -Reduction of Set Up Times -Combining Processes -New Embroidery Machines • Flexibility “Mass Customization” -All Machinery on Wheels -Hand Presses for Special Orders

  11. Sewing • Labels and Collars -Formerly Outsourced • Capacity -20 Machines /3 Shifts • Bottleneck

  12. Sewing (cont.) • Identified as “Herbie” • How to Move Herbie Upstream -Collars -Smaller Batches -QC Runners

  13. Sewing cont. • Other Changes Made: -Pay for Performance -Purchase of 10 New Machines -Limit Order to Size Scale

  14. Sewing- Competive Priorities • Quality -QC Runners • Speed and Flexibility -Additional Machines -Improved Throughput

  15. Summary - Operations Support of Competitive Priorities • Quality -Inspections, QA Dept. • Flexibility -Mobile Production Equipment -Order Size Variance • Speed -JIT, Moving /Combining Processes

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