Morning Sun
Screen Printing Company
Presented by:
George Holk
James Gemperle
& Kim Dubois
Morning Sun OP506
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
Morning Sun OP506
Competitive Priorities
High
Quality
Flexibility
Speed of Delivery
Morning Sun OP506
Plant Layout and Work Flow
(Approximately 150,000 Square Feet)
Warehouse
Warehouse
Sewing
Screen
Prep
Printing
Shipping
Offices
Art
Morning Sun OP506
Embroidery
Plant Operations
& Methods of Supporting the
Competitive Priorities of:
Quality, Flexibility and Speed
Morning Sun OP506
Raw Materials Inventory
 JIT
System
 Strong
Supplier Relationships
 Quality
Inspections Performed
 Orders
Stacked by Design and Size Scale
Morning Sun OP506
Art and Screen Preparation
 Designs
200
by In-House Art Department
In Stock Designs (Down from 500)
 Frames
 Design
Morning Sun OP506
and Screens are Constructed
Image “Positive” is Burned onto Screen
Competitive Priorities
 Quality
-Supplier Relationships
-Raw Material Inspection
-Design Engineering
 Speed,
Flexibility
-Reducing Inventories (JIT)
-Fewer Designs
Morning Sun OP506
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
Morning Sun OP506
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
Morning Sun OP506
Sewing
 Labels
and Collars
-Formerly Outsourced
 Capacity
-20 Machines /3 Shifts
 Bottleneck
Morning Sun OP506
Sewing (cont.)
 Identified
 How
as “Herbie”
to Move Herbie Upstream
-Collars
-Smaller Batches
-QC Runners
Morning Sun OP506
Sewing cont.
 Other
Changes Made:
-Pay for Performance
-Purchase of 10 New Machines
-Limit Order to Size Scale
Morning Sun OP506
Sewing- Competive Priorities
 Quality
-QC Runners
 Speed
and Flexibility
-Additional Machines
-Improved Throughput
Morning Sun OP506
Summary - Operations Support
of Competitive Priorities
 Quality
-Inspections, QA Dept.
 Flexibility
-Mobile Production Equipment
-Order Size Variance
 Speed
-JIT, Moving /Combining Processes
Morning Sun OP506