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Blended prototyping: a conceptual framework towards lean sustainable supply chain: A Case Study in...
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Transcript of Blended prototyping: a conceptual framework towards lean sustainable supply chain: A Case Study in...
Blended Prototyping: a conceptual framework towards
lean sustainable supply chainCase Study in Fashion Industry
Dr. Maged Youssef, PhD
GOLD SPONSORS
BRONZE SPONSOR SUPPORTER
MEDIA PARTNERS
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Questions to Answer?
• What is the traditional prototyping process in apparel export-import context?
• How could we improve the prototyping process by integrating 3D visual technology (blended process)?
• What is the impact of using this new concept on the prototyping process?
Contents:
• Supply Chain Management for Garment Production
• 3D design technology and Virtual prototyping
• Case Study : Virtual Lean prototyping
Supply Chain Management for
Garment Production
The supply chain for garment production
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
The supply chain for garment production
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
Fabric
Supply
1
Accessory
Supply
2 4
In-house
Production
3
Sub-
contractors
The supplier’s immediate
supply chain
Problems can’t be solved only between supplier and customer
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
Fabric
Supply
1
Accessory
Supply
2 4
In-house
Production
3
Sub-
contractors
The supplier’s immediate
supply chain
PRICE
SPEED
ON-TIME
DELIVERY
QUALITY
SOCIAL
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
Fabric
Supply
1
Accessory
Supply
2 4
In-house
Production
3
Sub-
contractors
The supplier’s immediate
supply chain
Problems can’t be solved only between supplier and customer
PRICE
SPEED
ON-TIME
DELIVERY
QUALITY
SOCIAL
Problems must be solved throughout the chain
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
Fabric
Supply
1
Accessory
Supply
2 4
In-house
Production
3
Sub-
contractors
The supplier’s immediate
supply chain
PRICE
SPEED
ON-TIME
DELIVERY
QUALITY
SOCIAL
How does SCM work?
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
Fabric
Supply
1
Accessory
Supply
2 4
In-house
Production
3
Sub-
contractors
PHASE 1: Prototyping
Producer
5
3
Sub-
contractorsAccessory
Supply
2
Fabric
Supply
1
How does SCM work?
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
Fabric
Supply
1
Accessory
Supply
2 4
In-house
Production
3
Sub-
contractors
Producer
5
4
In-house
Production
PHASE 2: prototyping optimization
3
Sub-
contractorsAccessory
Supply
2
Fabric
Supply
1
How does SCM work?
Rawmaterials Producerdyeing/
finishing
Weaving/
knittingSpinning
1 2 3 4 5 6
Brand/
Customer
Fabric
Supply
1
Accessory
Supply
2 4
In-house
Production
3
Sub-
contractors
PHASE 3: Brand requirements
Producer
5
4
In-house
Production
Brand/
Customer
Folie 15
2D-operation – Bodywear
Design specs
Body measurements
Anthropometric knowledge to derive rules of proportion
Development of construction classifications (cuts)
Folie 16
3D-Body-Scanner
International available systems
3D body scanners allow the collection of anthropometric data at a very high level of accuracy without touching the human body.
3D-Body-Scanner von
Vitronic
HUMAN BODY
Folie 19
Creating the peripheral lines on the figurine
Length of the perimeter
Value of the hip girthin measurement table
Skalierungs-faktor
Anchor point
rot
blau
scaled circumferential line
All measurements shall be entered in MS Excel tables and linked to scale the geometry model with the CAD system.
Cutting level of the terso
Parametric models (circumference scaling)
Folie 21
3D-Construction Method
It does not require mathematical formulation of the relationship between the body and the two-dimensional pattern pieces and is based on an intuitive way of working
Model Design
Product development of Bodywear
Automatic generation of 3D-surface into 2D-cutting patterns (Maged Kamal,2013).
scaling Surface generation Model design 3D generation 2D pattern
Fabric Assurance by Simple Testing (FAST)
• Tensile properties
• Bending properties
• Compression
• Dimensional stability
FAST 1 Compression
Meter
FAST 2 Bending Meter
FAST 3 Extension Meter
FAST 4 Dimensional
Stability
Folie 24
Processing (material based)
Implementation of Stress-Strain curves in simulation software
Folie 25
Visualisation
Fit simulation
Background information on the companies in the exploratory study
A B C D E
Nature of
business
manufacturer manufacturer manufacturer manufacturer manufacturer
Product
sector
knitwear knitwear knitwear knitwear variety
Turnover
(USD)
30 million 10 million 7 million 6 million 20 million
Geographic
market
served
North
America and
Europe
North
America and
Europe
Europe North
America
USA,Europe
Number of
employees
1300 560 450 380 1000
The traditional sampling process and its potential to be made virtual
conceptual Model for blended sampling process (developed by author)
Virtual samples
Physical samplesSM: Size measurements
MP: Material Properties
3
4
12
4
4
2
8
2
2
1
-
-
4
4
-
4
2
2
the average number of physical samples has to be reduced by 59 %
Sample process types NO New
Total Number of Samples 41 17
Expected benefits
• 24 samples x $20 = $ 480/ order
• 480X 200 order/year = $96000/year (potential Savings
• Pay back Period= 150000/96000= 1.56 Years
• Prototyping lead time reduced by 50%
• Enhancing customer satisfaction, creativity and improve communications
Conclusion
Lean blended prototyping framework is a new concept that could
contribute effectively towards lean sustainable supply chain
management.
References• Maged Kamal (2014/1), Producing of customized comfortable sportswear
using three dimensional (3D) technology, International Design Journal-volume 4 issue 2
• Maged. Kamal (2014 /2), Effect of adoption the Visual Production Planning and Control System (VPPCS) in apparel manufacturing companies , International Design Journal- volume 4 issue 3
• McNally, R. C., Akdeniz, M. B. and Calantone, R. J. (2011). New Product Development Process and New Profitability: Exploring the Mediating Role of Speed to Market and Product Quality. Journal of Product Innovation Management. Vol. 28 No.1, pp. 63-67
• Rudolf, A.; Jevšnik, S. & Stjepanovič, Z. (2012). Influence of Knitted Fabric’s Stretch on Virtual Prototyping of the Underwear, Proceedings of 14th Romanian Textiles and Leather Conference, 46th International Federation of Knitting Technologists Congress, Dodu A. (Ed.), Blaga M. (Ed.), pp.946-953, Sinaia, Romania, 6-8 September.
Thank you for your kind attention