Figure 1: Excessive work-in-process before bucket brigades/TSS
Champion Products sews sports apparel, such as t-shirts, gym shorts, and similar items. Initially, all sewing was done on traditional flow lines, with batches of work-in-process moving through the line (Figure 1). Workers were paid piece rate, which encouraged them to create work-in-processas fast as possible.
Figure 1: Excessive work-in-process before bucket brigades/TSS
Champion implemented the Toyota Sewing System (TSS), which is similar to bucket brigades (but with certain omissions that do not enable the best productivity). Figure 2 shows a team of workers following (almost) the bucket brigade protocol while sewing t-shirts. Note the U-shaped line and the chest-high sewing machines to facilitate walking between stations. When the lady on the left finishes product, she walks back and takes over work from her predecessor, and so on, until the gentleman on the right reaches into the large box of cut cloth and begins sewing a new t-shirt.
Figure 2: WIP disappeared under bucket brigades/TSS.
Champion reported mild increases in productivity but great increases in flexibility: Because of the reduced WIP, a team could quickly change to the manufacture of a new product, which could simply follow the last of the former products onto the line, with each worker changing thread as required.