Toshiba : Ome Works Presented By :- Group 8
Suggest an efficient line balancing method for new notebook that will reduce cost and improve productivity.
Kitting Master BOM Laptop model • master BOM Component: monitor Component: keyboard Component Cd drive box lcd keys frame box Drive
Need for Kitting • Each operator is responsible for allocating screws for the next operation • It can be avoided by Kitting of the screws • The Bill of Material of laptops can be updated by replacing the loose hardware by Kits
Boons of Kitting • Avoid operator error due to miscalculation of screws • Time saved in assembly line • Time saved can be used to assemble more computers
Kitting of screws saves 30 Secs per laptop assembly time • Saves a total of 30 secs x 900 units i.e. 27000 secs saved per day • Therefore total time saved is 7.5 hrs
1228 secs required for assembly of one laptop • Extra units produced 27000/1228 =22 units
Total units produced 900+22 = 922 units Production increase of 2.4 % per day keeping all other parameters same
Efficiency earlier 900/40 = 22.5 units/person • Efficiency after applying Kitting 922/40 = 23.05 units/person • Increase of 5.5 %
Reorganizing of Operations • Minimal Shuffling of Operations . • Sanctity of the Sequence of Operations is abided. • Reduction in the Cycle Time. • Productivity Analysis
Edges via the Approach Initial Units Produced : - 3*300 =900 Total Number of People Involved =3*10+10 (others) = 40 Total Productivity = 900/40 = 22.5 Now After the new technique, total time saved =114(bottleneck) – 100 =14 So for a total of 900 units, time saved =14*900 = 12600 =12600/100 = 126 new units!!! A marvelous figure, with just a trade off for 3 new workers.
Aspect of Productivity: - Initially : 900/40 = 22.5 After : (900+126)/(40+3)=1026/43=23.86 A clear edge of 6.04%.
Rationale Behind Cycle Time Reduction :--- > Time Saving which in effect increases Productivity. > Process tends to be effective and efficient. > Reduced cycle time….an embodiment of reduced bottleneck.
An Alternate Approach • One person One Table Solution A complete revamp from existing scenario …Assembly line replaced by individual operators who assembles a unit from scratch to final form. This method is successfully implemented in Sony’s factory in making handycams.
Advantages :-- Less of monotony. Better Development of Core Competency through multi-skilling. Accountability Error can to tracked down and minimal.
Lacunae In This Case Per-se Unavailability of data for assembling a unit by various skill level workers. Revamp of such an infrastructure…how feasible is it ??
Proposal:-> As per the segregated analysis of the various aspects , we would like to infer that the second point of analysis would make a better deal as this involves a critical breakthrough in which both the kitting and the reorganizing has been taken into consideration.