mountain tran's thesis
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The Feasibility Study of Combo Production Line in Notebook (NB)Computer Manufacturing.
by
Tran. Mountain Tran Hoai Son
A research study submitted in partial fulfillment of the requirements for the studying
and researchingin
COMPAL ELECTRONICS INC.
Examination Committee: Yue. Joel
Nationality:
Previous Degree:
Vietnamese
Engineer
Hanoi University of Technology
Hanoi, Vietnam
Scholarship Donor: COMPAL ELECTRONICS INC.
COMPAL ELECTRONIC INC.
Kunshan, China
April 2008
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Acknowledgement
First of all, I would like to thank the management of Compal electronics
inc for all of yours supports through to this process. I have a good opportunity to
practice all my fundamental theory that I have studied in my university and
researched a new specialist knowledge system. Some experiences are known and
how to work is taught.
Next, I would like to thank to my Mentor Sarah. Tran. She was good
engineer, and always takes cares about my percentage of process thesis. She was
a great helpful for my ideals. I know that this process have been immensely more
difficult with out her present.
I would also like to thank my professor Dich. Tran. He advised me to
get this opportunity and give some direction to solve problem in my thesis. As a
Dean of Mechanical Engineering, he was a great source of information on
technology, process control, and manufacturing system.
I would like similarly like send thank to management of MFG A31
workshop: Ms. Do Loan, Ms. Kate Nguyen, and Mr. Dinh Leo. This is my
practice workshop; they have been working here for a long time. They were a
great source of information and the real situation manufacturing of MFG. All of
my data and figures were supplied by them.
Addition I would like to thanks my friends and my family. My friends
found some information and knowledge and send it to me. All my friends include
who are working in Compal: Nguyen. Neo, Tran. Ronan, Bui. Kaku, Nguyen.
Rainbows, and classmate Hoang Quyet Chi, Cao Xuan Huy, etc... My family
always takes interest in me and encourage when I fell tired.
Finally, I would like to thanks all reader for listening to proposal and give
some comments.
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Abstract
My thesis was written at COMPAL ELECTRONICS INC. It describes
whole process I have studied and researched in four month. My topic is The
feasibility study of combo production line in Notebook Computer
Manufacturing and I study basic knowledge about Continuous flow
manufacturing system and Cell manufacturing system. In other ways, other
knowledge such as industrial engineering, plan layout and some relative concept
were studied. It is very helpful for my future work.
In general, there are different manufacturing models in electronic
manufacturing factories, including Batch Manufacturing Process, Full Automatic
Manufacturing Process, Semi-Auto Manufacturing Process, Flow Manufacturing
Process, and Cell Manufacturing Process. The selection of manufacturing
process/model depends on many different factors, such as the complexity of
products, average ordering volume, order fulfillment requirement, and so on. In
order to achieve the lowest manufacturing cost and the highest customer
satisfaction, it is critical to analyze and understand what would be the best fit for
each company. In current NB computer manufacturing, flow manufacturing ispopular. Recently many companies start to look into different manufacturing
process due to the change in competitive environment, such as lower volume and
higher number of models offered, higher requirement on Configured to Order
(CTO) for on-line ordering, and so on. Thus, it is important to look into further
optimal manufacturing process for NB manufacturing, such as combo production
line the combination of cell manufacturing and flow manufacturing.
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Table of Content
Chapter 1 .....................................................................................................................7
INTRODUCTION ............................................................................................................71.3 Research Background: ............................................................................................7
1.4 Objective of the research .........................................................................................8
1.5 Scope of the research ..............................................................................................8
Chapter 4 ........................................................................................................................57
METHODOLOGY .........................................................................................................57
Chapter 5 ........................................................................................................................61
CONCLUSION AND RECOMMENDATIONS ...........................................................61
REFERENCES ...............................................................................................................62
Appendix A .....................................................................................................................63
Appendix B .....................................................................................................................64
Appendix C .....................................................................................................................65Appendix D Commendation ..........................................................................................67
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List of TablesTable 1: Action progress..................................................................................................12
Table 2: Data relation......................................................................................................21
Table 3: Time of working group operations...................................................................35
Table 4: time of each station...........................................................................................36
Table 5: time of AFT.......................................................................................................38
Table 6:Time of group cell..............................................................................................39
Table 7: tools for Cell......................................................................................................39
Table 8: Time of Cell proposal.......................................................................................52
Table 9: Cost for Cell......................................................................................................52
Table 10: Overhead for Cell Proposal 1..........................................................................53Table 11: Time for Cell 2................................................................................................54
Table 12: cost for cell 2...................................................................................................54
Table 13: Overheads for cell 2........................................................................................55
Table 14: Compare between two proposal......................................................................56
Table 15: Work descriptions of research.........................................................................60
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List of FigureFigure 1: The law 5W-1H................................................................................................13
Figure 2 : Flow manufacturing........................................................................................18
Figure 3: General Cell layout..........................................................................................22
Figure 4: Type of Cell layout..........................................................................................23
Figure 5: Matrix part families.........................................................................................26Figure 6: Group machine................................................................................................28
Figure 7: matrix of machine............................................................................................29
Figure 8: sequence of parts............................................................................................30
Figure 9: Flow chart IPQ00.............................................................................................35
Figure 10: Time of Assemble..........................................................................................36
Figure 11: time of AFT....................................................................................................37
Figure 12: Time of PFT...................................................................................................38
Figure 13: Time of Packing.............................................................................................38
Figure 14: Cell ASSY work station 1.............................................................................40
Figure 15: AFT and PFT work station.............................................................................41
Figure 16: Cell for Packing.............................................................................................42Figure 17: Layout for Cell proposal 1.............................................................................43
Figure 18: Cell layout proposal 2....................................................................................44
Figure 19: Assemble cell 2..............................................................................................45
Figure 20: AFT and PFT Cell proposal 2.......................................................................46
Figure 21: Kitting............................................................................................................48
Figure 22: Cell table........................................................................................................49
Figure 23: Frame for Cell................................................................................................50
Figure 24: layout cell proposal 2.....................................................................................51
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Chapter 1
INTRODUCTION
The year of 2007 marks a significant milestone as Vietnam, Taiwans
Compal Electronics Inc., the worlds second largest contract computer maker, is
considering building a factory in Vietnam, Taipei Times reported. Compal could
join the growing number of Taiwanese electronic companies investing in
Vietnam, in pursuit of more cost-effective manufacturing sites outside China.
Opportunities are opened up and challenges are confronted to every entity. In the
cooperate program between Compal electronics inc. and Hanoi University of
Technology, I have been studying and researching in Kunshan, China for four
months. This is the result of whole process.
1.3 Research Background:
In current situation of Compal electronics Inc., all of manufacturing system
is flow manufacturing. It has been existing for a long time when customer
requirement batch and lot size manufacturing. Nowadays, due to the change
in competitive environment, such as lower volume and higher number of
models and so on. The Compal have to select a suitable process
manufacturing and satisfy customer required.
In accordance with the new trend of age, there is many manufacturing
models in electronic factory: Full automatic process, Semi-auto manufacturing
process, Flow Manufacturing process, and cell manufacturing process. Besides,
depend on many different factors such as the complexity of products, average
ordering volume, order fulfillment requirement and so on. Compal Electronics
Inc. researched and experiment on Cell manufacturing. However, to re-layout is
more expensive and waste, it is implement gradually. After that, we compare
between Flow manufacturing and Cell manufacturing to find a manufacturing
model more benefit and effective. Basic applications such as Sub line, Re-layout
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line H. The staff has gradually gained Cell manufacturing concepts and more and
more experiment in Cell. Nevertheless, the Cell manufacturing application here
is just in the early stage of the development with partial implementation at the
simple level. The number of applications remains limited and does not bring
more benefit and effective as other Cell complimented company.
Aware of the significance of Cell manufacturing and its benefits, after the
study about cell manufacturing and many relative data. I set the target of
building a combo production line Cell manufacturing and flow
manufacturing, which is saving cost, meet customer requirement, feasible to
implement in manufacturing.
1.4 Objective of the research
The objectives of this study and researching are listed below:
To identify Cell manufacturing and flow manufacturing
To propose combo production line in notebook manufacturing
To analyze relative data: cost, time, square, so on
1.5 Scope of the research
Cell manufacturing study is diverse and complicated, concerning various
different levels. Time is limited, all data document and material is lack, the
initiation and implementation of study face many challenges, such as
document in Chinese, some time is barrier of language, thus the realization
requires the gradual approach. Furthermore, the concept of Cellmanufacturing is seen from different aspects, i.e. car manufacturer Toyota,
Dell cell manufacturer, NEC cell manufacturer. Its successful realization
requires the manufacturing system. This study will focus on the
recommendation of a solution with the design a new production line for
MFG A31.
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Chapter 2
LITERATURE REVIEW
In this chapter, I write about basic knowledge which I have studied and
researched for four month. In other word, I applied it to research the current
situation of MFG.
1.1. Industrial Engineering seven tools:
The concept of Industrial engineering: Industrial engineering is
concerned with the design, improvement, and installation of integrated systems
of man, material, and machines for the benefit of humankind. It draws upon
specialized knowledge and skills in the mathematical and physical sciences
together with the principles and method of engineering analysis and design to
specify predict and evaluate the results to be obtained from such systems.
The basic objectives of industrial engineering are improving operating
methods and controlling costs and reducing these cost thought cost reduction
program. And the IE department is to provide specialized services to production
department, such as method improvement, time study, developing wage
incentives schemes, and merit rating and to head a new project if required.
IE department uses scientific approach in identifying and solve problem.
It collects factual information and regarding the problem, analysis problem,
prepare alternative solutions take into account all internal and external
constrains, selects the best solutions for implementations. This is problem
identification that includes four step: Collect detail about job, using standard
techniques likes chart, diagram, models and templates Recorder facts are
subjected to critical examination using a series of question Find alternative
solutions for problem Evaluate the alternative and find the best solution.
With the development of industry and manufacturing, the scope and
techniques of industrial engineering is more widen. The main aim of tools and
techniques of industrial is to improve the productivity of organization by
optimum utilization of resource: man, machines, and materials. There is thirteen
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items of industrial engineering but in Compal its sum up 7 tools to suit with the
electronic industrial. It includes:
Foolproof .
The motion study.
The law of 5W 1H.
Hands operation or the hands act.
Man- machine chart.
The sampling method.
The improvement action progress.
1.1.1. The foolproof:
Foolproof method known as anti-error, just to prevent stupid people who
do something wrong. In other ways, its meaning is how to design a method with
minimum level of mistakes.
Basic principles:
Move operations easily
No operation and skills base on intuitive.
The is no risk in operations
Application of Principle:
Root principle: The cause of the error is not result from the
fundamental rules.
Insurance principle: two or more than two moves followed to
complete the work.
Automatically principle: in a variety of optical, electrical,
mechanical, learning institutions, such as chemical principle to
limit the implementation of certain actions and no error happens.
Line principle: To Prevent the entire mistake from the beginning.
Order principle: to choice a process, we must consider inversion
process and process to find error.
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Isolation principle: Depend on each destination, it has standard and
all actions and progress base on it.
Copy principle: with a work to do if two or more, preferably using
"Copy" approach to achieve.
Another layer principle: To avoid mistakes will be different, and to
try to distinguish all the error from many respect of problem.
1.1.2. Motion study:
This principle to at least reach the largest labor work results, the former
Jierboshi (Gilbert) was first proposed, study after finishing additions and
deletions.
Classified into three:
1>. Spent on the human aspects of principle, includes an eight
principle
2>. On the layout of the workplace and the environment principle,
includes a six
3>. Tools and equipment design principles.
There are 20 principle of this tools will be presented in detail at the back.
1.1.3. The action progress:
Objects Focus
Equipment layout Process product
Work arrangement improvement
Process improvements
Test improvements
Material handling waste analysis
The improvement of bottleneck situation
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Operation improvements
Eliminate waste action
Utilization of machines
Fixed rate machine
Eliminate of disorder
Table 1: Action progress
1.1.4. The law 5W 1H:
The purpose of this study is in the way: Familiar with the system have
questioned to identify the problem, Root of causes and possible ways to create
improvements.
Every work includes:
1. Prepared: time and labor spent on adjustments such as machinery, such
as the area of preparation work.
2. Operation: actual work on value-added products.
3. Pack: such as time and labor spent on the processing of removed, the
remnants of debris disposal, storage or cleaning work, and no productive action.
Direction of Improvement
Each work can be in accordance with the following four main
directions to explore possible directions.
Elimination: Many operators may be unnecessary; Review of all
process and improve it with the best way.
Combination: Seeking the possibility of merging; the two
operations together, it can be saved handling, inspection, storage, and
other movements. Merger two actions is very difficult, As far as
possible should be made in the handling of the merger.
Rearrangement: should change its priorities, location and the
possibility of operator, these changes may lead to delete and merger
inspiration.
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Simplify: delete, merge and change operation review, the study
"how" to do to achieve the purpose of simplification.
30
5W1H Law principles below
IE 20
Designated points, or issues (such as
increasing the efficiency of the quality of work
Total doubt
WHY
Some doubt
WHY
HOW
4 action
WHO
WHEN
WHERE
WHAT
Sinmplification
Elimination
Elimination
Combination
Rearrangement
Figure 1: The law 5W-1H1.1.5. The law of man machine:
Learn how to record man and the machine work with in process. Then,
build the chart, that is the way with a record of the operator and the machine or
operating machinery of the relationship, and to record do further analysis and
improvement.
Function
1. Understanding of the current situation, operator of the machinery
and the time.
2. According to the records contained in the above query to find ways
to improve.
3. Improve before and used to compare the differences to improve the
situation.
1.1.6. The hands act:
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"Hands operation" is to help us to understand his hands in operation "idle"
status, and seek to improve the approach to the best hands capacity. To chart the
way to record the operator hands (feet) process moves to the records do further
analysis and improvement.
Function:
1. Records for the existing operators hands (feet) of the action
process.
2. According to (1>.) Records to be challenged to find ways to
improve the place.
3. Improve before and used to compare the differences to improve the
situation
1.1.7. The sampling method:
Application of statistical sampling method means the sampling principle
to study the work of the staff and activities in the machinery and equipment; it is
a fact-finding one of the most effective tools. It can in the shortest possible time
and under the lowest cost between the manpower and equipment with useful
information.
Step in making work-sampling study:
1. Define problem: state objective and purpose, then describe
in detail each element to be measured. The elements should
be so chosen as to real the delays with in control of
operator.
2. Obtain department supervisors approval and co-operation
of operators and department. They must understand the
purpose.
3. State confidence level and desired accuracy.
4. Make a preliminary study
5. Design the study: determines the number of observations to
be made, the number of observers needed, number of
day/night shifts needed. The plan procedure, timings, and
route of observers. Design the observation form( should
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contain all the information needed to prepare the final of
study).
6. Make observations: Record observations and date,
summarize the data at the end of each day, plot data end
control chart.
7. Check the accuracy of the data obtained.
8. Prepare report and state conclusion.
All above knowledge is seven tools of industrial engineering in Compal. It
is basic knowledge for us to find the way to improve work. The criteria of IE is
no thing is the best but it can be better, we have to continuously improvement.
1.2. Plan layout:
A plant layout is an optimum arrangement of Facilities and services in
an existing or proposed plant on order to obtain maximum output of high quality
at the lowest possible production cost.
1.2.1. Objectives of a good plant layout:
Integrate the production centers into a logical balanced and
effective production unit. Reduce material handling (distance as well as time)
Effective space utilization (vertical and horizontal).
Flexibility (permits possible changes in production program)
Worker convenience and job satisfaction(control temperature,
humidity, noise, light, ventilation)
Remove of bottle necks.
Quick work disposal.
Industrial accidents avoided (proper aisle width, safe guards, clean
area).
Reduces physical effort.
Decency and orderliness inside the plan area.
1.2.2. Principle of plant layout:
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1. Principle of overall integration of men, machines, material,
supporting activities.
2. Principle of minimum movement and material handing
3. Principle of smooth and continuous flow. Remove bottle neck,
congestion and back tracking.
4. Principle of cubic space utilization. Use vertical space thoughts
racks, cartoons, bag, etc
5. Principle of safety and satisfaction for better morale.
6. Principle of flexible. Permits rearrangement of layout with least
in convenience and minimum cost.
1.2.3. Type of plan layout:
There are four type of Plan layout: process layout, product layout,
combines of process and product, fixed position layout. At this time, Compal use
product layout in almost workshop, because of the development of industry and
the change Customer requirement so the new manufacturing system was
appeared cell manufacturing. Thus, I describe more detail about product layout.
T is T- lathe
M is Milling machine
D is Drill machine
G is Grinder machine
Product layout also known as line layout. The operation are performed insequence of their occurrence, and the equipment are arrange accordingly. This
type of layout is preferred for continuous production of a given product.
Advantage:
- Less space requirement for the same production volume.
- Automatic materials handling possible.
- Reduced product movement and processing time.
- Simply production planning and control, better co-ordination.
T T M M G
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- Smooth and continuous work flow.
- Less skilled workers can serve the purpose
Disadvantage:
- Product changes require major changes in layout. Lay out is in
flexible.
- Pace of working depends upon the pace of the slowest machine.
- More machines are needs as machines arranged operation wise.
At some locations, standby machines are needed, where one
machine failure may result in complete shutdown of production
line. Thus, the system requires higher capital investment.
- Inspection become difficult.
In additions, I want to confirm one a again, Plant layout classified three kinds:
product layout, process layout, cell layout. However, in the scope of this topic, I
have not enough time to descript all of it more detail. Product layout includes:
continuous flow, mass production, and batch-processing arrangements are
usually organized by product layout. Equipment arrangement is based on the
sequence of operation performed in production, and products move in a
continuous path from one workstation to the next. Thus, I am concerned with
continuous flow manufacturing.
1.3. Continuous flow manufacturing and line balance:
1.3.1. Continuous flow manufacturing
As above writing, machines and equipments are arrange in one line
depending upon the sequence of operations required for the next product. The
materials move form one workstation to another sequentially without any
backtracking or deviation. In addition, machines are grouped in one sequence.
There for materials are fed into the first machines and finish goods travel
automatically from machine to machine, the output of one machine becoming
input of the next, for instants, in the line manufacturing, logic lower is checked
and assembled main board , output is logic lower and main board and next
workstation assembled PCMCIA frame, so input is the output of previous station.
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The raw material moves very fast from one workstation to another stations with a
minimum work in process storage and material handing.
This image illustrate the continuous flow manufacturing of MFG A31:
Figure 2 : Flow manufacturing
In this model, the material moved two straight lines, because RUN-IN is
round and to saved the space of the workshop. Product layout often follow a
straight line, a straight line is not always best, and layout may take an L, O, S or
U shape. In this situation, O is better than other is. And how to set up a
continuous flow layout. The grouping of machines should be done keeping in
mind the general principle:
- All the machine tools or other items of equipments must be
placed at the point demanded by the sequence of operations.
- There should no points where one line crossed another line.
- Materials may be fed where they are inquired for assembly but
not necessarily at the one point.
- All the operations including assembly, testing packing must be
included in the line
Advantages: Product layouts provide the following benefits
- Low cost of material handling, due to straight and short route
and absence of backtracking.
- Smooth and uninterrupted operations
- Continuous flow of work
- Lesser investment in inventory and work in progress
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- Simple and effective inspection of work and simplified
production control
- Lower cost of manufacturing per unit.
- WIP is shorter, requirement space is smaller.
Disadvantage of flow line:
- High initial capital investment in special purpose machine.
- Heavy overhead charges.
- Breakdown of one machine will hamper the whole production
process.
- Lesser flexibility as specially and laid out for particular
production.
- Waste time when change type product.
- Output is not stable, because of some mistake on the line
Suitability:
- Mass production of standardized products.
- Simple and repetitive manufacturing process.
- Operation time for different process is more or less equal.
- Reasonably stable demand.
- Continuous supply of materials
Therefore, the manufacturing units involving continuous manufacturing
process, producing few standardized products continuous on the firms own
specifications and in anticipation of Compal- Electronics Inc. Nowadays, the
demand of customer is changed very fast, from the mass production to the
diversification of products and high quality reduces cost product. Due to this
demand, Compal is changing the manufacturing system gradually, step by step.
To satisfy the demand of customer, the highest quality and the lowest of cost
production, Lean manufacturing is more suitable for Compal and the best choice
is Cell manufacturing. All of them are writing in next part. The law of change
does not demolish old things and we have to improve and maintain all of them.
Thus, I deal with tools of continuous flow manufacturing Line balance.
1.3.2. Line balance:
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Line balance in a layout means balancing the production or assembly line
particularly in product layout. It may arise: the fact that the production capacity
of each machine is the sequence is nor identical. For example, suppose there are
three workstations A, B, C with productions capacity per 25, 50, 100 pieces per
hour. A = 100, B= 50, C = 25. It is very difficult to balance and the layout. To
balance this layout, the production capacities of workstations A and B will have
to be increase to match with the maximum capacity workstation. This will be
permitted all stations to work to their maximum capacities.
Define of line balance: Line balance of production line is uniformed to
work step of production system about time by adjust operating load.
To estimate the line balance rate we calculate percentage of flow
production line. This percentage will show the rate of production line.
Method to calculate the balance rate:
1
WTTotal Workstations time
Balance rate= *100% *100% Number Operator * Time of bottle neck DL*BT
n
i
After calculate the balance rate, we are mention to another relationship
such as Balance, CWS, Grate.
The aim to reduces bottleneck station operating time Improve the line
balance enhance the production line reduce the CWS Improve the
production line Labor cost per station will be reduce.
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Table 2: Data relation
We have to use all of above formula to calculate the production line. After
that, we use ECRS (Eliminate, Combination, Rearrange, and Simplify) to
improve the line to get the best result.
1.4. Cell Manufacturing Systems and Cell Formation Problems, CFP:
1.4.1. Cell manufacturing system:
a. Define:
Cell manufacturing is a manufacturing approach that challenges the
traditional Job Shop approach for a organizing a factory. In traditional Job shop,
manufacturing is organized by process or departments - each department
specializes in one or more manufacturing process such as screw drive machine,
scanned barcode, assembly, screw feeder When a product is manufactured it
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usually built in a large batch which is then routed thought each of station, finally
move to the stock. Therefore, under the traditional Job Shop system components
and products are continuously manufactured in excess and at the wrong times.
This approach creates excessive Work in Process (WIP) inventory and lengthy
manufacturing lead-times.
Thus, Cell manufacturing (Cellular Manufacturing)is not a product-
orientated approach. Manufacturing facilities are organized to build specific
products or families or products in work cells. These work cells are design to be
product focused and arranged to contain each of resources necessary such as
machines, people, tools, etc to build a product or product family to complete
from start to finish. If a product can be built completely in the same cell, this cell
is called a Product Cell.
b. The classification of Cell layout:
Because Cell layout is free style, there are many types of Cell layout.
However, it bases on define and general template. We can divided into four kind
of Cell layout.
The general of Cell layout:
Figure 3: General Cell layout
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Figure 4: Type of Cell layout
c. Step to design cell:
1. Analysis product:
In this step, the characteristic and specifications of product is
analyzed. After all that, we have to bring out analyzed result. It
concludes: Element of production: sequence and tools
Time standard: movement and time of it
2. Design cell workstation:
To rely on above analyzed process, we have to list: Tools and
equipments, number of operators, fixture. Then we calculate standard time per
one product.
3. Design layout of workshop:
To analyzed Material Requirement Planning (MRP) and Capacity
Requirement Planning (CRP), it is an effort to develop a match between
the production plan and production capacity of a company. CRP must be
coordinated with the MRP. Afterward, we calculate the number of cell
workstation and arrange in determined space with principle:
Saving space.
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The way of transport do not congestion and have aestheticism.
To satisfy of CRP from one to two year.
d. Advantage and disadvantage of Cell manufacturing:
Advantage of Cell manufacturing:
- The cell operates like an independent business with total
responsibility for quality, manufacturing and delivery of the product
to customers.
- All cells have the resources within their organization to accomplish
their mission.
- The requirements are known and goals are established.
- Cell member are flexible and work in teams to accomplish their
goals including continuous improvement.
Disadvantages of cell manufacturing:
- Lower equipment utilization
- Increase set up cost.
1.4.2. Cell Formation Problem:
In this scope of thesis, I introduce about General Cell Formation Problem.
Because the time is not enough for me to researching more detail about it. It has
long been recognized that productivity in manufacturing can often increase by
producing similar products in manufacturing cells. This involves: assign parts
into individual machines and forming machines into manufacturing cell. These
two activities have traditional carried out separately. Here we present a new
model that deals with two activities above simultaneously, then we extend this
model to allow for the reassignment of operations to different machines type s by
incorporating machine type modification costs. Such modification enables
additional machine type to process certain parts, with view to reducing inter-cell
travel. The cost of such modifications must be balance by the consequent
reduction in inter-cell travel cost. The extended model specifies which individual
machines should be modified to enable them to process additional part types,
part-machine assignment, and the grouping of individual machines for cell
formation. The objective is to minimize, the grouping of individual machine
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modification cost, and the inter-cell travel. We call this endeavor the General
Cell Formation Problem. The idea work best for medium-variety, medium-
volume situations, batch production. The focused factory is constructed using the
notions of either flexible manufacturing system or group technology, which are
based on the precept that certain activities should be dedicated to a family or
related parts in manufacturing cell.
Suppose that a number of different products have to be manufactured
using certain machines types. It is known from the process plans of the parts
which machine types. It is known from the process plans of the part, which
machines types are required for producing the individual parts, and the routing
(machine ordering) for each part is given. We wish to assign the different parts to
the individual machines of the types required and to group machines so that each
group forms a manufacturing cell. This leads to the following activities:
- Assign part families to groups of machine types,
- Find lot sizes of the parts produced,
- Determine the number of machines needed of each machine type,
- Assign parts to individual machines and
- Group individual machines into manufacturing cells,
Formation of Families of Parts and Their Assignment to manufacturing
Cells of Machine Types
Assume that n parts, numbered 1, 2,...,n, are to be processed on m
machine types: numbered 1,2,,m, which are to be grouped into up to p
manufacturing cells, numbered 1.2,,p. The information as to which parts are to
be processed on which machine types is given by the so-called machine type-part
matrix, with elements:
aij = 1, if part j is processed on M i, and= 0, otherwise,
(i = 1, 2, ..., m; j = 1, 2, ..., n.),where M i denotes the machine type i.
We attempt to reorder the machine type rows and part columns of the
machine type-part matrix to obtain a block diagonal structure as shown in Figure:
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Figure 5: Matrix part families
The term "block diagonal" implies that we can partition the matrix such
that the boxes on the main diagonal contain as many 1's as possible, but
the off-diagonal boxes contain only 0's. If such a block diagonal structure
(as shown) is obtained, the items that correspond to columns of one block
(constituting a family of parts) are processed only on those machine types that
correspond to the rows of that block (a group of machine types). Each
block is a candidate for a manufacturing cell.
Computation of Lot Sizes and Minimum Number of Machines
For each part j, let dj be the demand rate, Kj be the set up cost, and hj be
the inventory holding cost per unit per period. We can often choose the lot size or
batch size qj , to be the economic order quantity:
2 ., j= 1,2,.....m
j j
j
j
K dq
h
Next, for each Mi , 1,2,,m, we determine the minimum number of
machines needed. Let Ci be the capacity of each M i (measured by its
running time, including set up) available per period. Let sij be the required set
up time per batch or lot of part j for any M i and let tij be the processing time
(without set up time) for one unit of part j on any M i. We do not consider
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conveyance times as they can be neglected within each manufacturing cell.
The processing time pij of a job j (of batch size qj) on any Mi then
ijsij j ijp q t
The utilization uij, of the Mi's by part j is given by
j ij
j ij
j
ij
i
d sd t
qu
C
Note that uij is the number of Mi 's, or fraction thereof, that is required for
the processing of part j. We set uij= 0 if part j is not processed on any Mi. The
numerator in above formula represents the running time of a Mi per period
required for part j. If uij > 1, say, 1 < uij < 2, we introduce a dedicated Mi to
process part j.
Given the utilization uij of the Mi's by part j (j = 1, 2, ,n) the minimum
number ei, of Mi 's required for producing all parts, can be computed as:
1
n
i ij
j
e u
Wheree
is the smallest integer greater than or equal to e (rounded up).
The average utilization ie of an Mi is:
1
n
ij
j
i
i
u
ee
We now go on to use the concepts we have just defined to address the two
activities assign parts into individuals machines and. In the next section, we
survey traditional heuristic methods that address above two activities
sequentially. Next, we present new models that address these two activities
simultaneously.
Machine-Part Assignment and the Grouping of Machines into Cells:
If part j must be processed by an Mi and ei > 1, we must specify to which
of the ei Mi 's that part j is assigned. Thus, for each Mi with ei > 1, we have to
solve a machine-part assignment problem whose objective function (to beminimized) is a measure of the material flow or material handling cost
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between different manufacturing cells. In other words, the solving of the
machine-part assignment problem requires some preliminary knowledge of the
solution to the machine grouping problem.
The machine-part assignment problem can be modeled as a
graph-partitioning problem, where the nodes of the graph correspond to the parts
processed on Mi's. We seek to determine a minimum-cost partition into ei sub
graphs .
The construction procedure determines an assignment of the parts to
the machines so that machine capacities are not exceeded. Consider an Mi with
ei > 1. Let Ji {1,2,..., n} be the set of parts processed on Mi's. To
construct a feasible solution, assign the parts j Ji successively to the first
M i , with capacity available. If the capacity of the first M i is exceeded, we
use a second machine, and proceed analogously. Only if none of the M i 's has
sufficient capacity to process all of part j, should the operation be divided
into partial processing by more than one Mi.
Figure 6: Group machine
As an example, we apply the construction procedure to the M 4 's, where
J4 = {2,4,5,6} and e4 = 3. Let M i represent the kth machine of type i. Part 2
has a utilization of M4 that exceeds one. This creates a dedicated M41 , that
processes a single part (part 2). The remaining utilization by part 3 is assigned
to M 4 , along with part of the utilization of part 4.
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The solution to the assignment problem for all machine types
can be summarized in a machine-part incidence matrix with elements:
brj= 1, if part j is assigned to machine r,
= 0, otherwise, where the number r, is the unique numerical label
of some individual machine.
Example:
Figure 7: matrix of machineGiven a machine-part incidence matrix, the machine grouping
problem (that is, the formation of manufacturing cells) can be solved in a
variety of ways which involve the solution of problems assign parts to individual
machines and group individual machines into manufacturing cell sequentially.
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Figure 8: sequence of parts
In other way, to achieve optimality we develop a new model that solves
tasks assign parts to individual machines and group individual machines into
manufacturing cells simultaneously. But it is a program, and I do not descript
here because of this limit of thesis.
1.4.3. Group technology and group efficiency:
a. Group technology:
Group Technology (GT) seeks to obtain the economies of scale of mass
production in a batch production environment. The attractions for the pioneers of
GT were, however based on cost directly but rather indirectly as a result of
having more effective control over the manufacturing systems. GT can be critical
element in the rejuvenation of outdated and unproductive plant. GT addresses the
following issues as a single coherent problem.
Component are arrange into families with similar production requirements
Small group of machines are matched to the component families
Groups of operatives are assign to cells
The basic idea of part families manufacture originally consisted of
grouping parts with similar machining characteristics together to form so-calledadditive batches and routing them though the functional machine layout with
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assistance of the production control. The basic ideal of GT cell is to split the
manufacturing area into machine group in which all the machine groups in which
all the machining operations required for the manufacture of a certain parts
spectrum can be accomplished. Within the GT cell itself all the forms of work
can be employed with the advantage that the task area limited such a way that
the members of the group also have the feeling of belonging to a team.
a) Define of group technology
In the simple terms, GT can be defined as grouping of parts with similar
operation and machines corresponding to these operations, which makes GT to
be recognized as one the key factors to improve productivity in any
manufacturing systems. GT have got different definition such as:
1. Identifying and grouping similar or related machines, parts in a
production in order to use their similarities by considering the
inherent economies of flow-production methods.
2. Logical arrangement and sequence of all facets of company
operation to bring in the benefits of mass production to high variety,
mix quantity production.
3. Development of technological processes, efficient setting up of
machine tools and equipment planning, so as to insure the most
profitable technical planning of production in the shortest time.
4. By realizing that many problems are similar and that by grouping
similar problem, a single solution can be found to set of problems,
these by saving time and effort.
5. Classification of parts or machines into groups in order to increase
the efficiency in the field of design as well as in production.
When viewed from a manufacturing perspective, GT can be defined as the
decomposition of manufacturing system into various subsystem by categorizing
parts into part families and machine into machines cell depending on the part
manufacturing characteristics. The advantage of grouping machine into cells will
reduce the number of production must be scheduled. Also grouping parts into
families reduces the complexity and number of parts for schedule purpose.
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Implementing GT may result in the following benefits:
- Reduction in new shop drawings 30%
- Reduction the number of drawings through standardization (10%)
- Reduction in raw material stocks 42%
- Reduction in new parts designs 53%
- Reduction in work in process inventory 62%
- Reduction in overdue orders 80%
- Reduction in throughput time 70%
- Reduction in setup time 69 %
- Reduction in industrial engineering time 60%
- Reduction in production space required
b) Classification of Group technology:
The main of classification in any manufacturing environment is to provide
an efficient and rapid method of information retrieval for making decision. But
still today in most companies, production decisions are solely base on guess
work. The need for GT classification can be the following purposes:
- To find the parts for tooling material families
- To find the optimal component for parts
- To find the optimal scheduling sequence for loading
Parts classification is method by which slightly dissimilar parts are
identified and grouped together to take advantage of their basic similarities in
manufacturing and design. Once the parts have been organized, GT cells can be
design around the part family; with each cell handling one or more part families
and all parts in a given family are expected to be more or less identical and able
to process by a standardized process plan.
b. Group efficiency:
Group efficiency is defined as the ratio of the difference between the total
of the external cells that can be visited and the total number of external cells
actually visited by all components to the total of the maximum number of
external cells that can be visited them (only applicable when number of cells is
more than one)
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1
1 , 1n
w j
j
E q c
Where,
qj is the number if different machine belonging to component j
routing.
The total number of cells actually visited by all components is
1 1
( 1)n c
w jk
j k
A x
Where,
xij =1 if component pj visits cell ck, k = 1,2,,c
= 0 otherwisew w
w
E AGroup efficiency =
E
If all machine groups within manufacturing cell have equal cycle time, the
work stations should be allocated to machine groups such that the machine group
have a approximately the same efficiency. This is because the efficiency of the
manufacturing cell is best equal to the efficiency of the worst performing
machine group. By making all machine groups approximately equal, the
efficiency of the worst performing machine group is maximized.
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Chapter 3
Design a combo production line and analyze
According the fundamental knowledge and the step to design cell, I give
some cell proposal and analyze it.
2.1. Analyze product:
In whole studied and research process, I have practiced on Line D and line
G with model IBQ00. Therefore, I design a combo production line to produce
IBQ00. This model represent for other notebook computer.
2.1.1. The flow chart of product:
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STRU
AFT
R/I
Repair
Pass
Fail
OK
PFT
COSM
Packing
Pass
Pass
RepairFail
WIP
SWDL
OBE
Shipping
RepairNG
OK
OK
TPDL
Figure 9: Flow chart IPQ00
Number Period Time (second)
1 STRUC 86,15s
2 AFT- assembly function test 89,23s
3 TPDL 120s4 R/I RUN IN 3600s
5 PFT Program function test 116,03s
6 PACKING 101,59s
Table 3: Time of working group operations
According the above flow chart, the production line classified into 2 parts: before
R/I and after R/I. I have measured, grouped, and divided time of each operator.
So this is shown in the behind chart:
Number Operation Time (second)
1 Pick up MainBoard and paste PPID 10,4s
2 Pick up Logic Lower 2,19s
3 Assemble Fan 5,85s
4 Assemble Logic Lower and MB 5,84s
5 Screwed on 7,12s
6 Assemble CPU 4,25s
7 Assemble thermal 6,25s
8 Assemble Modem 6,54
9 Assemble RAM 3,25s
10 Assemble PCMCIA Frame 10,73s
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11 Assemble Speaker 6,15s
12 Plug cable 7,71s
13 Screw hexagonal screwed 12,78s
Table 4: time of each station
Main board
10,4s
Logic Lower
Assemble Fan
Assemble Main boardand Logic lower
Screwed on
AssemblePCMCIAFrame
Assemble cable
Assemble speaker
AssembleRAM
AssembleCPU
Assemble thermal
Assemble modem
2,19s5,85s
5,84s
7,12s
10,73s
7,71s
3,25s
4,25s
6,25s
6,54s
12,78s
Screwedhexagonal-
screw on
6,15s
Figure 10: Time of Assemble
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Check Rj45 Port
COSMETIC
Check 1394 port
Check USB
CheckSY CARD Unplug HDD and
keyboardScan barcode
Plug HDD and
key board
6,10s
5,96s 12,38s
5,51s
CheckKeyboard
24,28s
5,65s
4,46s
6,6s
A
Pick up toRUNIN Frame
4,51s
Figure 11: time of AFT
Number Operation Time (second)
1 Plug HDD and keyboard 6,10s
2 Cosmetic 5,96s3 Check RJ45 Port 12,38s
4 Check 1394 port 5,51s
5 Check keyboard 24,28s
6 Check USB 13,78s
7 Check SY CARD 5,56s
8 Unplug HDD and keyboard 4,46s
9 Scan Barcode 4,51s
10 Pick up into RUNIN Frame 4,51s
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Table 5: time of AFT
A
Take baseto the line
3,63s
Assemble component of Computer:
Change RAM A to RAM B
Assemble BIOS battery
Plug battery
HDD, ODD
Mouse
WWAN card
Button printed circuit to check
TEST items: DVD
Sound and MIC
Power Modem
Smart Card
Power by multimeter
36,38s 41,83s
Disassemble
Battery
HDD, DVD Mouse
WWAN card
Power
Paste PPID label
32,07s
Pick up SWDL
A
2,12s
Figure 12: Time of PFT
A B
Scan barcode and pick
up to line
3,28s
Disassemble
Battery, BIOS
RAM
Thermal
CPU
Assemble RAM DOORPast temp
Paste PPID
DELL temp
14,21s
31,04s
Cosmetic
14,36s
Scanbarcode
10,3s
PACKING
28,4s
Figure 13: Time of Packing
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2.1.2 Table time of above process:
Number Period Time (second)
1 STRUC 86,15s
2 AFT- assembly function test 89,23s3 TPDL 120s
4 R/I RUN IN 3600s
5 PFT Program function test 116,03s
6 PACKING 101,59s
Table 6:Time of group cell
2.1.3. Tools for cell:
Number Period Tools (quantity)1 STRUC De-ion fan (1), Screw-drive
machine(2),Fixture for thermal (1) and
screwed on, Tape dispenser (1), screw
feeder (1)
2 AFT- assembly function
test
HDD, Keyboard, net wire RJ45
standard, printed check USB, SY-card,
scanner, Notebook
3 TPDL Frame TPDL
4 R/I RUN IN Frame RUN IN
5 PFT Program function
test
Battery, BIOS battery, ODD, HDD,
WWAN card, printed button, scanner,
notebook
6 PACKING Screw driver machine, temp, scanner,
DTC, box
Table 7: tools for Cell
2.2. Design Cell
2.2.1. Cell proposal 1:
Cell working station for Assembly:
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AFT and PFT
Figure 15: AFT and PFT work station
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PACKING
Figure 16: Cell for Packing
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Layout to produce a Completed product:
Figure 17: Layout for Cell proposal 1
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Figure 18: Cell layout proposal 2
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2.2.2. Cell proposal 2:
Layout ASSY area:
Figure 19: Assemble cell 2
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AFT and PFT area:
Figure 20: AFT and PFT Cell proposal 2
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Kitting
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Figure 21: Kitting
CELL table:
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Figure 22: Cell table
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Frame:
Figure 23: Frame for Cell
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Figure 24: layout cell proposal 2
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2.3. Detail analyzes:
In this part, I analyze for above proposal that includes labor, time,
frequency of product, and cost.
2.3.1. Proposal 1:
a) Time and frequency of product:
Table 8: Time of Cell proposal
Name Abbreviation Formula Value
Direct labor DL 4
Work Hour standard WHS 8 hour
Loss rate LR 5%
Bottleneck cell BT Max(cell) 116,03s
Working hour WH WH=DL*WHS 32h
Current
workstation time
CWT *
(1 )*3600
BT DLCWT
LD
0,1357h
Rate Rate 3600*
*(1 )
WHSRate
BT LR
261,27
b) Cost for Cell:
Material
Table 9: Cost for Cell
Name Quantity Price
Logic Lower 1 113
Fan 1 17
Modem 1 22
PCMCIA 1 11
MainBoard 1 469
Speaker 1 9
Other 27
SUM 668
Salary for Operator:
Salary of operator calculated as bellow:
- New operator from 1000 to 1500 RMB
- Skill operator from 850 to 1000 RMB
Average salary of operator
850 1500 11752
S RMB
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Sum of salary:
K= 1175x4=4700RMB
Overheads:
Table 10: Overhead for Cell Proposal 1
Items Equipment, tool,
fixture
Type Quantity Price
(RMB)
Sum
(RMB)
1 Cell table Equipment 4 2800 11200
2 Tray Equipment 20 50 1000
3 Frame Equipment 1 4000 4000
4 Conveyer Equipment 2,13 2000 4260
5 Small handcart Equipment 3 380 1140
6 De-ion Fan Equipment 5 400 2000
7 Magnetic charger Equipment 1 40 408 ESD bracelet Equipment 5 6 30
9 NG product table Equipment 4 65 260
10 MI table Equipment 5 6 30
11 Black board Equipment 1 280 280
12 Torsion Test Tooling 0.5 10500 5250
13 Multi-watch Tooling 1 950 950
14 Screw tray Tooling 10 22 220
15 Screw head Tooling 12 3 36
16 Tape feeder Tooling 2 740 1480
17 Carpet table Tooling 4 22 8818 Caliper thickness Fixture 4 140 560
19 Screw driver
machine
Tooling 10 900 9000
20 Fixture for
hexagon screw
Fixture 1 120 120
SUM (Vt) 41944 RMB
- Transport cost Vv= 2% Vt= 2%.41944= 839 RMB- Maintain and warranty cost :
Vm=7%.Vt=7%.41944=2940RMB
Management cost:
Vql = 150300% S= 250%.4700=11750 RMB
Sub material cost Vvlp= 1%Vc= 1%.688=6,88
Electric, water, other energy cost:
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Vp =10%. S = 4700.10%= 47 RMB
Overheads:
Vtp = Vp +Vvlp +Vql + Vm= 41944+2940+11750+6,88+47 +839 =57526,88
2.3.2. Proposal 2:
a) Time and frequency of product:
Table 11: Time for Cell 2
Name Abbreviation Formula Value
Direct labor DL 62
Work Hour standard WHS 8 hour
Loss rate LR 5%
Bottleneck cell BT Max(cell) 5,95Working hour WH WH=DL*WHS 496h
Current
workstation time
CWT *
(1 )*3600
BT DLCWT
LD
0,1078
Rate Rate 3600*
*(1 )
WHSRate
BT LR
3600
b) Cost for Cell:
Material
Table 12: cost for cell 2
Name Quantity Price
Logic Lower 1 113
Fan 1 17
Modem 1 22
PCMCIA 1 11
MainBoard 1 469
Speaker 1 9
Other 27SUM 668
Salary for Operator:
Salary of operator calculated as bellow:
- New operator from 1000 to 1500 RMB
- Skill operator from 850 to 1000 RMB
Average salary of operator
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850 1500
11752
S
RMB
Sum of salary:
K= 1175x62=72850RMB
Overheads:
Table 13: Overheads for cell 2
Items Equipment, tool,
fixture
Type Quantity Price
(RMB)
Sum
(RMB)
1 Cell table Equipment 4 2800 11200
2 Tray Equipment 20 50 1000
3 Frame Equipment 1 4000 4000
4 Conveyer Equipment 2,13 2000 42605 Small handcart Equipment 3 380 1140
6 De-ion Fan Equipment 5 400 2000
7 Magnetic charger Equipment 1 40 40
8 Kitting Equipment 2 4000 8000
9 ESD bracelet Equipment 5 6 30
10 NG product table Equipment 4 65 260
11 MI table Equipment 5 6 30
12 Black board Equipment 1 280 280
13 Torsion Test Tooling 0.5 10500 5250
14 Multi-watch Tooling 1 950 95015 Screw tray Tooling 10 22 220
16 Screw head Tooling 12 3 36
17 Tape feeder Tooling 2 740 148018 Carpet table Tooling 4 22 88
19 Caliper thickness Fixture 4 140 560
20 Screw driver
machine
Tooling 10 900 9000
2 Fixture for
hexagon screw
Fixture 1 120 120
SUM (Vt) 49944 RMB
- Transport cost Vv= 2% Vt= 2%.49944= 988,88 RMB
- Maintain and warranty cost :
Vm=7%.Vt=7%.49944=3496RMB
Management cost:
Vql = 150300% S= 250%.4700= 11750 RMB
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Sub material cost Vvlp= 1%Vc= 1%.688=6,88
Electric, water, other energy cost:
Vp =10%. S = 11.10%= 7285 RMB
Overheads:
Vtp = Vp +Vvlp +Vql + Vm= 49944+7285+11750+6,88+3496 +988,88
=73470,76 RMB
2.3.3. Compare (cost for one cell)
Table 14: Compare between two proposal
Items Proposal 1 Proposal 2
Product frequency 65 58Overheads 57526 73470
Space 14m2 6,05m2
According the above table cell proposal is more effective: saving cost,
increase frequency of product and it can be change model as quick as
possible. Because one cell change model, other cell do not affect, it will be
continue produce. Some advantage and disadvantage of this cell model:
Advantage:
- Saving space.
- This is a cell and it contains advantage of Cell as above
characteristics, for example as comparison of worker, flexible
of product.
- Easy to contribute product and material.
Disadvantage:
- High initial capital.
- Low machine utilization.
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Chapter 4
METHODOLOGY
To Design a combo production line cell manufacturing and flow manufacturing
To identify clearly about cell manufacturing and flow manufacturing.
To propose combo production line
To analyze cost, time, product and other relative data
The following chart shows the way to implement with six steps:
57
Begin
Identifying the goal of
the research
Identifying the objectives ofthe research
Defining the problems
Analyzing the problems
Solving method
Solving the problems
Discussion & Conclusion
End
Chapter 1
Introduction
Chapter 2Literature review
Chapter 3
Methodologies
Chapter 4
Chapter 5
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Actions To achieve results
1 Identifying thegoal of the
research
Interview:
Meeting owner, trainer, mentor of MFG A31,
Discussing about study and research plan of MFG A31
2 Identifying the
objectives of theresearch
Interview:
Meeting and discussing about Topic with owner, trainer,
mentor Identifying and discussing about topic, study research plan
Determining the scope of the topic
=> To identify topic => To target of topic
3 Defining theproblems
To determine the work
processes required for the
research.
Lecture
Lecture the leader of MFG,
trainer, mentor: To get
information of
manufacturing process of
MFG A31.
Lecture the leader of MFG
- Information of
manufacturing process
- Flow production
- IE tools
- Cell manufacturing
4 Analyzing the
problems To identify the definition Cell
manufacturing and flow
manufacturing.
To determine which line and
product will be applied for the
research.
Discussing by email with
trainer and mentor
To determine the process
of research and study.
To determine the benefits
of combo production line
successful.
5 Solving the
problems
To propose production line
and detail analyze data.
To prove the feasible of
combo production line
6 Discussing To evaluate the new solution. To evaluate the new
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Table 3.1: Work descriptions of the research
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Table 15: Work descriptions of research
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Chapter5
CONCLUSION AND
RECOMMENDATIONS
5.1. Conclusion
I have been studying and researching at Compal Electronics Inc. for a
long time, managements and staff has taught some basic knowledge and
experiment. I understand about Compal Electronics Inc. and role and
responsibility of MFG A31 one relative department. Needless to say, this is
helpful for my job.
Pass whole process studying and researching, I have some other skill as
search information from internet, read and comprehend foreign book and
material of Cell manufacturing and flow manufacturing, the most important is
Industrial Engineering 7 tool of Compal. The English skills are improved such as
reading, writing, speaking, and listening. Beside, I studied Chinese, thebeginning step to communicate with Chinese friend.
I studied about new knowledge system such as concept of Lean
manufacturing, Cell manufacturing, Industrial engineering tool. Then, I can use
them to do work more effective. Add more, fundamental understanding about
manufacturing process of MFG A31 and how to improve, calculate relative data,
get information were transfers.
Having of above information, it helps me to studying and researching
topic. Then, I write this report as a fulfillment requirement to accomplish the
beginning step of my work. In my thinking, this report is useful for Compal to
improve and become the leader of ODM (Original Design Manufacturer). In the
end, study about teamwork and work in group is the most important for myself.
5.2 Recommendations :
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Accoding to my analyze, the cell proposal is more effective than flow
manufacturing. In other hand, it is achieve the lowest manufacturing cost and the
highest customer satisfaction such as diversify of product, small batch size and so on.
However, to re-layout is more expensive, it could be applied in Compal Vietnamto get more benefit and effective.
REFERENCES
Professor M.I.KHAN: Industrial Engineering
Professor Tran Van Dich : Design Production line
Professor Tran Van Dich : Organizing manufacturing
J M Wilson and L R Foulds: Approach to cell formation problem
Introduction cell manufacturing Mekong Capital
http://dspace.mit.edu/ - Thesis
Group technology with flow shop cell (from Germany in English)
Applied continuous manufacturing to low volume electronic manufacturer by
Denis Hager
http:// www.google.com.vn
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Appendix A
QUESTIONNAIRE
MFG A31 and cell manufacturing
Date / venue:
Interviewee name:
Position & Role:
Location / contact info:
Objectives of the interview
- Studying and discussing about strategies study of MFG A31,Compal
- Identifying and discussing about manufacturing problem at MFG A31, Compal
1. Could you describe briefly about MFG role and responsibility in Compal?
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2. How do you thing about MFG development in Compal?
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3. How do you thing about Cell manufacturing development in Compal?
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4. Do we need to improve MFG development from flow manufacturing to Cell
manufacturing
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Appendix B
QUESTIONNAIRE
Sevices/applications needed at MFG
Date: ________________
Location: ________________________
Name of interviewer: ______________________
Position of job: __________________________________
Objective of the interview
- To get information of manufacturing process of MFG departments at Compal
- Information of manufacturing process
1. Could you describe to me, how many functional departments at the Compal?
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2. Did you have working process documentations of functional departments?
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3. How many kind of product were required by customer in Compal?
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Appendix D Commendation
OW
NER
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TRAINER
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M
ENTOR
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