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Suggest an Efficient Line Balancing for the new model of Notebook which would improve productivity and reduce cost
QUESTION FOR THE GROUP
TOSHIBA Satellite Notebook Computers Assembly Line
In August 1995, total workforce 2600 employees.
Worktime 7.5 hours per day for full time factory workers 6 hours for part time workers
4 assembly lines for producing Notebook computers 1 Idle 1 For overseas production 2 For domestic production
Initial Production to be at 150 units per day, to be increased to 300 units in the next week.
Each line can produce 8 different models Each model can have 6 different combinations of featuresTotal model types possible = 48Production PlanMonthly Production Plan specified quantities and model numbers of the units for the month.Each model type allotted 20 daily lots depending upon the monthly production plan.Total units on each line = 300.Average time for producing 1 notebook = 2 minutes per 10 line workers.
TOSHIBA Satellite Notebook Computers Assembly Line…
Solution 1 – LEVEL STRATEGY (OT)
Number of stations 10 and workers 11
Cycle time c =10 hour/300 units = 120 sec
Therefore 2.5 hours is the overtime required for producing 300 units per day
Line Balancing Based on 90 Seconds
per station !!!
Solution 2 – CHASE STRATEGY
Line Balancing Based on 90 Seconds per station….
Maintaining Work time = 7.5 hours/ day
Output rate r = 300 / 7.5 = 40 unit/hour
Cycle time c = 1 unit produced in 60 / 40 = 1.5 minutes
= 90 seconds
Line Balancing Based on 90 Seconds per station….
CalculationsΣ T = Total time = 1011 secc = cycle time = 90 secTM = Σ T / c = 11.23 ≈ 12 Stations
Hence
Increase 2 stations and hire 4 workers
Line Balancing : 90 seconds
Comparison between both solutions
Cost analysis of Level strategy Direct cost (10 people * 7.5 hours * X sal) + (10 people * 2.5 hours * 1.3 X sal)
= (107.5 X sal) Indirect costNo additional cost
Efficiencyή= Σ T / Σ Available = 1059 / 10*120 = 88.25 %
Comparison between both solutions
Cost analysis of Chase strategy Direct cost (14 people * 7.5 hours * X sal) = (105 X sal) Indirect cost Hiring & Training cost for 4 workers, 1 Shock test unit
Efficiencyή= Σ T / Σ Available = 1011 / 12*90 = 93.61 %
RABBIT CHASE STRATEGY
Both the alternatives suggested incorporate the use of the RABBIT CHASE
Seemingly the purpose of rabbit chase is to chase-down and catch a rabbit. Now this rabbit is an elusive little devil – it can hop randomly in any direction. You can run at least as fast as the rabbit, maybe even faster.
In other words it is work procedure where each of the 2/3 work persons goes through all the steps of the multi step process, performing the same tasks (staring from the beginning to end). This is applicable within an assembly line or for part Supply task.
B B
B B
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Rabbit chasing
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Prototype
ADVANTAGES
Multi tasking
Eliminating Support Worker
Increase Productivity and Quality
Decrease dependability on working skills
Other possibilities
1. Increase the conveyor speed ( With rabbit chase flexible task workers )
2. Outsource Certain sub-assemblies
3. Layout optimization
o 3
Rejections
PCB Assembly Automated
PCB manual assembly
Prot
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R&D /Design lab
Suggested Layout
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