Toshiba : Ome Works Group 7

QUESTION FOR THE GROUP Suggest an Efficient Line Balancing for the new model of Notebook which would improve productivity and reduce cost

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.

TOSHIBA Satellite Notebook Computers Assembly Line… Each line can produce 8 different models Each model can have 6 different combinations of features Total model types possible = 48 Production Plan Monthly 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.

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

Solution 2 – CHASE STRATEGY Line Balancing Based on 90 Seconds per station !!!

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…. Calculations Σ T = Total time = 1011 sec c = cycle time = 90 sec TM = 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 cost No additional cost Efficiency ή= 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 Efficiency ή= 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.

R Store Prototype Store R Workers are chasing the activities in a module Rabbit chasing Workers are stationary B B B B B

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

PCB Assembly Automated Suggested Layout Engine Assembly Unit Admin and Prodcution HD Drive Final Assy Prototype assy PCB Assembly Automated PCB manual assembly R&D /Design lab

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