1. 1 Notebook Activity JP CABRERA, MUNS Manager, Updated 10/04/2001

2. 2 Notebook project 3 assumptions : –280 units/shift, only productivity increase –560 units/shift, capacity + productivity increase –840 units/shift, capacity + productivity increase Investments : Payback : Planning Annex 1 : stockroom improvement Annex 2 : production process improvement

3. 3 THE 3 ASUMPTIONS

4. 4 Simulated specifications :

5. 5 Simulated investments and payback period :

6. 6 INVESTMENTS

7. 7 For 280 units / shift

8. 8 For 560 units / shift

9. 9 For 840 units / shift

10. 10 Pay back

11. 11 For 280 units / shift (release 2)

12. 12 For 560 units / shift (release 2)

13. 13 For 840 units / shift (release 2)

14. 14 Capacity versus budget :

15. 15 Schedule for the project:

16. 16 Annex 1 : Stockroom improvement : - Current process - New process - Gains

17. 17 Stockroom : description of the current process –step 1 : –Book of previous preparation (screen on MAPICS) –print current Manufacturing Order –print locating list of components –step 2 : pick first part of components –step 3 : pick expensive parts (CPU/RAM/HDD) –step 4 : pick components on the flow rack –step 5 : pick last part of the preparation –step 6 : prepare each tray on the conveyor

18. 18 Stockroom : current situation Office Area 2 Flow rack Area 1 Prod NB Area 3.1 Area 3.2 Area 3.3 CPU room 1 2 3 4 6 5 Kitting This process is adapted to Mos of large quantities

19. 19 Stockroom :description of the new process –step 1 : –print current Manufacturing Order –print locating list of components –step 2 : pick expensive parts (CPU/RAM/HDD) –step 3 : pick 1 component (PREKIT) –step 4 : pick components on the flow racks –step 5 : scans the preparation for booking

20. 20 Stockroom : projected situation Office Area 1 Prod NB Area 3.1 Area 3.2 Area 3.3 Prekits CPU room 4 3 2 1 Area 2 No more Kitting 5 This process is adapted to Mos of little quantities (ATO/CTO)

21. 21 Stockroom : picking loop Parameters: –the loop is 88 meters long –the operator needs 15 minutes per cycle: –2,5 minutes to prepare 1 unit –6 units picked at once –7 hours of work per shift => 28 cycles –THEN a warehouseman runs 2,5 kilometers per shift This value is normal : the law gives no limit in this case, because the load to carry is very low : 80 kg on an adapted trolley

22. 22 Stockroom : Gains obtained First step : improving manual process = gain from 9’ to 4’ the gains are obtained by : –suppressing 1 operation : the kitting, gain 3’ –grouping components, gain 1’ –reducing the length of the picking way, gain 1’ Second step: opportunity to use the Pick to voice = gain from 4’ to 2’ the gains are obtained by : –improving quality by asking a checksum key at each step, –improving concentration of the operator on the picking itself –removing 3 steps : »printing of MO »printing of Locating list »booking in the system –simplifying the training = 1 hour instead of 2 days

23. 23 Annex 2 : Production process improvement : - Current process - New process : - the cell - layout with 4 EAP - layout with 6 EAP - Gains

24. 24 Production : Current Layout Prekits Flow

25. 25 Production : the new cell

26. 26 Production : new layout for 4 “EAP” (release 2)

27. 27 Production : new layout for 6 “EAP”

28. 28 Production : Gains obtained Only on a cell of 2 “EAP”, we gain 6,2 direct people in KITTING+ASSEMBLY+PACKING : –current process = 16,7 people –new process = 10,5 people

29. 29 END