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 BOM model master Component: monitor box lcd Component: keyboard keys Component Cd drive 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 Station Operation Time 1 2 3 4 5 6 7 8 9 10 11 1 2-7 8, 10-15 16-25,43 26-37,41 38-46 47-53 54-58 59-62 64,65 66-68 100 98 100 100 95 94 98 96 50 76 100 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.