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.