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 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

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

B

Wor

kers

are

sta

tion

ary

Store

R

Wor

kers

are

cha

sing

the

acti

viti

es in

a m

odul

eRabbit chasing

R

Store

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

Pro

toty

pe a

ssy

HD

Dri

ve F

inal

Ass

y

Eng

ine

Ass

embl

y U

nit

R&D /Design lab

Suggested Layout

Adm

in a

nd P

rodc

utio

n