toshiba: ome works
TRANSCRIPT
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Outline
List ofFact(s)/Issu(e
s)
PossibleSolution(s)
FocusProblem(s)
Recommendation(s)
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Background
Began operate in 1968
Produced : - Personal computers
- PC Boards
- Word processors- Hard disk drives
- Optical character readers
- Computer and communications system
4 Catergory of employees: - Full time - Temporary- Part time - Affiliated
2600 employees in 1995 : - 440 direct factory workers
- 1050 design engineers
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Fact/ Issue (1) Trouble in finishing the installation of floppy disk drive
COMPETITION in notebook PC market was FIERCE/strong
LIFETIME of a notebook model : 6 months MISSING crucial product cycle/ DELAYING introduce new product large LOSSES
in market share
PC assembly PROCESS :
1) two 60-meter assembly conveyors 45 operators each
2) three 27-meter lines 14 operators each
3) three 14.4-meter lines 10 operators each (Exhibit 7)
Total 7 PC assembly line :
- 4 IDLE use only if demand increased)- 3 lines DAILY operation 1 overseas, 2 domestic market
Previously, Ome produced 8 different models 6 different features COMBINATION
each models
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1995: SHORT LIFE TIME of each model
- 300 units per line 3 to 10 different model per line per day
- 504,000 units per yearASUMMPTION 7 lines used
(7 lines) x (300 unit per line) x (20 daily lots) x (12 months)
EACH PC model sequentially assembled
EMPLOYEES on notebook assembly line in November 1995 :
- 50% full-time,
- 25% part-time,
- 25% affiliated companies.
Characterized word processor for Japanese market adjacent to PCnotebook assembly lines :
- high product variety
- low volume
- no longer expanding.
Fact/ Issue (2)
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Exist. Ome`s PC assembly line process
Word Processor
Assembly
R
S/T
Notebook
Assembly(3 lines active,
4 lines idle)
PKG
R
S/
T
PKG
Operator
Conveyor Belt
Parts
Repair Area
Pre Install software & test
Racks for burn-in
Packaging
Pallets of finished Product
Computer Displayed
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Existing PC Assembly Line Process Flow Chart
START
Computer displayeddaily productionschedule
1st operator laid outmajor component
2nd operatorentered barcode
Modelchanged?
1st operator placecontainer of small
parts on the blank
space
2nd operatorscanned the barcode
The rest of operatorpick up the smallerpart they need onshelv above theirwork area
NO
YES
Portable computer displayed theoperations realted to eachstation
Snapping connector together or
attaching parts with small screws
HW
test
Shock-
Test
Burn-InDone
shock test?
NO
YES
Softwarepre-installed
Packaging &placed on pallets
EN
D
Note:
1)Supporter per line to replace break operator or assist if problem occured.
2)Supervisor, qulity assurance, Supporter and Repair worker often worked during
early morning and late afternoon. The speed of conveyor also decreased during this time.
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Focus Problem
LIFETIME of a notebook model : 6 months Competitor can minimize production & sales cost, lower
product price:
*refer to Exhibit 2
Technology appliance (e.g Notebook)create best on both
quality assurance and after sales service is critical.
1993 1994Market Share 10.8 % 13.8 %
Unit 663 1,192
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Solution(s)1) Improving INNOVATION of new model in design process
with sufficient speed of time
2) Increasing product demand improving itsMANUFACTURING PROCES increase speed of assemblyline + cutting production cost lower product price thancompetitor.
3) Increasing QUALITY CONTROL of product & after salesservice
4) Reduce the RESOURCES to process word processor productto improve capacity ofPC Notebook product.
5) Creating system for DISTRIBUTING channel to reach biggermarket
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Recommendation(s)1) Improving INNOVATION of new model in design process with sufficient
speed of time
2) Increasing product demand improving its MANUFACTURING PROCES
increasing speed of assembly line + cutting production cost lower
product price than competitor.3) Increasing QUALITY CONTROL of product and after sales service
Analysis Process + Job Design + WorkMeasurement
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ecommen at on
Improving INNOVATION of new model
Inside OUTSIDE
INSIDE Outside
CUSTOMER
Hardware Type/Model ?
Feature?
Improving both of hardware andsoftware for adaption to market
demand
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ecommen a on
Increasing production unit with low production cost (1)
Increase quality controlling of product & after sales service
No Scenario sort by Priority + -
1. REGULAR worker to work additionalovertime
(+) low cost(+) more responsible(+) skillfull
(-) fatigue employee(-) short term(-) empty post
2. Reevaluate the work load of the entireplant, SHIFTING worker intoassembly area
(+) low cost(+) more responsible
(-) empty post(-) short term(-) less skillfull
3. Obtain help from AFFILIATEDcompanies
(+) medium cost(+) more responsible
(-) empty post(-) short term(-) training needed
4. Hiring TEMPORARY or PART-TIMEworkers
(+) long term (-) high cost(-) high risk(-) less responsible(-) unskill , training
needed
Table of Increasing Worker Scenario based on Strength & Weakness
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Increasing production unit with low production cost (2)
R
S/T
Notebook
Assembly(3 lines active,
4 lines idle)
PKG
R
S/
T
PKG
Operator
Conveyor Belt
Parts
Repair Area
Pre Install software & test
Racks for burn-in
Packaging
Pallets of finished Product
Computer Displayed
1. NO EXTEND LINE : 3 op. + 4 idles
possible COMBINATION ofincreasing worker is scenario
2/3/4/ mix of them
(refer table on previous slide)
3. REDUCE S/T timeNo need toincrease worker, but INCREASE
SKILL NEEDED for worker in thissection
(refer to table on exhibit 1)
2. EXTEND LINE : operate > 3 op.
possible COMBINATION ofincreasing worker is scenario
1/2/3/4/mix of them
(refer table on previous slide)
4. Improving TECHNOLOGY
on assembling line in order
to improve manufacturing
process
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Increasing QUALITY ASSURANCE of product & AFTER SALES service
START
Computer displayeddaily productionschedule
1st operator laid outmajor component
2nd operatorentered barcode
Modelchanged?
1st operator placecontainer of small
parts on the blank
space
2nd operatorscanned the barcode
The rest of operatorpick up the smallerpart they need onshelv above theirwork area
NO
YES
Portable computer displayed theoperations realted to eachstation
Snapping connector together or
attaching parts with small screws
HW
test
Shock-TestBurn-InDone
shock test?
NO
YESFinal Quality
TestPackaging &placed on pallets
STOP2) increase step in QUALITY CONTROL section before packaging(Shock Check, HW Check, SW Pre Installed Check) increase worker
Softwarepre-installed3) After Sales Service: FAST service
assure AVAILABILITY ofsensitive spare part on outlet (eg.Floopy disk drive, hardisk drive,
LCD, keyboard & mouse)
1) Developing INDIVIDUAL SKILL of employees directed to
specific characteristic of product
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Thank You