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ANNISA TRINEZIA 1 2911137

Case: Designing Toshiba s Notebook Computer Assembly Line


Production of the subnotebook was scheduled to begin in 10 days, with initial production was at 150 units per day, increasing to 250 units per day, and eventually 300 units per day. Assumptions: Assembly lines staffed by 10 operators at a 14.4 meter long. Maximum operator is 12. Operating hour 7.5 hours. 1 notebook = 2 , 10 operators. From exhibit 6A.18 we know that there are 10 stations. Sum of Task Times (T) = 1258 Cycle Time = 2 minutes = 120 Station 1 Task Time 110 Opn. # 1 2 3 4 5 2 114 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Time (Sec) 100 6 4 50 13 16 13 16 6 26 10 13 23 6 6 13 4 15 11 8 8 8 13 6 13 8 13 4

101

107

ANNISA TRINEZIA 2 2911137 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 6 107 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 6 13 6 8 11 6 11 10 10 16 6 13 6 6 5 23 18 18 8 10 18 10 11 8 33 22 6 58 8 8 8 6 5 31 208 71 5 75 10 15 Assumed that opn. # 63 can produce 3 units at the same time in parallel. But this opn. Still have to wait unit from station 8 and so on, so the bottleneck is in station 2, which is the longest station takes 114

103

108

93

310

10

105

ANNISA TRINEZIA 3 2911137

a) Daily Capacity 1 day operation = 7.5 hours = 27000 (T) = 1258 Bottleneck is in Station 2 = 114 Daily Capacity = 27000 = 236 units / day 114

b) Efficiency of the line at the maximum capacity Efficiency = Sum of Task Times (T) Number of Workstations (Nt) X Cycle Time (C)

= 1258 = 1.103 = 110 % 10 X 114 c) Redesigned to Operate 300 units / day Cycle Time = 27000 = 90 300 Assumption: In opn.# 63 station 9 the hardware test is performed in parallel on three different units. But this opn. Can not divide three because the process is not held at the same time. Therefore; Nt = 1258 = 13.9 or 14 workstations 90 Adding 4 workstations means adding 4 more operators. Therefore need to be added 1 operator each, except Station 11 because the longest task is loading the software already done by the hardware test. In other words, operator only add in Station 1, Station 12, and 13 at Station 14. So, without overtime use, to fulfill 300 units / day need to add 4 workstations and 4 operators. Efficiency = 1258 = 0.998 = 99.8% 14 X 90

ANNISA TRINEZIA 4 2911137 Make Balance the Line using Cycle Time 90 Remaining Unassigned Time Number of Operator

Station

Opn. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Task Time 50 3 2 25 13 16 13 16 6 26 10 13 23 6 6 13 4 15 11 8 8 8 13 6 13 8 13 4 6 13 6 8 11 6 11 10 10

Sum of Task Time

80

10

90

90

81

75

15

ANNISA TRINEZIA 5 2911137 Task Time 16 6 13 6 6 5 23 18 18 8 10 18 10 11 8 33 22 6 58 8 8 8 6 5 31 208 71 5 75 10 15 Sum of Task Time Remaining Unassigned Time Number of Operator

Station

Opn. # 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

75

15

82

80

10

88

10 11 12 13 14

36 208 76 85 15

54

1 automatic

14 5 65

1 1 1

ANNISA TRINEZIA 6 2911137 Issues to be Considered If Toshihiro using this new assembly line, issues that need to be consider are: 1. cost for adding 4 workstations 2. Cost for adding 4 operators 3. Assembly line layout Assuming that the production and sales reach 300/day with selling price for $100 each, then the company will get revenue $30.000/day. 14 operators are working everyday for 7.5 hours without overtime use. Assuming each operator salary is $5/hour, and then the company has to pay $37.5 to each operator per day, or $525 for 14 operators. The company will get $29.475/day. But this is not including another operating expense, cost of goods sold and another expense. The comparison between design new assembly line with adding more stations and operators should be compared with using same assembly line without adding stations and operators but using overtime. To produce 300 unit/day with old assembly line which consists of 10 stations that can fit for until 12 operators, it takes for 11 operators and overtime for 2.5 hours. Assuming that overtime payment is $3/hour, then: $412.5 $82.5 $495 It will be cheaper for the company to use overtime with 11 operators than to design new assembly line, adding more stations and hire more operators. The assembly line layout also needs to be considered. The assembly line consisted of a 14.4 meter conveyor belt and separated at 1.2 meter intervals for 10 workstations. If the company design new assembly line with 14 workstations but still with the same length of conveyor, then the interval is shorter than before, about 1 meter for 14 workstations. Position of the operators also needs to be considered, because if the operators don t feel comfortable then they can t work well. Especially in station 1 because there are 2 operators working there. 11 operator/day $37.5 x 11 Overtime payment $3 x 2.5 x 11