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Toshiba DP-2506_SM_EN_
ANNISA TRINEZIA 2911137
Case: Designing Toshibas Notebook Computer Assembly Line Production 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
2
3
4
Task Time
110
114
101
107
Opn. #
Time (Sec)
1
100
2
6
3
4
4
50
5
13
6
16
7
13
8
16
9
6
10
26
11
10
12
13
13
23
14
6
15
6
16
13
17
4
18
15
19
11
20
8
21
8
22
8
23
13
24
6
25
13
26
8
27
13
28
4
1
ANNISA TRINEZIA 2911137
5
6
7
8
9
10
103
107
108
93
310
105
29
6
30
13
31
6
32
8
33
11
34
6
35
11
36
10
37
10
38
16
39
6
40
13
41
6
42
6
43
5
44
23
45
18
46
18
47
8
48
10
49
18
50
10
51
11
52
8
53
33
54
22
55
6
56
58
57
8
58
8
59
8
60
6
61
5
62
31
63
208
64
71
65
5
66
75
67
10
68
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
2
ANNISA TRINEZIA 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
3
ANNISA TRINEZIA 2911137
Make Balance the Line using Cycle Time 90
Station
1
2
3
4
5
Task Time
Opn. #
Remaining Unassigned Time
Number of Operator
80
10
2
90
-
1
90
-
1
81
9
1
75
15
1
Sum of Task Time
1
50
2
3
3 4
2 25
5
13
6
16
7
13
8
16
9
6
10 11
26 10
12
13
13
23
14
6
15
6
16
13
17
4
18 19
15 11
20
8
21
8
22
8
23
13
24
6
25
13
26 27
8 13
28
4
29
6
30
13
31 32
6 8
33 34
11 6
35
11
36
10
37
10
4
ANNISA TRINEZIA 2911137
Station
6
7
8
9
10 11 12 13 14
Opn. #
Task Time
38
16
39
6
40
13
41 42
6 6
43
5
44 45
23 18
46
18
47
8
48
10
49
18
50 51
10 11
52 53
8 33
54
22
55
6
56
58
57 58
8 8
59
8
60
6
61
5
62
31
63
208
64
71
65 66
5 75
67
10
68
15
Sum of Task Time
Remaining Unassigned Time
Number of Operator
75
15
1
82
8
1
80
10
1
88
2
1
36
54
1
208
automatic
76
14
1
85
5
1
15
65
1
5
ANNISA TRINEZIA 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: 11 operator/day $37.5 x 11 Overtime payment $3 x 2.5 x 11
$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 dont feel comfortable then they cant work well. Especially in station 1 because there are 2 operators working there.
