Toshiba : Ome Works

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Toshiba Ome Works
Group 7
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QUESTION FOR THE GROUP
Suggest an Efficient Line Balancing for the new
model of Notebook which would improve
productivity and reduce cost
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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.

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TOSHIBA Satellite Notebook Computers Assembly
Line

• Each line can produce 8 different models
• Each model can have 6 different combinations of
  features
• Total model types possible 48
• Production 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.

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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

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Solution 2 CHASE STRATEGY
Line Balancing Based on 90 Seconds per
station !!!
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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

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Line Balancing Based on 90 Seconds per station.

• Calculations
• S T Total time 1011 sec
• c cycle time 90 sec
• TM S T / c 11.23 12 Stations
• Hence
• Increase 2 stations and hire 4 workers
  

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Line Balancing 90 seconds
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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
• Efficiency
• ? S T / S Available 1059 / 10120 88.25

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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
• Efficiency
• ? S T / S Available 1011 / 1290 93.61

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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.

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Workers are stationary
B
B
B
B
B
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ADVANTAGES

• Multi tasking
• Eliminating Support Worker
• Increase Productivity and Quality
• Decrease dependability on working skills

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Other possibilities

• 1. Increase the conveyor speed
• ( With rabbit chase flexible task workers )
• 2. Outsource Certain sub-assemblies
• 3. Layout optimization

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Suggested Layout
Engine Assembly Unit
Admin and Prodcution
HD Drive Final Assy
Prototype assy
PCB Assembly Automated

PCB manual assembly
RD /Design lab
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Thank You