Suggest an efficient line balancing method for new notebook that will reduce cost and

improve productivity.

Slide 3

Kitting
Master BOM
Laptop model

master BOM
Component:
monitor
Component:
keyboard
Component
Cd drive
box
lcd
keys
frame
box
Drive

Slide 4

Need for Kitting

Each operator is responsible for allocating screws for the next operation
It can be avoided by Kitting of the screws
The Bill of Material of laptops can be updated by replacing the loose hardware by Kits

Slide 5

Boons of Kitting

Avoid operator error due to miscalculation of screws

Time saved in assembly line
Time saved can be used to assemble more computers

Slide 6

Kitting of screws saves

30 Secs per laptop assembly time

Saves a total of 30 secs x 900 units

i.e. 27000 secs saved per day

Therefore total time saved is 7.5 hrs

Slide 7

1228 secs required for assembly of one laptop

Extra units produced
27000/1228
=22 units

Slide 8

Total units produced

900+22 = 922 units
Production increase of 2.4 % per day keeping all other parameters same

Slide 9

Efficiency earlier
900/40 = 22.5 units/person

Efficiency after applying Kitting

922/40 = 23.05 units/person

Increase of 5.5 %

Slide 10

Reorganizing of Operations

Minimal Shuffling of Operations .

Sanctity of the Sequence of Operations is abided.
Reduction in the Cycle Time.
Productivity Analysis

Slide 12

Edges via the Approach

Initial Units Produced : - 3*300 =900
Total Number of People Involved =3*10+10 (others) = 40
Total Productivity = 900/40 = 22.5
Now After the new technique, total time saved
=114(bottleneck) 100 =14
So for a total of 900 units, time saved =14*900 = 12600
=12600/100 = 126 new units!!! A marvelous figure, with just a trade off for 3 new workers.

Slide 13

Aspect of Productivity: Initially : 900/40 = 22.5

After : (900+126)/(40+3)=1026/43=23.86
A clear edge of 6.04%.
Rationale Behind Cycle Time Reduction :--> Time Saving which in effect increases Productivity.
> Process tends to be effective and efficient.
> Reduced cycle time.an embodiment of reduced bottleneck.

An Alternate Approach

One person One Table Solution

A complete revamp from existing scenario Assembly line replaced by individual
operators who assembles a unit from scratch to final form.
This method is successfully implemented in Sonys factory in making handycams.

Advantages :-Less of monotony.

Better Development of Core Competency through multi-skilling.
Accountability
Error can to tracked down and minimal.

Lacunae In This Case Per-se

Unavailability of data for assembling a unit by various skill level workers.
Revamp of such an infrastructurehow feasible is it ??
Proposal:->
As per the segregated analysis of the various aspects , we would like to infer that the
second point of analysis would make a better deal as this involves a critical breakthrough
in which both the kitting and the reorganizing has been taken into consideration.