Beruflich Dokumente
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Donner Company
Case write up for OM course
Group Number 5
Members:
KEK Sashank
Pooja Gupta
Sangbarta Chakraborty
Sandip Datta
Sanket Kale
:
:
:
:
:
1511393
1511444
1511431
1511430
1511398
b) Capacity analysis:
i.
Donner company has seven manual drills and one CNC drill for drilling operation. As can be
seen from Exhibit 2 of the case, the setup time required for CNC drill is 16 times that of setup
time required for manual drill. But the run time of CNC drill is 16 times lesser than manual
drills. Hence for orders of large size, CNC drilling would consume lesser time than manual
drills.
As with the profile punches, the setup time for CNC router is 3 times that of manual punch
press while the time required per board by CNC is only half of what is taken by manual punch
press. Hence for profile punching the order size has to be considerably large enough to get
the advantage from CNC punch press.
The following calculations find the minimum order size above which CNC drill CNC router
would take less time than manual machines to complete the processes.
Let x be the number of boards ordered.
Comparing 1 Manual drill time = 1 CNC drill time for x boards
15+0.080*500*x=240+0.004*500*x => x = 5.92
Hence for orders of size >5 CNC drill is the suitable option.
Group No. 5
There are 7 Manual drills and one CNC drill. If we consider the case each board is fed into each
manual drill simultaneously the equation gets modified to
15+0.080*500*x/7=240+0.004*500*x => x = 60.58 [7 simultaneous manual drill usage]
Hence for orders of size >60 CNC drill seems the suitable option but it is highly unlikely to get
n number of manual drills free for 1 order as there will be almost continuous simultaneous
stream of orders being made and worked upon.
Similarly Punch press and CNC router has a trade-off in setup time and run time.
Let x be the number of boards ordered.
Comparing 1 Punch Press time = 1 CNC router time for x boards.
50+1*x=150+0.5*x => x = 200
Hence for orders of size >200 CNC router is the suitable option.
ii.
As we clearly proved in the last part that for an order of one board we would be only using
one manual drill. And we have also proved that in case of using one drill for one order, CNC
drill can be used for orders of quantity greater than 6 boards. But in the case of using seven
drills for one order, CNC drill should be used for orders greater than 61 boards.
In this question, we have to find the standard labour time for an order of 1 board, 8 boards
and 200 boards. In case of 1 board it is clear that only 1 drill can be used. In case of 8 boards,
we have two options of either using 1 drill or 7 drills in manual method. If only 1 drill is used,
the condition from previous part says for order greater than 6 boards, CNC drill is more
preferable. The option of using 7 drills for an order of 8 boards is discarded because it doesnt
make economic sense to separate individual boards and use different drills for boards from
the same panel. Calculations show that using CNC drill would save the standard labour time
by a great extent. For an order of 200 boards, it is clear that only CNC drill has to be used.
All the calculations are explained in the table attached in the Appendix. Calculations show
that the standard labour times for the given orders are as follows:
Order size
1
8
200
Manual
Manual (CNC)
CNC drill
In the case of profile punching we saw that the order size has to be more than 200 for CNC
router to take less time than manual punching press. For order sizes of 1 and 8 boards, manual
profile punching takes less time. For order size of 200, both CNC router and profile punching
take the same time and hence the decision depends on the availability of the resource in case
of profile punching.
Group No. 5
As can be observed from the exhibit, the drilling process is the bottleneck process irrespective
of the batch size and also irrespective of the decision to use manual drilling presses of CNC
presses. Hence it becomes necessary for Donner, to schedule in such a way that the drilling
processes, both manual and CNC are never starved.
Group No. 5
the checklist option after completing that process. This would ensure all the activities
are completed in sequence and no activity is missed out when completing the order.
4. Use of ICT for quicker procurement: Donner needs to make contracts with the
suppliers to ensure cheaper procurement costs. The suppliers should be developed
to meet the requirements of Donner. Use of ERP systems like SAP with suppliers can
help suppliers track real time what orders are received by Donner and immediately
send the required material to Donner. This can reduce the procurement time required
from 4 days to about 1 or 2 days even for normal orders.
5. Apart from that, proper training of workers to develop their skills since most of the
jobs require a lot of judgement and proper layout of factory to reduce walk times of
workers must be done to improve productivity.
6. The programming of CNC drilling which takes 240 minutes of setup time is currently
done when the order reaches the CNC workstation. Instead Altmeyer can create a
programme required for that order and save it into the CNC machine beforehand. The
programme can be retrieved when the batch reaches the CNC station. The added
advantage of this is also that if Donner gets two orders with similar drilling
requirements, the saved programme can suffice both the orders thus saving the setup
time.
Group No. 5
Exhibit 1
Preparing
Customer
Bid
(Plummer
&
Altmeyer)
Metallizati
on
Yes
Customer
Response
Manual
Drilling
Factory
Order
(Altmeyer
for normal
Schnabs for
rush)
Punch
Tooling
Holes
Manual
or CNC?
Procureme
nt (1-2
days, same
day for
rush order)
Scheduling
of the
order
Inspect and
Shear
Artwork
Generation
CNC
Drilling
Panel
Preparation
Inspect,
Test and
Pack
Laminate
and Expose
Punch
Press
Develop
Electroplate
Punch
Press or
CNC?
CNS Router
Strip DFPR
Solder Dip
Etch and
tin strip
Soldermask
Group No. 5
Exhibit 2: Calculation of standard labour time for 1 board, 8 boards and 200 boards
Standard Production Times
Operation
PREPARATION
Setup
Time
(min)
Run Time
(min)
Run
Time/
Board
1 Board
8 boards
200 boards
Time taken
(Manual)
Time taken
(CNC)
Time Taken
(CNC)
Artwork
Generation
Inspect & Shear
29
0
20 0.5/panel
0
0.5
29
20.5
29
20.5
29
32.5
Punch Tooling
Holes
10 0.5/panel
0.5
10.5
10.5
22.5
IMAGE
TRANSFER
Drill
Drill (Manual)
CNC Drill
Metallization
15 0.08/hole
240 0.004/hole
10 0.75/panel
40
2
0.75
55
10.75
256
10.75
640
28.75
5 0.2/panel
0.2
5.2
5.2
10
2/panel
0.2/panel
8.5/panel
0.2/panel
0.2/panel
2
0.2
8.5
0.2
0.2
22
20.2
33.5
5.2
10.2
22
20.2
33.5
5.2
10.2
70
25
237.5
10
15
45 1.5/panel
30 0.5/panel
1.5
0.5
46.5
30.5
46.5
30.5
82.5
42.5
50 1/board
150 0.5/board
1
0.5
51
154
250
45 1.5/board
1.5
46.5
Dry Film
Photoresist
Panel Prep
Laminate &
Expose
Develop
Electroplate
Strip DFPR
Etch & Tin Strip
FABRICATION
Soldermask
Solder Dip
Profile
Punch Press
(Manual)
CNC Router
Inspect, Test,
Pack
Total Time
(min)
20
20
25
5
10
396.55
Total Time
(hours)
345
654.05
1840.25