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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

3

101

4

107

# 63 can produce 3 units at the same time in parallel. which is the longest station takes 114 5 103 7 108 8 93 9 310 10 105 .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. Still have to wait unit from station 8 and so on. But this opn. so the bottleneck is in station 2.

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. without overtime use. In other words. Station 12.103 = 110 % 10 X 114 c) Redesigned to Operate 300 units / day Cycle Time = 27000 = 90 300 Assumption: In opn. Therefore.8% 14 X 90 .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 = 1.998 = 99. operator only add in Station 1. Efficiency = 1258 = 0.ANNISA TRINEZIA 3 2911137 a) Daily Capacity 1 day operation = 7.# 63 station 9 the hardware test is performed in parallel on three different units. to fulfill 300 units / day need to add 4 workstations and 4 operators. Can not divide three because the process is not held at the same time. But this opn. So. Nt = 1258 = 13. and 13 at Station 14.9 or 14 workstations 90 Adding 4 workstations means adding 4 more operators.

# 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 1 80 10 2 2 90 - 1 3 90 - 1 4 81 9 1 5 75 15 1 .ANNISA TRINEZIA 4 2911137 Make Balance the Line using Cycle Time 90 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 6 75 15 1 7 82 8 1 8 80 10 1 9 88 2 1 10 11 12 13 14 36 208 76 85 15 54 1 automatic 14 5 65 1 1 1 .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.

5 hours without overtime use. then the company will get revenue $30. The assembly line consisted of a 14. it takes for 11 operators and overtime for 2. Position of the operators also needs to be considered.2 meter intervals for 10 workstations. Assembly line layout Assuming that the production and sales reach 300/day with selling price for $100 each. or $525 for 14 operators.5 $495 It will be cheaper for the company to use overtime with 11 operators than to design new assembly line. cost for adding 4 workstations 2.000/day.5 $82. Assuming each operator salary is $5/hour. then the interval is shorter than before. Assuming that overtime payment is $3/hour. If the company design new assembly line with 14 workstations but still with the same length of conveyor. The assembly line layout also needs to be considered. about 1 meter for 14 workstations.475/day. To produce 300 unit/day with old assembly line which consists of 10 stations that can fit for until 12 operators.5 hours. The company will get $29.5 x 11 Overtime payment $3 x 2. then: $412.ANNISA TRINEZIA 6 2911137 Issues to be Considered If Toshihiro using this new assembly line. issues that need to be consider are: 1.5 x 11 .5 to each operator per day. adding more stations and hire more operators. Especially in station 1 because there are 2 operators working there. 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.4 meter conveyor belt and separated at 1. Cost for adding 4 operators 3. 14 operators are working everyday for 7. because if the operators don t feel comfortable then they can t work well. 11 operator/day $37. cost of goods sold and another expense. But this is not including another operating expense. and then the company has to pay $37.