CASE STUDY: CIRCUIT BOARD FABRICATORS, INC.

Case Question #1: What type of process flow structure CBF is using?
Solution: CBF uses a Job shop type of process flow. This is because CBF makes different
circuit boards for different customers based on their requirement. The engineer of the
customer companies prepares a draft of the board they require using Computer Aided Design
and then sends over to the CBF process engineer to fabricate the boards.
Case Question #2: Diagram the process flow.
Solution: *The process flow diagram is shown at the end of the document

Case Question #3: Analyse the capacity of the process.

Solution: Since CBF Inc. uses a Job shop process flow, the capacity is relatively low. The
circuit building process is customizable by the customer and requires very complex
processes and with a lot of skilled manual handling, this is not possible via mass production.
Each circuit board required detailed work and time and thus the volume produced is low.
Case Question #4: What is the impact of losses in the process of Inspection and final test?
Solution: The impact of the losses in the system is quite large. The case study shows that
15% of the boards are typically during early inspection of the boards and an additional 5%
during the final testing. This in turn results in an increase in the production order by 25%. A
lot of time is consumed for the materials that turn out to be unfit for delivery. Time and
resources are spent on this 25% materials, this also takes a hit in their production capacity.
Case Question #5: What recommendation would you make for a short-term solution to CBF
Inc.’s problems?
Solution: A short term solution for their problem would be to either increase the working
hours or to increase the average job size capacity. If this solution produces results, then this
could be a possible long-term solution.
Case Question #6: What long-term recommendation would you make?
Solution: Long term solution for the company’s problem would be to employ additional
machines at each section of the process, mainly in the fabrication process. Additional
machines would result in more productivity throughout the processes. Also, automated
machines would result in the reduction of manual handling and in term reduce the production
cost.
 Order acceptance and Numerical machines
verification with CBF are programmed using
equipments CAD to produce the
order

ACCEPTANCE VERIFICATION AND DESIGNING (Customised)

CLEAN COAT
Boards manually Liquid plastic is
loaded in the deposited on both
Machines. sides of the board.
Machines: 1 no Machines: 1 no

Machine 1 Machine 2 Machine 3 Machine 4 Machine 5

Each machine does the following tasks:

• Load and unload each individual board

• Photo graphic process
• Moves the exposed plastic coating
• Resistant to disobeying where copper traces are needed
EXPOSE PROCESS
Machines: 5 nos.

DEVELOPMENT Stage 1 Stage 2 BAKING

PROCESS PROCESS
Machines Machines
Machines: 1 no : 1 no : 1 no Machines: 1 no

INSPECTION PROCESS
Machines: 2 nos.

Machine 1.1 Machine 2.1 Machine 3.1 UNLOADING

PROCESS

Machines: 1 no
Machine 1.2 Machine 2.2 Machine 3.2
DRILLING PROCESS
Machines: 6 nos.
Employees: 3 nos.
 Machine 1 Machine 3 Machine 5

COPPER PLATING
PROCESS

Machines: 1 no

Machine 2 Machine 4 Machine 6

FINAL TESTING PROCESS

Machines: 6 nos.
Employees: 6 nos.

BOARD FABRICATION PROCESS

SHIPPING AND DELIVERY