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Case: Designing Toshiba's Notebook Computer Line
Transcript of Case: Designing Toshiba's Notebook Computer Line
and History Tweaking the Initial
Assembly-Line Design The Case Study ㅡ Toshiba Corporation is a Japanese multinational engineering and electronics conglomerate corporation headquartered in Tokyo, Japan. Toshiba is organized into four main business groupings:
1. The Digital Products Group
2. The Electronic Devices Group
3. The Home Appliances Group
4. The Social Infrastructure Group In 1985, Toshiba produced the first notebook computer - the T3100. In 2010, Toshiba was the world's fourth-largest manufacturer of semiconductors by revenues (after Intel Corporation, Samsung Electronics and Texas Instruments). Toshiba is listed on the Tokyo Stock Exchange, where it is a constituent of the Nikkei 225 and TOPIX indices, the Osaka Securities Exchange, the Nagoya Stock Exchange and the London Stock Exchange. Introduction & History - Answering 4 problem questions PRESENTATION
OUTLINE Case: Designing Toshiba's Notebook
Computer Line Operations and
Supply Management Prof. Park Byeonghwa Team Members: Cristina Monroy - 1401422
Ibragimov Botir - 1401386
Rasulov Botirjon - 1401472 Chapter 4: TOSHIBA Toshiba was founded in 1939 as Tokyo Shibaura Electric K.K. through the merger of Shibaura Seisaku-sho (founded in 1875) and Tokyo Denki (founded in 1890). THE CASE STUDY The principle of an assembly line is that each worker is assigned one very specific task, which he or she simply repeats, and then the process moves to the next worker who does his or her task, until the task is completed and the product is made.
It is a way to mass produce goods quickly and efficiently.
All workers do not have to be human; robotic workers can make up an assembly line as well. ASSEMBLY LINE Factory: 3 assembly line Assembly of robotic workers Consists of two or more pulleys, with a continuous loop of material - that rotates about them.
Use to transport light or heavy goods from one place to another. Conveyor Belt Tweaking the Initial Assembly-Line Design Answer (1) Q.2 Answer (2) Answer 3 Q.3 Q.4 Q.1 Answers to four (4) problem questions What is the daily capacity of the assembly line designed by the engineers? When it is running at maximum capacity, what is the efficiency of the line? How should the line be redesigned to operate at the target 300units/day, assuming that no overtime will be used? What is the efficiency of your new design? What other issue might Toshihiro consider when bringing the new assembly line up to speed? END Exhibit 4.10 Exhibit 4.10: A Prototype Assembly Line for the Subnotebook Computer CASE: Designing Toshiba's Notebook
Computer Line Toshihiro Nakamura, manufacturing engineering section manager, examined the prototype assembly process sheet for the newest subnotebook computer model.
This new computer was a marvel of high-tech low cost innovation and should give Toshiba an advantage during the upcoming fall/winter selling season. -Staffed by 10 operators who worked at 14.4 meters assembly line.
-The line normally operates for 7.5 hours a day.
[8:15am-5:00pm] -1 hour unpaid lunch, - 15 minutes scheduled breaks
-It is possible to run one; two, or three hours overtime, but employees need at least three days’ notice for planning purposes. Designing Toshiba's Notebook
Computer Line Summary:
Toshihiro Nakamura, manufacturing engineering section manager, examined the prototype assembly process sheet for the newest subnotebook computer model.
When every new model was designed, considerable attention was directed toward; (1) reducing the numbers of components, (2) simplifying parts production, (3) and assembly requirements.
This new computer was a marvel of high tech, low cost innovation and should give Toshiba the advantage during the upcoming fall/winter selling season. CASE: Production of the subnotebook was scheduled to begin in 10 days.
Initial production for new model was to be at 150 units per day.
increasing to 250 units per day the following week.
Management thought that eventually production would reach 300 units per day. Assembly Line
Model type: variation of hard disk size, memory, and battery power
Lot size : 10 – 100units
Assembly line : 14.4 meter conveyor
Total station: 10
Workers: 8 – 12 operators (workers) + 1 supporter
Operating hour: 7.5 hours (450min)
Possible to run 1-3 hours overtime, but employees need at least 3 days notice
1 notebook is assembled every two minutes by ten line workers DEFINITION The Assembly Line Summary
The Assembly Line 1 2 3 4 5 6 7 8 9 10 110 sec 114 sec 101 sec 107 sec 103 sec 107 sec 108 sec 93 sec 310 sec 105 sec Total flow time:
= 1,258 seconds
= 20min & 58 seconds CONVEYOR BELT There is only 1 notebook at every 2min, thus daily capacity is: Answer (a)
450 min / 2 min
= 225 unit notebooks (maximum) There is only 1 notebook at every 2min, thus daily capacity: Answer (b)
Start from zero:
450 min - 20 min = 430 min
Thus the daily capacity is 430 min / 2 min
= 215 unit notebooks per day (maximum) 215 ~ 225 unit of notebooks per day Efficiency Formula:
Sum of Task time (T) = 1258 sec
Actual no. of workstation (N) = 10 stations
Workstation cycle time (C) = ? 7.5 hr x 60min x 60 sec = 27000 sec / / / / = = = = = = = = / / / / = = = = Answer 4 =100% Designed by Engineer = = = = = = = = Output: 215 Computers/day 3.Redesign the Assembly Line Redesign the assembly line to 7-stations Answer:
1. Use more skilled workers
2. Use parallel workstation
3. Redesign the assembly line lowest highest Target: 140% Efficiency= 300 Computers/day Target: 140% Efficiency= 300 Computers/day 2.Use Parallel Workstation = 306 Computers / day = 215 Computers / day Toshihiro need to consider the following:
1) Need to consider the space at the conveyor for redesigning the assembly line.
2) Need to re-calculate the task time, in order to obtain real production task time.
3) Need to train those slow performing operators, and reposition those higher performing operators at critical work station.
4) Need to check and upgrade the machines and equipments for speed improvement. - = Cycle Time Target: 140% Efficiency= 300 Notebook computers/day