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An Efficiency Improvement: A Case Study of an Upper Housing of a

Telephone Assembly Line

1* 2 1,2

E-mail: Wisanu@eng.buu.ac.th*

Wisanu Boonrawd1* Sasikarn Pansuar2

1,2Department of Industrial Engineering, Faculty of Engineering, Burapha University, Chonburi, Thailand E-mail: Wisanu@eng.buu.ac.th*

(Upper Housing) IP-1230 PICTO 5W+1H ECRS

12 12

(Takt time) 12.62

(Cycle time) 15.70 89.48 47.48%

4 12.09 83.83 86.67%

360,000

ECRS 5W+1H

Abstract

This study presents a case study of an efficiency improvement of an upper housing of telephone

assembly line, IP-1230 PICTO model. The principles of work study, 5W+1H questions and ECRS had

been applied to reduce unnecessary works (waste), simplify tasks and improve line efficiency. The assembly line comprised of 12 work stations (12 operators) and 12.62 seconds of takt time. A cycle time

of 12 work stations was 15.70 seconds and a total assembling time for the 12 works stations was 89.48 seconds. The assembly process had an efficiency of 47.48%. The improvement resulted in elimination of

4 work stations. The cycle time has been decreased to 12.09 seconds. The total assembling time consumed in all stations decreased to 83.83 seconds. The line efficiency has been improved to 86.67%.

Keywords: Work study, ECRS, 5W+1H, Line Balancing

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1.

(Kaizen) 5 (5S) (Just In Time,

JIT) (Work study) (ECRS) (Line balancing)

(Waste)

[1], [2]

12.62

12.62

15.70

ECRS

[3], [4], [5]

ECRS 5W+1H

IP-1230

2.

(Pareto chart)

1

1

-

-

ECRS (Eliminate Combine Rearrange

Simplify) 5W+1H (What Why When Where Who How)

ECRS -

3.

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3.1

IP-PHONE

6 2 TEXT

PICTO 3 Upper Housing (Button)

TEXT PICTO

1

1 IP-PHONE

IP-PHONE

PICTO

IP-1210

IP-1220

IP-1230

TEXT

IP-1210

IP-1220

IP-1230

4 . . 2554 IP-1230 PICTO

IP-1230 TICTO

IP-1230 TEXT 66.18%

IP-1230 2

IP-1230 PICTO IP-1230 TEXT

PICTO

TEXT

8 3

IP-1230 PICTO

IP-1230 PICTO

2

- 2554

IP-1230 TEXT IP-1230 PICTO

IP-1230 TEXT

3 IP-1230 PICTO

3.2

IP-1230 PICTO

IP-1230

PICTO 12 1 25

IP-1230 PICTO 4

3.3

10

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4 Upper Housing

95% 13

5% 5

44 2

IP-1230 PICTO

5

2

5

1) (Takt time) 12.62

2

IP-1230 PICTO

Process

Transport

Delay

Checking

Store

1 1 15.70

2 1.34

3 2.74

4 1.26

5 5.44

6 3.18

7 5.18

8 3.92

9 2.38

5 10 5.28

11 4.41

12 5.47

13 3.79

14 2.68

15 3.75

16 2.37

17 2.30

18 2.28

19 2.36

20 1.48

21 1.97

22 1.65

23 3.39

24 2.79

25 2.37

89.47 85.43 0 0 4.05 0 3.79

2

Logo Plate

Logo Plate

Paper Lens

Plunger Spring

Time

(s.)

SYMBOL

12

9

10

11

6

7

8

3

4

MACHINE

Conclusion

Detail

Line Button 10 Upper Housing

Call Lamp

Upper Housing

Menu Button

Navi + Enter Button

Dial Button

Line Keypad Line Button

Upper Housing

Runner Dial

Button Menu Button

Upper Housing

Upper Housing

Conference Button MSG Button

Volume(+) Button Goodbye Button

Service Button, Redial Button

Volume(-) Button , Application Button

Handfree Button

Quit Button Directory Button

Mute Button, Hold Button Handset

Dial Keypad

MAN

AfterBefore

Improvement Improvemen

23

0

Flow Process Chart

No. 11 Page 11 From 11

Activity : Before / After

ReduceActivity Product / Material / Personal

Actvity : Assemble Upper Housing

Total

0

2

0

Tota l 85.69

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(Cycle time) 15.70

2)

1 3 3)

47.48%

1

89.48/12.62 = 7.09 8 [6]

(1) 4) 5W+1H

3.4

8

ECRS

1) 3 1

2 Logo

2) 2

5.34 Plunger Spring 4

3) 1 Line 10 1

4

Line 6 4 5

4) 8 9 10

5)

3.5

83.83 4 8

86.67% 3

3

1 Logo Plate

2 Logo Plate

3 Paper Lens

4 Call Lamp Upper Housing

Call Lamp

5 Upper Housing

6

7 Plunger Spring Upper Housing

8 Line Button 6 Upper Housing

9 Menu Button Upper Housing

10 Line Button 4 3 Upper Housing

11 Navi + Enter Button Upper Housing

12 Conference Button MSG Button

13 Volume(+) Button Goodbye Button

14 Line Keypad Line Button

15 Dial Button

16 Service Button, Redial Button

17 Quit Button Directory Button

18 Volume(-) Button Application Button

19 Mute Button Hold Button

20 Handfree Button Handset Button

21 Upper Housing

Runner Dial Button Menu Button

22 Upper Housing

23 Upper Housing Runner

24 Dial Keypad Dial Button

25

26

27

83.83

12.09

5

6

7

1

2

3 8.19

8.67

10.53

8 10.63

11.85

12.09

9.82

12.054

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4.

ECRS 5W+1H

47.48% 86.67%

4

360,000 ( 300

25 )

ECRS

5

4/2555

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