mountain tran's thesis

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The Feasibility Study of Combo Production Line in Notebook (NB)Computer Manufacturing.

by

Tran. Mountain Tran Hoai Son

A research study submitted in partial fulfillment of the requirements for the studying

and researchingin

COMPAL ELECTRONICS INC.

Examination Committee: Yue. Joel

Nationality:

Previous Degree:

Vietnamese

Engineer

Hanoi University of Technology

Hanoi, Vietnam

Scholarship Donor: COMPAL ELECTRONICS INC.

COMPAL ELECTRONIC INC.

Kunshan, China

April 2008

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Acknowledgement

First of all, I would like to thank the management of Compal electronics

inc for all of yours supports through to this process. I have a good opportunity to

practice all my fundamental theory that I have studied in my university and

researched a new specialist knowledge system. Some experiences are known and

how to work is taught.

Next, I would like to thank to my Mentor Sarah. Tran. She was good

engineer, and always takes cares about my percentage of process thesis. She was

a great helpful for my ideals. I know that this process have been immensely more

difficult with out her present.

I would also like to thank my professor Dich. Tran. He advised me to

get this opportunity and give some direction to solve problem in my thesis. As a

Dean of Mechanical Engineering, he was a great source of information on

technology, process control, and manufacturing system.

I would like similarly like send thank to management of MFG A31

workshop: Ms. Do Loan, Ms. Kate Nguyen, and Mr. Dinh Leo. This is my

practice workshop; they have been working here for a long time. They were a

great source of information and the real situation manufacturing of MFG. All of

my data and figures were supplied by them.

Addition I would like to thanks my friends and my family. My friends

found some information and knowledge and send it to me. All my friends include

who are working in Compal: Nguyen. Neo, Tran. Ronan, Bui. Kaku, Nguyen.

Rainbows, and classmate Hoang Quyet Chi, Cao Xuan Huy, etc... My family

always takes interest in me and encourage when I fell tired.

Finally, I would like to thanks all reader for listening to proposal and give

some comments.

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Abstract

My thesis was written at COMPAL ELECTRONICS INC. It describes

whole process I have studied and researched in four month. My topic is The

feasibility study of combo production line in Notebook Computer

Manufacturing and I study basic knowledge about Continuous flow

manufacturing system and Cell manufacturing system. In other ways, other

knowledge such as industrial engineering, plan layout and some relative concept

were studied. It is very helpful for my future work.

In general, there are different manufacturing models in electronic

manufacturing factories, including Batch Manufacturing Process, Full Automatic

Manufacturing Process, Semi-Auto Manufacturing Process, Flow Manufacturing

Process, and Cell Manufacturing Process. The selection of manufacturing

process/model depends on many different factors, such as the complexity of

products, average ordering volume, order fulfillment requirement, and so on. In

order to achieve the lowest manufacturing cost and the highest customer

satisfaction, it is critical to analyze and understand what would be the best fit for

each company. In current NB computer manufacturing, flow manufacturing ispopular. Recently many companies start to look into different manufacturing

process due to the change in competitive environment, such as lower volume and

higher number of models offered, higher requirement on Configured to Order

(CTO) for on-line ordering, and so on. Thus, it is important to look into further

optimal manufacturing process for NB manufacturing, such as combo production

line the combination of cell manufacturing and flow manufacturing.

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Table of Content

Chapter 1 .....................................................................................................................7

INTRODUCTION ............................................................................................................71.3 Research Background: ............................................................................................7

1.4 Objective of the research .........................................................................................8

1.5 Scope of the research ..............................................................................................8

Chapter 4 ........................................................................................................................57

METHODOLOGY .........................................................................................................57

Chapter 5 ........................................................................................................................61

CONCLUSION AND RECOMMENDATIONS ...........................................................61

REFERENCES ...............................................................................................................62

Appendix A .....................................................................................................................63

Appendix B .....................................................................................................................64

Appendix C .....................................................................................................................65Appendix D Commendation ..........................................................................................67

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List of TablesTable 1: Action progress..................................................................................................12

Table 2: Data relation......................................................................................................21

Table 3: Time of working group operations...................................................................35

Table 4: time of each station...........................................................................................36

Table 5: time of AFT.......................................................................................................38

Table 6:Time of group cell..............................................................................................39

Table 7: tools for Cell......................................................................................................39

Table 8: Time of Cell proposal.......................................................................................52

Table 9: Cost for Cell......................................................................................................52

Table 10: Overhead for Cell Proposal 1..........................................................................53Table 11: Time for Cell 2................................................................................................54

Table 12: cost for cell 2...................................................................................................54

Table 13: Overheads for cell 2........................................................................................55

Table 14: Compare between two proposal......................................................................56

Table 15: Work descriptions of research.........................................................................60

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List of FigureFigure 1: The law 5W-1H................................................................................................13

Figure 2 : Flow manufacturing........................................................................................18

Figure 3: General Cell layout..........................................................................................22

Figure 4: Type of Cell layout..........................................................................................23

Figure 5: Matrix part families.........................................................................................26Figure 6: Group machine................................................................................................28

Figure 7: matrix of machine............................................................................................29

Figure 8: sequence of parts............................................................................................30

Figure 9: Flow chart IPQ00.............................................................................................35

Figure 10: Time of Assemble..........................................................................................36

Figure 11: time of AFT....................................................................................................37

Figure 12: Time of PFT...................................................................................................38

Figure 13: Time of Packing.............................................................................................38

Figure 14: Cell ASSY work station 1.............................................................................40

Figure 15: AFT and PFT work station.............................................................................41

Figure 16: Cell for Packing.............................................................................................42Figure 17: Layout for Cell proposal 1.............................................................................43

Figure 18: Cell layout proposal 2....................................................................................44

Figure 19: Assemble cell 2..............................................................................................45

Figure 20: AFT and PFT Cell proposal 2.......................................................................46

Figure 21: Kitting............................................................................................................48

Figure 22: Cell table........................................................................................................49

Figure 23: Frame for Cell................................................................................................50

Figure 24: layout cell proposal 2.....................................................................................51

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Chapter 1

INTRODUCTION

The year of 2007 marks a significant milestone as Vietnam, Taiwans

Compal Electronics Inc., the worlds second largest contract computer maker, is

considering building a factory in Vietnam, Taipei Times reported. Compal could

join the growing number of Taiwanese electronic companies investing in

Vietnam, in pursuit of more cost-effective manufacturing sites outside China.

Opportunities are opened up and challenges are confronted to every entity. In the

cooperate program between Compal electronics inc. and Hanoi University of

Technology, I have been studying and researching in Kunshan, China for four

months. This is the result of whole process.

1.3 Research Background:

In current situation of Compal electronics Inc., all of manufacturing system

is flow manufacturing. It has been existing for a long time when customer

requirement batch and lot size manufacturing. Nowadays, due to the change

in competitive environment, such as lower volume and higher number of

models and so on. The Compal have to select a suitable process

manufacturing and satisfy customer required.

In accordance with the new trend of age, there is many manufacturing

models in electronic factory: Full automatic process, Semi-auto manufacturing

process, Flow Manufacturing process, and cell manufacturing process. Besides,

depend on many different factors such as the complexity of products, average

ordering volume, order fulfillment requirement and so on. Compal Electronics

Inc. researched and experiment on Cell manufacturing. However, to re-layout is

more expensive and waste, it is implement gradually. After that, we compare

between Flow manufacturing and Cell manufacturing to find a manufacturing

model more benefit and effective. Basic applications such as Sub line, Re-layout

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line H. The staff has gradually gained Cell manufacturing concepts and more and

more experiment in Cell. Nevertheless, the Cell manufacturing application here

is just in the early stage of the development with partial implementation at the

simple level. The number of applications remains limited and does not bring

more benefit and effective as other Cell complimented company.

Aware of the significance of Cell manufacturing and its benefits, after the

study about cell manufacturing and many relative data. I set the target of

building a combo production line Cell manufacturing and flow

manufacturing, which is saving cost, meet customer requirement, feasible to

implement in manufacturing.

1.4 Objective of the research

The objectives of this study and researching are listed below:

To identify Cell manufacturing and flow manufacturing

To propose combo production line in notebook manufacturing

To analyze relative data: cost, time, square, so on

1.5 Scope of the research

Cell manufacturing study is diverse and complicated, concerning various

different levels. Time is limited, all data document and material is lack, the

initiation and implementation of study face many challenges, such as

document in Chinese, some time is barrier of language, thus the realization

requires the gradual approach. Furthermore, the concept of Cellmanufacturing is seen from different aspects, i.e. car manufacturer Toyota,

Dell cell manufacturer, NEC cell manufacturer. Its successful realization

requires the manufacturing system. This study will focus on the

recommendation of a solution with the design a new production line for

MFG A31.

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Chapter 2

LITERATURE REVIEW

In this chapter, I write about basic knowledge which I have studied and

researched for four month. In other word, I applied it to research the current

situation of MFG.

1.1. Industrial Engineering seven tools:

The concept of Industrial engineering: Industrial engineering is

concerned with the design, improvement, and installation of integrated systems

of man, material, and machines for the benefit of humankind. It draws upon

specialized knowledge and skills in the mathematical and physical sciences

together with the principles and method of engineering analysis and design to

specify predict and evaluate the results to be obtained from such systems.

The basic objectives of industrial engineering are improving operating

methods and controlling costs and reducing these cost thought cost reduction

program. And the IE department is to provide specialized services to production

department, such as method improvement, time study, developing wage

incentives schemes, and merit rating and to head a new project if required.

IE department uses scientific approach in identifying and solve problem.

It collects factual information and regarding the problem, analysis problem,

prepare alternative solutions take into account all internal and external

constrains, selects the best solutions for implementations. This is problem

identification that includes four step: Collect detail about job, using standard

techniques likes chart, diagram, models and templates Recorder facts are

subjected to critical examination using a series of question Find alternative

solutions for problem Evaluate the alternative and find the best solution.

With the development of industry and manufacturing, the scope and

techniques of industrial engineering is more widen. The main aim of tools and

techniques of industrial is to improve the productivity of organization by

optimum utilization of resource: man, machines, and materials. There is thirteen

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items of industrial engineering but in Compal its sum up 7 tools to suit with the

electronic industrial. It includes:

Foolproof .

The motion study.

The law of 5W 1H.

Hands operation or the hands act.

Man- machine chart.

The sampling method.

The improvement action progress.

1.1.1. The foolproof:

Foolproof method known as anti-error, just to prevent stupid people who

do something wrong. In other ways, its meaning is how to design a method with

minimum level of mistakes.

Basic principles:

Move operations easily

No operation and skills base on intuitive.

The is no risk in operations

Application of Principle:

Root principle: The cause of the error is not result from the

fundamental rules.

Insurance principle: two or more than two moves followed to

complete the work.

Automatically principle: in a variety of optical, electrical,

mechanical, learning institutions, such as chemical principle to

limit the implementation of certain actions and no error happens.

Line principle: To Prevent the entire mistake from the beginning.

Order principle: to choice a process, we must consider inversion

process and process to find error.

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Isolation principle: Depend on each destination, it has standard and

all actions and progress base on it.

Copy principle: with a work to do if two or more, preferably using

"Copy" approach to achieve.

Another layer principle: To avoid mistakes will be different, and to

try to distinguish all the error from many respect of problem.

1.1.2. Motion study:

This principle to at least reach the largest labor work results, the former

Jierboshi (Gilbert) was first proposed, study after finishing additions and

deletions.

Classified into three:

1>. Spent on the human aspects of principle, includes an eight

principle

2>. On the layout of the workplace and the environment principle,

includes a six

3>. Tools and equipment design principles.

There are 20 principle of this tools will be presented in detail at the back.

1.1.3. The action progress:

Objects Focus

Equipment layout Process product

Work arrangement improvement

Process improvements

Test improvements

Material handling waste analysis

The improvement of bottleneck situation

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Operation improvements

Eliminate waste action

Utilization of machines

Fixed rate machine

Eliminate of disorder

Table 1: Action progress

1.1.4. The law 5W 1H:

The purpose of this study is in the way: Familiar with the system have

questioned to identify the problem, Root of causes and possible ways to create

improvements.

Every work includes:

1. Prepared: time and labor spent on adjustments such as machinery, such

as the area of preparation work.

2. Operation: actual work on value-added products.

3. Pack: such as time and labor spent on the processing of removed, the

remnants of debris disposal, storage or cleaning work, and no productive action.

Direction of Improvement

Each work can be in accordance with the following four main

directions to explore possible directions.

Elimination: Many operators may be unnecessary; Review of all

process and improve it with the best way.

Combination: Seeking the possibility of merging; the two

operations together, it can be saved handling, inspection, storage, and

other movements. Merger two actions is very difficult, As far as

possible should be made in the handling of the merger.

Rearrangement: should change its priorities, location and the

possibility of operator, these changes may lead to delete and merger

inspiration.

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Simplify: delete, merge and change operation review, the study

"how" to do to achieve the purpose of simplification.

30

5W1H Law principles below

IE 20

Designated points, or issues (such as

increasing the efficiency of the quality of work

Total doubt

WHY

Some doubt

WHY

HOW

4 action

WHO

WHEN

WHERE

WHAT

Sinmplification

Elimination

Elimination

Combination

Rearrangement

Figure 1: The law 5W-1H1.1.5. The law of man machine:

Learn how to record man and the machine work with in process. Then,

build the chart, that is the way with a record of the operator and the machine or

operating machinery of the relationship, and to record do further analysis and

improvement.

Function

1. Understanding of the current situation, operator of the machinery

and the time.

2. According to the records contained in the above query to find ways

to improve.

3. Improve before and used to compare the differences to improve the

situation.

1.1.6. The hands act:

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"Hands operation" is to help us to understand his hands in operation "idle"

status, and seek to improve the approach to the best hands capacity. To chart the

way to record the operator hands (feet) process moves to the records do further

analysis and improvement.

Function:

1. Records for the existing operators hands (feet) of the action

process.

2. According to (1>.) Records to be challenged to find ways to

improve the place.

3. Improve before and used to compare the differences to improve the

situation

1.1.7. The sampling method:

Application of statistical sampling method means the sampling principle

to study the work of the staff and activities in the machinery and equipment; it is

a fact-finding one of the most effective tools. It can in the shortest possible time

and under the lowest cost between the manpower and equipment with useful

information.

Step in making work-sampling study:

1. Define problem: state objective and purpose, then describe

in detail each element to be measured. The elements should

be so chosen as to real the delays with in control of

operator.

2. Obtain department supervisors approval and co-operation

of operators and department. They must understand the

purpose.

3. State confidence level and desired accuracy.

4. Make a preliminary study

5. Design the study: determines the number of observations to

be made, the number of observers needed, number of

day/night shifts needed. The plan procedure, timings, and

route of observers. Design the observation form( should

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contain all the information needed to prepare the final of

study).

6. Make observations: Record observations and date,

summarize the data at the end of each day, plot data end

control chart.

7. Check the accuracy of the data obtained.

8. Prepare report and state conclusion.

All above knowledge is seven tools of industrial engineering in Compal. It

is basic knowledge for us to find the way to improve work. The criteria of IE is

no thing is the best but it can be better, we have to continuously improvement.

1.2. Plan layout:

A plant layout is an optimum arrangement of Facilities and services in

an existing or proposed plant on order to obtain maximum output of high quality

at the lowest possible production cost.

1.2.1. Objectives of a good plant layout:

Integrate the production centers into a logical balanced and

effective production unit. Reduce material handling (distance as well as time)

Effective space utilization (vertical and horizontal).

Flexibility (permits possible changes in production program)

Worker convenience and job satisfaction(control temperature,

humidity, noise, light, ventilation)

Remove of bottle necks.

Quick work disposal.

Industrial accidents avoided (proper aisle width, safe guards, clean

area).

Reduces physical effort.

Decency and orderliness inside the plan area.

1.2.2. Principle of plant layout:

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1. Principle of overall integration of men, machines, material,

supporting activities.

2. Principle of minimum movement and material handing

3. Principle of smooth and continuous flow. Remove bottle neck,

congestion and back tracking.

4. Principle of cubic space utilization. Use vertical space thoughts

racks, cartoons, bag, etc

5. Principle of safety and satisfaction for better morale.

6. Principle of flexible. Permits rearrangement of layout with least

in convenience and minimum cost.

1.2.3. Type of plan layout:

There are four type of Plan layout: process layout, product layout,

combines of process and product, fixed position layout. At this time, Compal use

product layout in almost workshop, because of the development of industry and

the change Customer requirement so the new manufacturing system was

appeared cell manufacturing. Thus, I describe more detail about product layout.

T is T- lathe

M is Milling machine

D is Drill machine

G is Grinder machine

Product layout also known as line layout. The operation are performed insequence of their occurrence, and the equipment are arrange accordingly. This

type of layout is preferred for continuous production of a given product.

Advantage:

- Less space requirement for the same production volume.

- Automatic materials handling possible.

- Reduced product movement and processing time.

- Simply production planning and control, better co-ordination.

T T M M G

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- Smooth and continuous work flow.

- Less skilled workers can serve the purpose

Disadvantage:

- Product changes require major changes in layout. Lay out is in

flexible.

- Pace of working depends upon the pace of the slowest machine.

- More machines are needs as machines arranged operation wise.

At some locations, standby machines are needed, where one

machine failure may result in complete shutdown of production

line. Thus, the system requires higher capital investment.

- Inspection become difficult.

In additions, I want to confirm one a again, Plant layout classified three kinds:

product layout, process layout, cell layout. However, in the scope of this topic, I

have not enough time to descript all of it more detail. Product layout includes:

continuous flow, mass production, and batch-processing arrangements are

usually organized by product layout. Equipment arrangement is based on the

sequence of operation performed in production, and products move in a

continuous path from one workstation to the next. Thus, I am concerned with

continuous flow manufacturing.

1.3. Continuous flow manufacturing and line balance:

1.3.1. Continuous flow manufacturing

As above writing, machines and equipments are arrange in one line

depending upon the sequence of operations required for the next product. The

materials move form one workstation to another sequentially without any

backtracking or deviation. In addition, machines are grouped in one sequence.

There for materials are fed into the first machines and finish goods travel

automatically from machine to machine, the output of one machine becoming

input of the next, for instants, in the line manufacturing, logic lower is checked

and assembled main board , output is logic lower and main board and next

workstation assembled PCMCIA frame, so input is the output of previous station.

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The raw material moves very fast from one workstation to another stations with a

minimum work in process storage and material handing.

This image illustrate the continuous flow manufacturing of MFG A31:

Figure 2 : Flow manufacturing

In this model, the material moved two straight lines, because RUN-IN is

round and to saved the space of the workshop. Product layout often follow a

straight line, a straight line is not always best, and layout may take an L, O, S or

U shape. In this situation, O is better than other is. And how to set up a

continuous flow layout. The grouping of machines should be done keeping in

mind the general principle:

- All the machine tools or other items of equipments must be

placed at the point demanded by the sequence of operations.

- There should no points where one line crossed another line.

- Materials may be fed where they are inquired for assembly but

not necessarily at the one point.

- All the operations including assembly, testing packing must be

included in the line

Advantages: Product layouts provide the following benefits

- Low cost of material handling, due to straight and short route

and absence of backtracking.

- Smooth and uninterrupted operations

- Continuous flow of work

- Lesser investment in inventory and work in progress

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- Simple and effective inspection of work and simplified

production control

- Lower cost of manufacturing per unit.

- WIP is shorter, requirement space is smaller.

Disadvantage of flow line:

- High initial capital investment in special purpose machine.

- Heavy overhead charges.

- Breakdown of one machine will hamper the whole production

process.

- Lesser flexibility as specially and laid out for particular

production.

- Waste time when change type product.

- Output is not stable, because of some mistake on the line

Suitability:

- Mass production of standardized products.

- Simple and repetitive manufacturing process.

- Operation time for different process is more or less equal.

- Reasonably stable demand.

- Continuous supply of materials

Therefore, the manufacturing units involving continuous manufacturing

process, producing few standardized products continuous on the firms own

specifications and in anticipation of Compal- Electronics Inc. Nowadays, the

demand of customer is changed very fast, from the mass production to the

diversification of products and high quality reduces cost product. Due to this

demand, Compal is changing the manufacturing system gradually, step by step.

To satisfy the demand of customer, the highest quality and the lowest of cost

production, Lean manufacturing is more suitable for Compal and the best choice

is Cell manufacturing. All of them are writing in next part. The law of change

does not demolish old things and we have to improve and maintain all of them.

Thus, I deal with tools of continuous flow manufacturing Line balance.

1.3.2. Line balance:

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Line balance in a layout means balancing the production or assembly line

particularly in product layout. It may arise: the fact that the production capacity

of each machine is the sequence is nor identical. For example, suppose there are

three workstations A, B, C with productions capacity per 25, 50, 100 pieces per

hour. A = 100, B= 50, C = 25. It is very difficult to balance and the layout. To

balance this layout, the production capacities of workstations A and B will have

to be increase to match with the maximum capacity workstation. This will be

permitted all stations to work to their maximum capacities.

Define of line balance: Line balance of production line is uniformed to

work step of production system about time by adjust operating load.

To estimate the line balance rate we calculate percentage of flow

production line. This percentage will show the rate of production line.

Method to calculate the balance rate:

1

WTTotal Workstations time

Balance rate= *100% *100% Number Operator * Time of bottle neck DL*BT

n

i

After calculate the balance rate, we are mention to another relationship

such as Balance, CWS, Grate.

The aim to reduces bottleneck station operating time Improve the line

balance enhance the production line reduce the CWS Improve the

production line Labor cost per station will be reduce.

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Table 2: Data relation

We have to use all of above formula to calculate the production line. After

that, we use ECRS (Eliminate, Combination, Rearrange, and Simplify) to

improve the line to get the best result.

1.4. Cell Manufacturing Systems and Cell Formation Problems, CFP:

1.4.1. Cell manufacturing system:

a. Define:

Cell manufacturing is a manufacturing approach that challenges the

traditional Job Shop approach for a organizing a factory. In traditional Job shop,

manufacturing is organized by process or departments - each department

specializes in one or more manufacturing process such as screw drive machine,

scanned barcode, assembly, screw feeder When a product is manufactured it

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usually built in a large batch which is then routed thought each of station, finally

move to the stock. Therefore, under the traditional Job Shop system components

and products are continuously manufactured in excess and at the wrong times.

This approach creates excessive Work in Process (WIP) inventory and lengthy

manufacturing lead-times.

Thus, Cell manufacturing (Cellular Manufacturing)is not a product-

orientated approach. Manufacturing facilities are organized to build specific

products or families or products in work cells. These work cells are design to be

product focused and arranged to contain each of resources necessary such as

machines, people, tools, etc to build a product or product family to complete

from start to finish. If a product can be built completely in the same cell, this cell

is called a Product Cell.

b. The classification of Cell layout:

Because Cell layout is free style, there are many types of Cell layout.

However, it bases on define and general template. We can divided into four kind

of Cell layout.

The general of Cell layout:

Figure 3: General Cell layout

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Figure 4: Type of Cell layout

c. Step to design cell:

1. Analysis product:

In this step, the characteristic and specifications of product is

analyzed. After all that, we have to bring out analyzed result. It

concludes: Element of production: sequence and tools

Time standard: movement and time of it

2. Design cell workstation:

To rely on above analyzed process, we have to list: Tools and

equipments, number of operators, fixture. Then we calculate standard time per

one product.

3. Design layout of workshop:

To analyzed Material Requirement Planning (MRP) and Capacity

Requirement Planning (CRP), it is an effort to develop a match between

the production plan and production capacity of a company. CRP must be

coordinated with the MRP. Afterward, we calculate the number of cell

workstation and arrange in determined space with principle:

Saving space.

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The way of transport do not congestion and have aestheticism.

To satisfy of CRP from one to two year.

d. Advantage and disadvantage of Cell manufacturing:

Advantage of Cell manufacturing:

- The cell operates like an independent business with total

responsibility for quality, manufacturing and delivery of the product

to customers.

- All cells have the resources within their organization to accomplish

their mission.

- The requirements are known and goals are established.

- Cell member are flexible and work in teams to accomplish their

goals including continuous improvement.

Disadvantages of cell manufacturing:

- Lower equipment utilization

- Increase set up cost.

1.4.2. Cell Formation Problem:

In this scope of thesis, I introduce about General Cell Formation Problem.

Because the time is not enough for me to researching more detail about it. It has

long been recognized that productivity in manufacturing can often increase by

producing similar products in manufacturing cells. This involves: assign parts

into individual machines and forming machines into manufacturing cell. These

two activities have traditional carried out separately. Here we present a new

model that deals with two activities above simultaneously, then we extend this

model to allow for the reassignment of operations to different machines type s by

incorporating machine type modification costs. Such modification enables

additional machine type to process certain parts, with view to reducing inter-cell

travel. The cost of such modifications must be balance by the consequent

reduction in inter-cell travel cost. The extended model specifies which individual

machines should be modified to enable them to process additional part types,

part-machine assignment, and the grouping of individual machines for cell

formation. The objective is to minimize, the grouping of individual machine

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modification cost, and the inter-cell travel. We call this endeavor the General

Cell Formation Problem. The idea work best for medium-variety, medium-

volume situations, batch production. The focused factory is constructed using the

notions of either flexible manufacturing system or group technology, which are

based on the precept that certain activities should be dedicated to a family or

related parts in manufacturing cell.

Suppose that a number of different products have to be manufactured

using certain machines types. It is known from the process plans of the parts

which machine types. It is known from the process plans of the part, which

machines types are required for producing the individual parts, and the routing

(machine ordering) for each part is given. We wish to assign the different parts to

the individual machines of the types required and to group machines so that each

group forms a manufacturing cell. This leads to the following activities:

- Assign part families to groups of machine types,

- Find lot sizes of the parts produced,

- Determine the number of machines needed of each machine type,

- Assign parts to individual machines and

- Group individual machines into manufacturing cells,

Formation of Families of Parts and Their Assignment to manufacturing

Cells of Machine Types

Assume that n parts, numbered 1, 2,...,n, are to be processed on m

machine types: numbered 1,2,,m, which are to be grouped into up to p

manufacturing cells, numbered 1.2,,p. The information as to which parts are to

be processed on which machine types is given by the so-called machine type-part

matrix, with elements:

aij = 1, if part j is processed on M i, and= 0, otherwise,

(i = 1, 2, ..., m; j = 1, 2, ..., n.),where M i denotes the machine type i.

We attempt to reorder the machine type rows and part columns of the

machine type-part matrix to obtain a block diagonal structure as shown in Figure:

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Figure 5: Matrix part families

The term "block diagonal" implies that we can partition the matrix such

that the boxes on the main diagonal contain as many 1's as possible, but

the off-diagonal boxes contain only 0's. If such a block diagonal structure

(as shown) is obtained, the items that correspond to columns of one block

(constituting a family of parts) are processed only on those machine types that

correspond to the rows of that block (a group of machine types). Each

block is a candidate for a manufacturing cell.

Computation of Lot Sizes and Minimum Number of Machines

For each part j, let dj be the demand rate, Kj be the set up cost, and hj be

the inventory holding cost per unit per period. We can often choose the lot size or

batch size qj , to be the economic order quantity:

2 ., j= 1,2,.....m

j j

j

j

K dq

h

Next, for each Mi , 1,2,,m, we determine the minimum number of

machines needed. Let Ci be the capacity of each M i (measured by its

running time, including set up) available per period. Let sij be the required set

up time per batch or lot of part j for any M i and let tij be the processing time

(without set up time) for one unit of part j on any M i. We do not consider

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conveyance times as they can be neglected within each manufacturing cell.

The processing time pij of a job j (of batch size qj) on any Mi then

ijsij j ijp q t

The utilization uij, of the Mi's by part j is given by

j ij

j ij

j

ij

i

d sd t

qu

C

Note that uij is the number of Mi 's, or fraction thereof, that is required for

the processing of part j. We set uij= 0 if part j is not processed on any Mi. The

numerator in above formula represents the running time of a Mi per period

required for part j. If uij > 1, say, 1 < uij < 2, we introduce a dedicated Mi to

process part j.

Given the utilization uij of the Mi's by part j (j = 1, 2, ,n) the minimum

number ei, of Mi 's required for producing all parts, can be computed as:

1

n

i ij

j

e u

Wheree

is the smallest integer greater than or equal to e (rounded up).

The average utilization ie of an Mi is:

1

n

ij

j

i

i

u

ee

We now go on to use the concepts we have just defined to address the two

activities assign parts into individuals machines and. In the next section, we

survey traditional heuristic methods that address above two activities

sequentially. Next, we present new models that address these two activities

simultaneously.

Machine-Part Assignment and the Grouping of Machines into Cells:

If part j must be processed by an Mi and ei > 1, we must specify to which

of the ei Mi 's that part j is assigned. Thus, for each Mi with ei > 1, we have to

solve a machine-part assignment problem whose objective function (to beminimized) is a measure of the material flow or material handling cost

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between different manufacturing cells. In other words, the solving of the

machine-part assignment problem requires some preliminary knowledge of the

solution to the machine grouping problem.

The machine-part assignment problem can be modeled as a

graph-partitioning problem, where the nodes of the graph correspond to the parts

processed on Mi's. We seek to determine a minimum-cost partition into ei sub

graphs .

The construction procedure determines an assignment of the parts to

the machines so that machine capacities are not exceeded. Consider an Mi with

ei > 1. Let Ji {1,2,..., n} be the set of parts processed on Mi's. To

construct a feasible solution, assign the parts j Ji successively to the first

M i , with capacity available. If the capacity of the first M i is exceeded, we

use a second machine, and proceed analogously. Only if none of the M i 's has

sufficient capacity to process all of part j, should the operation be divided

into partial processing by more than one Mi.

Figure 6: Group machine

As an example, we apply the construction procedure to the M 4 's, where

J4 = {2,4,5,6} and e4 = 3. Let M i represent the kth machine of type i. Part 2

has a utilization of M4 that exceeds one. This creates a dedicated M41 , that

processes a single part (part 2). The remaining utilization by part 3 is assigned

to M 4 , along with part of the utilization of part 4.

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The solution to the assignment problem for all machine types

can be summarized in a machine-part incidence matrix with elements:

brj= 1, if part j is assigned to machine r,

= 0, otherwise, where the number r, is the unique numerical label

of some individual machine.

Example:

Figure 7: matrix of machineGiven a machine-part incidence matrix, the machine grouping

problem (that is, the formation of manufacturing cells) can be solved in a

variety of ways which involve the solution of problems assign parts to individual

machines and group individual machines into manufacturing cell sequentially.

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Figure 8: sequence of parts

In other way, to achieve optimality we develop a new model that solves

tasks assign parts to individual machines and group individual machines into

manufacturing cells simultaneously. But it is a program, and I do not descript

here because of this limit of thesis.

1.4.3. Group technology and group efficiency:

a. Group technology:

Group Technology (GT) seeks to obtain the economies of scale of mass

production in a batch production environment. The attractions for the pioneers of

GT were, however based on cost directly but rather indirectly as a result of

having more effective control over the manufacturing systems. GT can be critical

element in the rejuvenation of outdated and unproductive plant. GT addresses the

following issues as a single coherent problem.

Component are arrange into families with similar production requirements

Small group of machines are matched to the component families

Groups of operatives are assign to cells

The basic idea of part families manufacture originally consisted of

grouping parts with similar machining characteristics together to form so-calledadditive batches and routing them though the functional machine layout with

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assistance of the production control. The basic ideal of GT cell is to split the

manufacturing area into machine group in which all the machine groups in which

all the machining operations required for the manufacture of a certain parts

spectrum can be accomplished. Within the GT cell itself all the forms of work

can be employed with the advantage that the task area limited such a way that

the members of the group also have the feeling of belonging to a team.

a) Define of group technology

In the simple terms, GT can be defined as grouping of parts with similar

operation and machines corresponding to these operations, which makes GT to

be recognized as one the key factors to improve productivity in any

manufacturing systems. GT have got different definition such as:

1. Identifying and grouping similar or related machines, parts in a

production in order to use their similarities by considering the

inherent economies of flow-production methods.

2. Logical arrangement and sequence of all facets of company

operation to bring in the benefits of mass production to high variety,

mix quantity production.

3. Development of technological processes, efficient setting up of

machine tools and equipment planning, so as to insure the most

profitable technical planning of production in the shortest time.

4. By realizing that many problems are similar and that by grouping

similar problem, a single solution can be found to set of problems,

these by saving time and effort.

5. Classification of parts or machines into groups in order to increase

the efficiency in the field of design as well as in production.

When viewed from a manufacturing perspective, GT can be defined as the

decomposition of manufacturing system into various subsystem by categorizing

parts into part families and machine into machines cell depending on the part

manufacturing characteristics. The advantage of grouping machine into cells will

reduce the number of production must be scheduled. Also grouping parts into

families reduces the complexity and number of parts for schedule purpose.

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Implementing GT may result in the following benefits:

- Reduction in new shop drawings 30%

- Reduction the number of drawings through standardization (10%)

- Reduction in raw material stocks 42%

- Reduction in new parts designs 53%

- Reduction in work in process inventory 62%

- Reduction in overdue orders 80%

- Reduction in throughput time 70%

- Reduction in setup time 69 %

- Reduction in industrial engineering time 60%

- Reduction in production space required

b) Classification of Group technology:

The main of classification in any manufacturing environment is to provide

an efficient and rapid method of information retrieval for making decision. But

still today in most companies, production decisions are solely base on guess

work. The need for GT classification can be the following purposes:

- To find the parts for tooling material families

- To find the optimal component for parts

- To find the optimal scheduling sequence for loading

Parts classification is method by which slightly dissimilar parts are

identified and grouped together to take advantage of their basic similarities in

manufacturing and design. Once the parts have been organized, GT cells can be

design around the part family; with each cell handling one or more part families

and all parts in a given family are expected to be more or less identical and able

to process by a standardized process plan.

b. Group efficiency:

Group efficiency is defined as the ratio of the difference between the total

of the external cells that can be visited and the total number of external cells

actually visited by all components to the total of the maximum number of

external cells that can be visited them (only applicable when number of cells is

more than one)

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1

1 , 1n

w j

j

E q c

Where,

qj is the number if different machine belonging to component j

routing.

The total number of cells actually visited by all components is

1 1

( 1)n c

w jk

j k

A x

Where,

xij =1 if component pj visits cell ck, k = 1,2,,c

= 0 otherwisew w

w

E AGroup efficiency =

E

If all machine groups within manufacturing cell have equal cycle time, the

work stations should be allocated to machine groups such that the machine group

have a approximately the same efficiency. This is because the efficiency of the

manufacturing cell is best equal to the efficiency of the worst performing

machine group. By making all machine groups approximately equal, the

efficiency of the worst performing machine group is maximized.

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Chapter 3

Design a combo production line and analyze

According the fundamental knowledge and the step to design cell, I give

some cell proposal and analyze it.

2.1. Analyze product:

In whole studied and research process, I have practiced on Line D and line

G with model IBQ00. Therefore, I design a combo production line to produce

IBQ00. This model represent for other notebook computer.

2.1.1. The flow chart of product:

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STRU

AFT

R/I

Repair

Pass

Fail

OK

PFT

COSM

Packing

Pass

Pass

RepairFail

WIP

SWDL

OBE

Shipping

RepairNG

OK

OK

TPDL

Figure 9: Flow chart IPQ00

Number Period Time (second)

1 STRUC 86,15s

2 AFT- assembly function test 89,23s

3 TPDL 120s4 R/I RUN IN 3600s

5 PFT Program function test 116,03s

6 PACKING 101,59s

Table 3: Time of working group operations

According the above flow chart, the production line classified into 2 parts: before

R/I and after R/I. I have measured, grouped, and divided time of each operator.

So this is shown in the behind chart:

Number Operation Time (second)

1 Pick up MainBoard and paste PPID 10,4s

2 Pick up Logic Lower 2,19s

3 Assemble Fan 5,85s

4 Assemble Logic Lower and MB 5,84s

5 Screwed on 7,12s

6 Assemble CPU 4,25s

7 Assemble thermal 6,25s

8 Assemble Modem 6,54

9 Assemble RAM 3,25s

10 Assemble PCMCIA Frame 10,73s

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11 Assemble Speaker 6,15s

12 Plug cable 7,71s

13 Screw hexagonal screwed 12,78s

Table 4: time of each station

Main board

10,4s

Logic Lower

Assemble Fan

Assemble Main boardand Logic lower

Screwed on

AssemblePCMCIAFrame

Assemble cable

Assemble speaker

AssembleRAM

AssembleCPU

Assemble thermal

Assemble modem

2,19s5,85s

5,84s

7,12s

10,73s

7,71s

3,25s

4,25s

6,25s

6,54s

12,78s

Screwedhexagonal-

screw on

6,15s

Figure 10: Time of Assemble

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Check Rj45 Port

COSMETIC

Check 1394 port

Check USB

CheckSY CARD Unplug HDD and

keyboardScan barcode

Plug HDD and

key board

6,10s

5,96s 12,38s

5,51s

CheckKeyboard

24,28s

5,65s

4,46s

6,6s

A

Pick up toRUNIN Frame

4,51s

Figure 11: time of AFT

Number Operation Time (second)

1 Plug HDD and keyboard 6,10s

2 Cosmetic 5,96s3 Check RJ45 Port 12,38s

4 Check 1394 port 5,51s

5 Check keyboard 24,28s

6 Check USB 13,78s

7 Check SY CARD 5,56s

8 Unplug HDD and keyboard 4,46s

9 Scan Barcode 4,51s

10 Pick up into RUNIN Frame 4,51s

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Table 5: time of AFT

A

Take baseto the line

3,63s

Assemble component of Computer:

Change RAM A to RAM B

Assemble BIOS battery

Plug battery

HDD, ODD

Mouse

WWAN card

Button printed circuit to check

TEST items: DVD

Sound and MIC

Power Modem

Smart Card

Power by multimeter

36,38s 41,83s

Disassemble

Battery

HDD, DVD Mouse

WWAN card

Power

Paste PPID label

32,07s

Pick up SWDL

A

2,12s

Figure 12: Time of PFT

A B

Scan barcode and pick

up to line

3,28s

Disassemble

Battery, BIOS

RAM

Thermal

CPU

Assemble RAM DOORPast temp

Paste PPID

DELL temp

14,21s

31,04s

Cosmetic

14,36s

Scanbarcode

10,3s

PACKING

28,4s

Figure 13: Time of Packing

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2.1.2 Table time of above process:

Number Period Time (second)

1 STRUC 86,15s

2 AFT- assembly function test 89,23s3 TPDL 120s

4 R/I RUN IN 3600s

5 PFT Program function test 116,03s

6 PACKING 101,59s

Table 6:Time of group cell

2.1.3. Tools for cell:

Number Period Tools (quantity)1 STRUC De-ion fan (1), Screw-drive

machine(2),Fixture for thermal (1) and

screwed on, Tape dispenser (1), screw

feeder (1)

2 AFT- assembly function

test

HDD, Keyboard, net wire RJ45

standard, printed check USB, SY-card,

scanner, Notebook

3 TPDL Frame TPDL

4 R/I RUN IN Frame RUN IN

5 PFT Program function

test

Battery, BIOS battery, ODD, HDD,

WWAN card, printed button, scanner,

notebook

6 PACKING Screw driver machine, temp, scanner,

DTC, box

Table 7: tools for Cell

2.2. Design Cell

2.2.1. Cell proposal 1:

Cell working station for Assembly:

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AFT and PFT

Figure 15: AFT and PFT work station

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PACKING

Figure 16: Cell for Packing

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Layout to produce a Completed product:

Figure 17: Layout for Cell proposal 1

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Figure 18: Cell layout proposal 2

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2.2.2. Cell proposal 2:

Layout ASSY area:

Figure 19: Assemble cell 2

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AFT and PFT area:

Figure 20: AFT and PFT Cell proposal 2

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Kitting

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Figure 21: Kitting

CELL table:

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Figure 22: Cell table

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Frame:

Figure 23: Frame for Cell

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Figure 24: layout cell proposal 2

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2.3. Detail analyzes:

In this part, I analyze for above proposal that includes labor, time,

frequency of product, and cost.

2.3.1. Proposal 1:

a) Time and frequency of product:

Table 8: Time of Cell proposal

Name Abbreviation Formula Value

Direct labor DL 4

Work Hour standard WHS 8 hour

Loss rate LR 5%

Bottleneck cell BT Max(cell) 116,03s

Working hour WH WH=DL*WHS 32h

Current

workstation time

CWT *

(1 )*3600

BT DLCWT

LD

0,1357h

Rate Rate 3600*

*(1 )

WHSRate

BT LR

261,27

b) Cost for Cell:

Material

Table 9: Cost for Cell

Name Quantity Price

Logic Lower 1 113

Fan 1 17

Modem 1 22

PCMCIA 1 11

MainBoard 1 469

Speaker 1 9

Other 27

SUM 668

Salary for Operator:

Salary of operator calculated as bellow:

- New operator from 1000 to 1500 RMB

- Skill operator from 850 to 1000 RMB

Average salary of operator

850 1500 11752

S RMB

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Sum of salary:

K= 1175x4=4700RMB

Overheads:

Table 10: Overhead for Cell Proposal 1

Items Equipment, tool,

fixture

Type Quantity Price

(RMB)

Sum

(RMB)

1 Cell table Equipment 4 2800 11200

2 Tray Equipment 20 50 1000

3 Frame Equipment 1 4000 4000

4 Conveyer Equipment 2,13 2000 4260

5 Small handcart Equipment 3 380 1140

6 De-ion Fan Equipment 5 400 2000

7 Magnetic charger Equipment 1 40 408 ESD bracelet Equipment 5 6 30

9 NG product table Equipment 4 65 260

10 MI table Equipment 5 6 30

11 Black board Equipment 1 280 280

12 Torsion Test Tooling 0.5 10500 5250

13 Multi-watch Tooling 1 950 950

14 Screw tray Tooling 10 22 220

15 Screw head Tooling 12 3 36

16 Tape feeder Tooling 2 740 1480

17 Carpet table Tooling 4 22 8818 Caliper thickness Fixture 4 140 560

19 Screw driver

machine

Tooling 10 900 9000

20 Fixture for

hexagon screw

Fixture 1 120 120

SUM (Vt) 41944 RMB

- Transport cost Vv= 2% Vt= 2%.41944= 839 RMB- Maintain and warranty cost :

Vm=7%.Vt=7%.41944=2940RMB

Management cost:

Vql = 150300% S= 250%.4700=11750 RMB

Sub material cost Vvlp= 1%Vc= 1%.688=6,88

Electric, water, other energy cost:

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Vp =10%. S = 4700.10%= 47 RMB

Overheads:

Vtp = Vp +Vvlp +Vql + Vm= 41944+2940+11750+6,88+47 +839 =57526,88

2.3.2. Proposal 2:

a) Time and frequency of product:

Table 11: Time for Cell 2

Name Abbreviation Formula Value

Direct labor DL 62

Work Hour standard WHS 8 hour

Loss rate LR 5%

Bottleneck cell BT Max(cell) 5,95Working hour WH WH=DL*WHS 496h

Current

workstation time

CWT *

(1 )*3600

BT DLCWT

LD

0,1078

Rate Rate 3600*

*(1 )

WHSRate

BT LR

3600

b) Cost for Cell:

Material

Table 12: cost for cell 2

Name Quantity Price

Logic Lower 1 113

Fan 1 17

Modem 1 22

PCMCIA 1 11

MainBoard 1 469

Speaker 1 9

Other 27SUM 668

Salary for Operator:

Salary of operator calculated as bellow:

- New operator from 1000 to 1500 RMB

- Skill operator from 850 to 1000 RMB

Average salary of operator

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850 1500

11752

S

RMB

Sum of salary:

K= 1175x62=72850RMB

Overheads:

Table 13: Overheads for cell 2

Items Equipment, tool,

fixture

Type Quantity Price

(RMB)

Sum

(RMB)

1 Cell table Equipment 4 2800 11200

2 Tray Equipment 20 50 1000

3 Frame Equipment 1 4000 4000

4 Conveyer Equipment 2,13 2000 42605 Small handcart Equipment 3 380 1140

6 De-ion Fan Equipment 5 400 2000

7 Magnetic charger Equipment 1 40 40

8 Kitting Equipment 2 4000 8000

9 ESD bracelet Equipment 5 6 30

10 NG product table Equipment 4 65 260

11 MI table Equipment 5 6 30

12 Black board Equipment 1 280 280

13 Torsion Test Tooling 0.5 10500 5250

14 Multi-watch Tooling 1 950 95015 Screw tray Tooling 10 22 220

16 Screw head Tooling 12 3 36

17 Tape feeder Tooling 2 740 148018 Carpet table Tooling 4 22 88

19 Caliper thickness Fixture 4 140 560

20 Screw driver

machine

Tooling 10 900 9000

2 Fixture for

hexagon screw

Fixture 1 120 120

SUM (Vt) 49944 RMB

- Transport cost Vv= 2% Vt= 2%.49944= 988,88 RMB

- Maintain and warranty cost :

Vm=7%.Vt=7%.49944=3496RMB

Management cost:

Vql = 150300% S= 250%.4700= 11750 RMB

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Sub material cost Vvlp= 1%Vc= 1%.688=6,88

Electric, water, other energy cost:

Vp =10%. S = 11.10%= 7285 RMB

Overheads:

Vtp = Vp +Vvlp +Vql + Vm= 49944+7285+11750+6,88+3496 +988,88

=73470,76 RMB

2.3.3. Compare (cost for one cell)

Table 14: Compare between two proposal

Items Proposal 1 Proposal 2

Product frequency 65 58Overheads 57526 73470

Space 14m2 6,05m2

According the above table cell proposal is more effective: saving cost,

increase frequency of product and it can be change model as quick as

possible. Because one cell change model, other cell do not affect, it will be

continue produce. Some advantage and disadvantage of this cell model:

Advantage:

- Saving space.

- This is a cell and it contains advantage of Cell as above

characteristics, for example as comparison of worker, flexible

of product.

- Easy to contribute product and material.

Disadvantage:

- High initial capital.

- Low machine utilization.

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Chapter 4

METHODOLOGY

To Design a combo production line cell manufacturing and flow manufacturing

To identify clearly about cell manufacturing and flow manufacturing.

To propose combo production line

To analyze cost, time, product and other relative data

The following chart shows the way to implement with six steps:

57

Begin

Identifying the goal of

the research

Identifying the objectives ofthe research

Defining the problems

Analyzing the problems

Solving method

Solving the problems

Discussion & Conclusion

End

Chapter 1

Introduction

Chapter 2Literature review

Chapter 3

Methodologies

Chapter 4

Chapter 5


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Actions To achieve results

1 Identifying thegoal of the

research

Interview:

Meeting owner, trainer, mentor of MFG A31,

Discussing about study and research plan of MFG A31

2 Identifying the

objectives of theresearch

Interview:

Meeting and discussing about Topic with owner, trainer,

mentor Identifying and discussing about topic, study research plan

Determining the scope of the topic

=> To identify topic => To target of topic

3 Defining theproblems

To determine the work

processes required for the

research.

Lecture

Lecture the leader of MFG,

trainer, mentor: To get

information of

manufacturing process of

MFG A31.

Lecture the leader of MFG

- Information of

manufacturing process

- Flow production

- IE tools

- Cell manufacturing

4 Analyzing the

problems To identify the definition Cell

manufacturing and flow

manufacturing.

To determine which line and

product will be applied for the

research.

Discussing by email with

trainer and mentor

To determine the process

of research and study.

To determine the benefits

of combo production line

successful.

5 Solving the

problems

To propose production line

and detail analyze data.

To prove the feasible of

combo production line

6 Discussing To evaluate the new solution. To evaluate the new

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Table 3.1: Work descriptions of the research

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Table 15: Work descriptions of research

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Chapter5

CONCLUSION AND

RECOMMENDATIONS

5.1. Conclusion

I have been studying and researching at Compal Electronics Inc. for a

long time, managements and staff has taught some basic knowledge and

experiment. I understand about Compal Electronics Inc. and role and

responsibility of MFG A31 one relative department. Needless to say, this is

helpful for my job.

Pass whole process studying and researching, I have some other skill as

search information from internet, read and comprehend foreign book and

material of Cell manufacturing and flow manufacturing, the most important is

Industrial Engineering 7 tool of Compal. The English skills are improved such as

reading, writing, speaking, and listening. Beside, I studied Chinese, thebeginning step to communicate with Chinese friend.

I studied about new knowledge system such as concept of Lean

manufacturing, Cell manufacturing, Industrial engineering tool. Then, I can use

them to do work more effective. Add more, fundamental understanding about

manufacturing process of MFG A31 and how to improve, calculate relative data,

get information were transfers.

Having of above information, it helps me to studying and researching

topic. Then, I write this report as a fulfillment requirement to accomplish the

beginning step of my work. In my thinking, this report is useful for Compal to

improve and become the leader of ODM (Original Design Manufacturer). In the

end, study about teamwork and work in group is the most important for myself.

5.2 Recommendations :

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Accoding to my analyze, the cell proposal is more effective than flow

manufacturing. In other hand, it is achieve the lowest manufacturing cost and the

highest customer satisfaction such as diversify of product, small batch size and so on.

However, to re-layout is more expensive, it could be applied in Compal Vietnamto get more benefit and effective.

REFERENCES

Professor M.I.KHAN: Industrial Engineering

Professor Tran Van Dich : Design Production line

Professor Tran Van Dich : Organizing manufacturing

J M Wilson and L R Foulds: Approach to cell formation problem

Introduction cell manufacturing Mekong Capital

http://dspace.mit.edu/ - Thesis

Group technology with flow shop cell (from Germany in English)

Applied continuous manufacturing to low volume electronic manufacturer by

Denis Hager

http:// www.google.com.vn

http://www.google.com/translate_t

http://dictionary.reference.com/translate/index.html

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Appendix A

QUESTIONNAIRE

MFG A31 and cell manufacturing

Date / venue:

Interviewee name:

Position & Role:

Location / contact info:

Objectives of the interview

- Studying and discussing about strategies study of MFG A31,Compal

- Identifying and discussing about manufacturing problem at MFG A31, Compal

1. Could you describe briefly about MFG role and responsibility in Compal?

---------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------

----------------

2. How do you thing about MFG development in Compal?

---------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------

------------

---------------------------------------------------------------------------------------------------------

----

3. How do you thing about Cell manufacturing development in Compal?

---------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------

---------------------------------------------------------------------------------------------------------

----

4. Do we need to improve MFG development from flow manufacturing to Cell

manufacturing

---------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------

------------

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Appendix B

QUESTIONNAIRE

Sevices/applications needed at MFG

Date: ________________

Location: ________________________

Name of interviewer: ______________________

Position of job: __________________________________

Objective of the interview

- To get information of manufacturing process of MFG departments at Compal

- Information of manufacturing process

1. Could you describe to me, how many functional departments at the Compal?

---------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------

----

2. Did you have working process documentations of functional departments?

---------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

----

3. How many kind of product were required by customer in Compal?

---------------------------------------------------------------------------------------------------------

----

---------------------------------------------------------------------------------------------------------

----

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Appendix D Commendation

OW

NER

.

TRAINER

.

M

ENTOR

mountain tran's thesis

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