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Assembly - Case Study

In: Business and Management

Submitted By SMARTPEGA
Words 564
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Assembling Smartphones : Takt Time not Equal to cycle time?
Takt time is a customer requirement.- It is the time at which each one good unit is required to be produced – it is should be …” goal”
How Lean helped to match Takt time to Cycle time
How they implemented Lean structure * U Shaped cell * Compressed line to smaller shape * Joint effort between lean team and Operators
Benefits from Lean structure * Reduced Space enabled reduction in overhead allocation * Due to U shape – all things kept at closer proximity * Cross trained operators could balance the work * 960 units per shift – cycle time matched to takt time * Operator count reduced from 23 to 9 * Space reduced to 616 sqft. * Improvement in yield – due to fewer reworks due for quality problems * Productivity improvement
Moon shine shop * Enabled rapid build, reconfigure tools and jig and production line toolings , line fixtures * No dependency on external providors, operators can try out the change and make iterative modifications on faster basis * Joint efforts between moonshine operators and production line operators * This was cheaper but also had fast turnaround time in hours.
Operator’s involvement in space reduction * As improvement decided to move line on first floor of building 5 to a much smaller place * 5 lines were moved in two days * 16200 ft was shifted to 3500 ft * Production increased from 800 to 930 per shift & Zero scrap * Team of 25 – 5 operators, 8 from maintenance, supervisor, materials manager, engineering manager, 6 from engineering and Alejandro * Headcount reduced from 23 to 9 * To avoid resistance from people (risk of loosing job),FDM did not fire them, used in other processes , improvements etc.

FDM challenges * Global completion from various companies * Profit...

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