Lean Manufacturing

Delta 1&2Cycle Time Reduction

Project Title : Delta 1/2 Cycle Time Improvement

Section : Production Engineering

Site : Elite Business Machine Mfg Co. Ltd

Team Leader : XJ Shi

Champion : CH Chan

Lean Manufacturing Road Map

1. 7 Wastes reduction2. Cycle Time Reduction3. UPH Improvement4. Financial Saving

Waste of Motion Eliminate Idle Time

Example: FCT Station

Place finished machine on line 10Place finished machine on line 10

Install 3pcs test jig 7Install 3pcs test jig 7Scan P/N + S/N. Connect to LAN 8Scan P/N + S/N. Connect to LAN 8Connect MMI assy 13Connect MMI assy 13

Install envelop inject platform 8

Power on machine 4Power on machine 4Machine initialization 95Worker: 1. record data in QC report 32. Install envelop inject platform 83. Record the results in check list 23

Machine initialization 95Worker : Record data in QC report 3

Test 197Test 197Record the results in check list 23

After improve Time: 339Before improve time: 370

Take machine from line 5Take machine from line 5

AfterBefore

Improvement

1.

1. 5 2. - 100% 3. ""

2. Balance HS label/Energy star label/Produce Label,WP24MMI2

3CasingBalance.

1. 1 2. Balance

3. 2 PD3

Waste of Waiting Line Balancing

92%May

82%Mar

95%92%82%Delta 1/2JunAprFebModel

82% 82%

92% 92%

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Feb Mar Apr May Jun

MonthMonthMonthMonth

Delta 1/2Delta 1/2Delta 1/2Delta 1/2

Cycle time Reduction

2700May

2220Jun

3162Mar

2700Apr

3162CasingFebCycle time

Cycle Time ReductionCycle Time ReductionCycle Time ReductionCycle Time Reduction

2220

27002700

31623162

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UPH Improvement

30Mar

30Feb JunMayAprMonths

413535UPH

30 30

35 35

41

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Feb Mar Apr May Jun

MonthMonthMonthMonth

Unit Per Hour (UPH)Unit Per Hour (UPH)Unit Per Hour (UPH)Unit Per Hour (UPH)

Financial Saving

Projected Saving till Nov = RMB 60,442.68

60,442.68 10,648.54 10,648.54 10,648.54 10,648.54 10,648.54 4,680.00 2,520.00 0.00 0.00 Total Cost Saving (RMB)

304.24 304.24 304.24 304.24 304.24 133.71 7200Total Man Hours Saved

303030303030303030Manpower Used

10.14 10.14 10.14 10.14 10.14 4.46 2.40 0.00 0.00 Man Hours Saved

27.66 27.66 27.66 27.66 27.66 26.74 14.40 0.00 22.63 Working Hour After Improvement

414141414135353030UPH After Improvement

37.80 37.80 37.80 37.80 37.80 31.20 16.80 0.00 22.63 Working Hour Before Improvement

303030303030303030UPH Before Improvement

113411341134113411349365040679Production Qty

OctSepAugJulyJuneMayAprMarFebMonthTotal

Forecast

Thank You