SONY TECHNICAL MANUAL

STM-1137

FIRST EDITION

ESTABLISHED 2009-12-17

SECURITY GRADECLASS B

SONY STANDARD WORK MEASUREMENT FOR PERFORMANCE

STM-1137

Security Grade: Class B

The Manuals under this security grade shall be applied by and be in the custody of the following parties only: (1) Sony Corporation (hereafter called Sony) (2) Sony and the associated companies taking responsibility of the whole operations related to Sony brand products.

For the handling of these Manuals in cases not specified above, refer to the secretariat of the Sony Technical Standards, Sony Corporation.

Established 2009. 12. 17

Drafted by ad hoc SS-00137, 138 Revision Committee (K. Takeda, Vice Chairman of an ad hoc Committee)

Proposed by Same as above

Authorized by Sony Engineering Standardization Committee (T. Iwasaki, Chairman)

Issued by Sony Engineering Standardization Committee (Secretariat of the Sony Technical Standards)

THIS DOCUMENT IS THE PROPRIETARY PROPERTY OF SONY CORPORATION AND IT SHALL BE HANDLED UNDER APPROPRIATE CONTROL. COPYRIGHT AND ALL INTELLECTUAL PROPERTY RIGHTS IN THE CONTENT OF THIS DOCUMENT BELONG TO SONY CORPORATION.

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SUMMARY STM-1137 SONY STANDARD WORK MEASUREMENT FOR PERFORMANCE

OVERVIEW This Manual defines the setting reference of standard net time (Sony Standard Time: hereinafter referred to as SST) for all products designed and manufactured by Sony.

SCOPE This Manual applies to all products designed and manufactured by Sony, including ODM products bearing the Sony brand name, and other-brand products designed and manufactured by Sony.

CONTENTS This Manual mainly consists of the following items: 4. Definition of SST 5. Basic Concept of SST Setting Reference (shortest reasonable time, direct operation at a constant rate,

plant in a well-managed state, modification of SST, method of SST setting, accuracy of SST) 6. Setting Reference of SST (scope of SST applicable operations, SST applicable operations)

This Manual defines the setting reference of standard net time (Sony Standard Time: hereinafter referred to as SST) for all products designed and manufactured by Sony, and it is ranked as the company-wide standardized index for administration in the unified planned business, evaluation of Sony products, etc.

BACKGROUND Sony Technical Standards for productivity (*See the Related Documents written below.) were established by the Sony Standard Time Committee in 1983 (No. 4 was in 1987). They were partially revised in 1987 but have been left over 20 years since then. As the Sony Standard Time Committee had been already dissolved, Technical Standards about productivity including SST could not be revised. In recent years, the activities in production innovation plan had been changed and a certain management layer had focused on the index of productivity, and this made Engineering Standardization Office in charge of the management of Sony Technical Standards carry out a questionnaire survey to the related plants. Based on the answers, it was concluded that the Technical Standards concerning labor productivity needed revision, thus the ad hoc SS-00137 and 138 Revision Committee was launched. And SS-00137 was finally revised in 2009.

TECHNICAL BASIS Sonys own rules

RELATED DOCUMENTS 1. SS-00137: Sony Standard Work Measurement for Performance 2. SS-00138: Performance Measurement System 3. SS-00139: Equipment Utilization Measurement System [Abolished] => OM-A1139 [Established],

administrated by Sony Jisso Technology Committee 4. SS-00164: Sony Standard Work Measurement for Machine Tact [Abolished] =>OM-A1164

[Established], administrated by Sony Jisso Technology Committee

CONTACT If you have any questions, comments or suggestions regarding this Manual, please fill out the form on the Contact Us page on the Sony Technical Standards website and click the Submit button.

http://www.ss-stm.sony.co.jp/index_e.html

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CONTENTS

1. PURPOSE ...................................................................................................................................1

2. SCOPE.........................................................................................................................................1

3. OPERATIONAL PROCEDURE....................................................................................................1

4. DEFINITION OF SST...................................................................................................................2

5. BASIC CONCEPT OF SST SETTING REFERENCE .................................................................2

5.1 Shortest reasonable time....................................................................................................2

5.2 Direct operation at a constant rate .....................................................................................2

5.3 Plant in a well-managed state ............................................................................................2

5.4 Modification of SST.............................................................................................................3

5.5 Method of SST setting ........................................................................................................3

5.6 Accuracy of SST .................................................................................................................3

6. SETTING REFERENCE OF SST ................................................................................................3

6.1 Scope of SST applicable operations ..................................................................................3

6.2 SST applicable operations..................................................................................................4

EXPLANATORY NOTES .....................................................................................................................6

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1. PURPOSE This Manual constitutes the setting reference of standard net time (Sony Standard Time, hereinafter referred to as SST) for all products produced by Sony bearing the Sony brand name, or by other companies using the Sony brand name, or by Sony using the brand names of other companies. All three types of product will hereinafter be referred to as "Sony products." Implementation of this Manual will increase the following effects in operation of Sony Standard Time. 1) Planning (for production, personnel, operation, equipment, outsourcing, cost estimation, etc.) and

administration (process control, efficiency control, cost control) will be done more consistently and efficiently by having a single standard, SST, which is not affected by different opinions of different managers or divisions.

2) Evaluation (profit and loss calculation, cost analysis, productivity measurement, etc) of Sony products can be done on a fair and objective scale.

3) Decisions about criteria for measuring standard time will influence the administration level. Implementing a consistent standard time policy will result in efficient use of resources and increase in profit, which are among the main objects of a corporation.

2. SCOPE This Manual applies to SST setting for Sony products.

3. OPERATIONAL PROCEDURE 1) Deliberations and decisions about the items related to this Manual shall be made by the Engineering

Committee, composed of representatives from all divisions of Sony. These items shall be authorized by the Chairman of the Sony Engineering Standardization Committee.

2) When this Manual requires revision or abolition, apply to the Engineering Committee that manages this Manual through the division responsible for SST setting.

3) The standards for setting Sony Standard Time Data (hereinafter referred to as SSTD) published by the Engineering Committee, which relates to this Manual, shall be deliberated and judged separately from this Manual.

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4. DEFINITION OF SST 1) SST (Sony Standard Time) is the shortest reasonable time required for a skillful operator to perform an

operation, following the prescribed operation methods and the quality conditions (usually defined by the work standard instruction manual), and making reasonable effort under standard operation conditions. Assuming that all the divisions related to production are in a well-managed state, SST is applied to "direct operations at a constant rate" only, it does not include factors such as fatigue, unavoidable delays on jobs, delays due to personal or physiological demand, and allowance time.

2) In order to clarify the difference between SST and what is generally referred to as "standard time," the relation between the former and the latter is shown below.

As shown in the figure above, among those time generally included in "standard time," the scope of SST is the "net time" in the main working time.

5. BASIC CONCEPT OF SST SETTING REFERENCE

5.1 Shortest reasonable time Net time is the amount of time required to manufacture products that satisfy the quality conditions, using machines and jigs as planned, following the working method and order as prescribed, and with normal operator skill and operating speed.

5.2 Direct operation at a constant rate Direct operations mean the work to add some kind of value to products in the planned manufacturing methods, not the unexpected temporary work. It does not generate the remarkable time change in an individual cycle.

5.3 Plant in a well-managed state The working environment in a plant can never be constant, various situation like malfunction of machines, or changes in material quality occurs from time to time. Those changes in plant inevitably alter the operation method, but this is undesirable. It is best to maintain the unchanged situation, based on the various optimum conditions including production conditions, therefore the production method in the best possible circumstance shall be picked up for a standard.

Standard time

Main working time

Allowancetime *1

Net time

Preparatory working time

*2 Allowancetime

Net time

Machine controlled time

Hand work time (SST scope)

*1 Main Working time is proportional to the processing amount. *2 Preparatory working time is the time used for preparations for processing, adjustment of

machines, affixing and removing of jigs and dies, rearranging things required by a previous operation, etc.

Figure 1 SST scope in standard time

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5.4 Modification of SST Once SST is set, it shall not easily be modified later. It is permissible to modify SST only when fundamental changes in design, components, jigs, machinery, or operating methods take place.

5.5 Method of SST setting SSTD (Sony Standard Time Data) calculated from standard time data system is used to set SST in order to provide an easy way to obtain a highly consistent net time. The SST of operations not covered by SSTD is to be calculated using the direct method based on DWF (Direct Work Factor) method.

5.6 Accuracy of SST The relative error of the accuracy of SST set by using SSTD shall be within 5 % from the value calculated by direct method.

Direct method SSTD method Relative error (%) = Direct method x 100

6. SETTING REFERENCE OF SST SST for an operation by hand or jig (excluding atypical ones) is set by using a unified operation method in Sony group as a reference. Operation simultaneously performed by both hands is analyzed as simultaneous one. The standard equipment for the operations by equipment or automated devices is set per each product category and operation unit (excluding the exclusive jigs for certain equipment). A guide for standard equipment setting is that the majority of equipment for the operation in question is installed, disregarding which division done the development investment for equipment. Majority: On the occasion of the standard equipment is installed to the majority of the production lines in a

plant, or the majority of the plants in Sony group. The introduction of the standard equipment setting shall be adjusted between the divisions to simultaneously install it in Sony or the business group. The timing of install shall be reflected to the annual business planning.

6.1 Scope of SST applicable operations SST shall be set to the following operations: - Processing of printed wiring boards (excluding auto insertion and auto mounting) - Adjustment of mounted boards - Assembly - Adjustment, inspection, and software loading - Packaging (until the finished products at a production line is carried out on a pallet)

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6.2 SST applicable operations The target operations of SST are classified into Sony Standard Time for Added-value, Sony Standard Time for Quality and Sony Standard Time for Corporate Social Responsibility as follows.

(1) Sony Standard Time for Added-value As a rule, the operations that generate added-value and the works accompanies with it are the targets of SST. 1) SST is not applied to the following operations, since they are not considered to generate added

value. - Unavoidable transferring of parts due to production line control, preparation work for other

processes, and waiting time. - The operations to supply parts and semi-finished products to a production line, and to open or

unpack the packages. 2) The number of handling of semi-finished products shall be minimized. 3) Automated machine generates added value, though full-automated machines that requires no

manned operation are excluded from target of SST. 4) SST is applied to the use time of man-machine operation.

Use time means unavoidable waiting time for operators during machines or sets are running (see Figure 2).

(2) Sony Standard Time for Quality The operations related to quality does not generate added value, though SST is applied to them. However SST is not applied to: 1) Single-part check assuming that the parts supplied to the production line have good quality. 2) Double check (confirmation after assembly, adjustment, or measurement) assuming that the

leading process had been done correctly. 3) Quality check after automated machine operation, assuming that quality is assured by the

automated machine. 4) Data creation operation upon introduction of a new model, because it is an impermanent event on

start up. 5) Check operations tentatively carried out in a limited period.

(3) Sony Standard Time for Corporate Social Responsibility The operations related to corporate social responsibility does not generate added value, though SST is applied to them. SST is applied to: - Operations related traceability. - Operations related safety standards. - Operations related compliance.

Time during machine running

Manual work Manual work

Use TimeFigure 2 Use time

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EXPLANATORY NOTES STM-1137 SONY STANDARD WORK MEASUREMENT FOR PERFORMANCE

1. ESTABLISHMENT OF STM-1137, FIRST EDITION (DEC. 2009)

In accordance with the redefinition of Sony Technical Standards (SS) and Sony Technical Manual (STM), the conventional number SS-00137 was replaced by STM-1137. The contents remain the same, and the old version of Explanatory Notes is also placed as a revision history.

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EXPLANATORY NOTES OF THE PREVIOUS SONY TECHNICAL STANDARD SS-00137 "SONY STANDARD WORK MEASUREMENT FOR PERFORMANCE"

1. BACKGROUND AND PURPORT OF THE THIRD EDITION

1.1 Background Sony Technical Standards for productivity (no. 1 to 4 below) were established by the Sony Standard Time Committee in 1983 (no. 4 was in 1987). Then, they were partially revised in 1987 and left over 20 years. At present time, the Sony Standard Time Committee had been dissolved, so that Technical Standards about productivity including SST could not be revised.

1. SS-00137 Sony Standard Work Measurement for Performance 2. SS-00138 Performance Measurement System 3. SS-00139 Equipment Utilization Measurement System 4. SS-00164 Sony Standard Work Measurement for Machine Tact

On the other hand, the production innovation activity started in 1992 aimed to improve the field sites in a short span. It fundamentally associates with the logical system regulated by the Sony Technical Standards, but the priority was put on the improvement of the field sites. What is more, the production formation was transferred from line to cell. As a result, the Technical Standards about productivity were considered less important, and the Sony Standard Time Committee was deactivated with the times. In recent years, the activities in production innovation plan have changed and a certain management layer has focused the index of productivity, and this made Engineering Standardization Office that manages Sony Technical Standards to carry out a questionnaire survey to the concerned plants. Based on the answers, it was concluded that the Technical Standards concerning labor productivity requires revision, thus the ad hoc SS-00137, 138 Revision Committee was launched.

1.2 Main purports The followings are the scope of the activity of "ad hoc SS-00137,138 Revision Committee."

1) Name: - ad hoc SS-00137,138 Revision Committee

2) Goals: - Improvement of estimation accuracy for products assembly by constructing a process design

system that incorporates a CAD system and the SSTD. - Cost optimization of design and production outsourcing (OEM and ODM). - Proper assessments to productivity of the plants. - Improvement of budget accuracy at preparing a design business plan. and so on.

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3) Purpose: - Reexamination of SST to realize process design that accords with current parts and assembly

methods (reexamination of SSTD).

4) Targets (scope of this activity of the "ad hoc SS-00137,138 Revision Committee"): - Clarification of the requirements and scheme for reviewing the reference of SST setting. - Partial revision of SS-00137, and 00138.

5) Deliverables - The proposal of the requirements and scheme for reviewing of reference of SST setting. - SS-00137, the 3rd edition. - SS-00138, the 3rd edition.

6) The role of the "ad hoc SS-00137,138 Revision Committee" - Achievement of the targets mentioned above. - Report and present the deliverables mentioned above to the Sony Engineering Standardization

Committee at a meeting. - Revision of SS-00137 and 00138.

7) Period - Six months from July to December 2008.

The "ad hoc SS-00137,138 Revision Committee" decided to focus on the followings by the members' consensus during the activity.

- Revision of SS-00137. - Summary of the future issues to be deliberated.

2. POINTS OF REVISION

2.1 Reexamination of operational procedure The General Manager of Production Planning Division, Corporate Planning Group was in charge of approval and authorization for establishment and revision of this Standard, but the group, division, position had already been disappeared. The division responsible for this Standard does not exist in the head quarters or business groups now, therefore the Chairman of the Sony Engineering Standardization Committee, who is responsible for the division promotes the company-wide engineering standardization, becomes the authorizer of this edition.

2.2 Reexamination of reference of SST setting Revision was mainly made to "6. Reference of SST Setting."

The items of "software loading" and "Packaging (until the finished products at a production line is carried out on a pallet)" were added to the existing items in SST applicable operations. Also the followings categories of SST applicable operations are thoroughly revised.

1) Sony Standard Time for Added-value: SSTA 2) Sony Standard Time for Quality: SSTQ 3) Sony Standard Time for Corporate Social Responsibility: SSTC

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3. FUTURE ISSUES

This Standard specifies the setting reference of standard net time (Sony Standard Time: SST) for Sony designed/manufactured products, also is ranked as the company-wide unified index for administration in the unified planned business, evaluation of Sony products. However, in the most actual factories, SST is calculated by adding the production requirements to the current net time based on the work standard instruction manual. It is confirmed by the "ad hoc SS-00137,138 Revision Committee" that the SST differs between factories because the operational reference was interpreted differently by each factory. This "ad hoc SS-00137,00138 Revision Committee" does not describe the operational area as mentioned above, and focuses on the reexamination of setting reference. Though, to solve the following issues, the issues related to the operational area (whether to rank this Standard as the company-wide unified index) should be deliberated by the adequate members.

[Issues] 1) Scope of SST

- Sony Standard Time for Quality (SSTQ) and Sony Standard Time for Corporate Social Responsibility (SSTC) * The current Sony Technical Standard excludes the operations related to quality assurance and

social responsibility (traceability) from value adding operations. It is difficult to limit the scope of the target above.

2) Relation with work standard instruction manual - SST is analyzed (calculated) based on the work standard instruction manual. - The value of SST varies because there is no unified rule for making a work standard instruction

manual.

3) Terms and definitions - Definition of the standard equipment is ambiguous (for example, "NEJICCO").

* There is no Sony unified setting for standard equipment.

4) Unification of operation - How to handle variations of SST arising from the different interpretation of Sony Technical Standards.

5) SSTD related issues - Estimation analysis accuracy degrades because SSTD is not being updated to accord with new parts

(formation of manufacturing). - Only a few personnel (now only three people have qualification) are able to analyze (DWF) SSTD. - As a result, SSTD lost accordance with the current manufacturing.

6) Reexamination of the application for SST calculating.

The members of the "ad hoc SS-00137,138 Revision Committee" and persons concerned shall be arranged to confirm that whether a continuous discussion organization is necessary to solve the above-mentioned problems. After that, apply it to the Sony Engineering Standardization Committee as needed, and deliberate about establishment of the discussion organization. Working group that solves the above-mentioned problems by the aspect of factory improvement shall act individually and independently, also the members of the "ad hoc SS-00137,138 Revision Committee" agreed to cooperate with them.

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COMMITTEE MEMBERS

ad hoc SS-00137,138 Revision Committee Vice Chairman of an ad hoc Committee

Sony Ericsson Mobile Communications Japan Inc.

Development & Common Mechanics Dept,, Mechanics, DU Tokyo, C&D K. Takeda

M. Kono Manufacturing Design Sec., Engineering Dept., Ichinomiya TEC M. Kawamoto

S. Uchida Mechanical Design Sec. 4, Mechanical Design Dept, Engineering Center, Koda TEC M. Enomoto

Y. Yamashita Sec. No.3, Production Engineering Dept, Design Div., Kosai TEC M. Yamamoto

T. Abe M. Hirano General Engineering Sec., Design Engineering Dept., Engineering Div., Kisarazu TEC K. Hirakawa M. Aoki Technical Information Sec., Dept. No.3, VAIO Design

Center, Nagano TEC Y. Yamada Engineering Sec. No.2, Engineering Dept., Cellular Business Div., Minokamo TEC H. Endo

Sony EMCS Corporation

MONO-ZUKURI Engineering Promotion Sec., Business Control Dept. M. Kuriyama

Audio & Video Business Gp General Engineering Dept., Operation Div. I. Shimada Electronic Devices Business Gp Biz. Promotion Dept., Communication Module Div. T. Hikichi Chemical & Energy Business Gp

HV Device Dept., Power Supply and Communication Device Energy Business Gp H. Amatatsu Global Production Planning Dept. F. Nishijima

M. Hodohara

Members

MONO-ZUKURI Gp MONO-ZUKURI Innovation Office, MONO-ZUKURI Technology Div. K. Hoshina

H. Ikeda Secretariat MONO-ZUKURI Gp Engineering Standardization Office, MONO-ZUKURI Technology Div. S. Kanke Remark: The contents of this list are correct at the time of deliberation of the draft.

CONTENTS1. PURPOSE2. SCOPE3. OPERATIONAL PROCEDURE4. DEFINITION OF SST5. BASIC CONCEPT OF SST SETTING REFERENCE5.1 Shortest reasonable time5.2 Direct operation at a constant rate5.3 Plant in a well-managed state5.4 Modification of SST5.5 Method of SST setting5.6 Accuracy of SST

6. SETTING REFERENCE OF SST6.1 Scope of SST applicable operations6.2 SST applicable operations

EXPLANATORY NOTES