QUESTION FOR THE GROUP

Suggest an Efficient Line Balancing for

the new model of Notebook which would
improve productivity and reduce cost
 TOSHIBA Satellite Notebook Computers Assembly Line

In August 1995, total workforce 2600 employees.

Worktime
7.5 hours per day for full time factory workers
6 hours for part time workers
4 assembly lines for producing Notebook computers
1 Idle
1 For overseas production
2 For domestic production
Initial Production to be at 150 units per day, to be
increased to 300 units in the next week.
TOSHIBA Satellite Notebook Computers Assembly Line

Each line can produce 8 different models

Each model can have 6 different combinations of features
Total model types possible = 48
Production Plan
Monthly Production Plan specified quantities and model numbers of
the units for the month.
Each model type allotted 20 daily lots depending upon the monthly
production plan.
Total units on each line = 300.
Average time for producing 1 notebook = 2 minutes per 10 line
workers.
Solution 1 LEVEL STRATEGY (OT)

Number of stations 10 and workers 11

Cycle time c =10 hour/300 units = 120 sec

Therefore 2.5 hours is the overtime required for producing

300 units per day
Solution 2 CHASE STRATEGY

Line Balancing
Based on 90 Seconds
per station !!!
Line Balancing Based on 90 Seconds per station.

Maintaining Work time = 7.5 hours/ day

Output rate r = 300 / 7.5 = 40 unit/hour

Cycle time c = 1 unit produced in 60 / 40

= 1.5 minutes
= 90 seconds
Line Balancing Based on 90 Seconds per station.

Calculations
T = Total time = 1011 sec
c = cycle time = 90 sec
TM = T / c = 11.23 12 Stations

Hence
Increase 2 stations and hire 4 workers
Line Balancing : 90 seconds
Comparison between both solutions

Cost analysis of Level strategy

Direct cost
(10 people * 7.5 hours * X sal) + (10 people * 2.5 hours * 1.3 X sal)
= (107.5 X sal)
Indirect cost
No additional cost

Efficiency
= T / Available = 1059 / 10*120 = 88.25 %
Comparison between both solutions

Cost analysis of Chase strategy

Direct cost
(14 people * 7.5 hours * X sal) = (105 X sal)
Indirect cost
Hiring & Training cost for 4 workers, 1 Shock test unit

Efficiency
= T / Available = 1011 / 12*90 = 93.61 %
 RABBIT CHASE STRATEGY

Both the alternatives suggested incorporate the use of the RABBIT CHASE

Seemingly the purpose of rabbit chase is to chase-down and catch a rabbit. Now
this rabbit is an elusive little devil it can hop randomly in any direction. You
can run at least as fast as the rabbit, maybe even faster.

In other words it is work procedure where each of the 2/3 work persons goes
through all the steps of the multi step process, performing the same tasks (staring
from the beginning to end). This is applicable within an assembly line or for part
Supply task.
 Workers are chasing the
activities in a module Rabbit
chasing

B
Store

R
B B
Workers are stationary
Store

B
B
R
Prototype
ADVANTAGES

Multi tasking

Eliminating Support Worker

Increase Productivity and Quality

Decrease dependability on working skills

Other possibilities

1. Increase the conveyor speed

( With rabbit chase flexible task workers )

2. Outsource Certain sub-assemblies

3. Layout optimization
 Prototype assy

PCB manual assembly

PCB Assembly Automated
Suggested Layout

HD Drive Final Assy

Engine Assembly Unit

Admin and Prodcution

R&D /Design lab