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You searched Library Catalogue - Title: Studying
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Call Number (WOU)
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SP CEMBA 2010 8
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Author
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Leong, Kam Min
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Title
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An evaluation of selected material feeding methodologies on work order cycle time (WOCT) improvement : a case study / Leong Kam Min
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Abstract
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The intensity of the globalization provided greater business opportunity for the Asia
Pacific region especially our country; Malaysia. With the 30 years of industrialized
experience in the electronics manufacturing and services, today we are able to complete
with other countries or regions offering with competitive pricing and higher product
quality level in dominated some of the specific product market place.
Flawless operation is the key focus for Plexus to excel in medical products sector by
offering world class manufacturing facilities and advance technology in design, assembly
and product testing which in gaining more recognition from world renown OEM
(Original Equipment Supplier).
The management focusing on the manufacturing excellent and targeted to shorter the
current WOCT (Work Order Cycle Time) from 3.5 days to 2.5 days in average and the
one day cycle time saving will help to improve nearly USD 2.5 millions in inventory
holding cost as well as to fulfill shorter customer OTD (On Time Delivery) with better
management in build to stock and time to market services.
Benchmarking on TPS (Toyota Production System) approaches, the deployment of lean
concept in evaluating various material feeding methodologies as well as construction of
value stream in identifying some of the non value added processes and move away the
time waste, movement waste, process waste and material waste in deriving a new
consolidated kitting approach by classifying the components into A/B/C class, unique,
partial common and full common with KTS (Kit to Standard) for unique and partial
common under stock-room, LSS (Line Side Stocking) for the full common under
production with permanent fixed feeder location to achieve optimum set-up and change
over time. The new approach also revised the conventional WO (Work Order) planning
by shift into week bucket with combined WO and save tremendous kitting time for stockroom.
Besides, the evolution of the conventional conveyor layout at store kitting also
converted into “U” shape work-cell in promoting “One Piece Flow” for greater quality
component handling during kitting.
xii
The quantitative analysis in various KPI (Key Performance Indicator) such as OEE
(Overall Equipment Efficiency), MUV (Material Usage Variance) and Kitting cycle time
are constructed and the models has been analyzed in qualitative way and forming the
final results and conclusions for the management review and decision.
The final results shown tremendous improvement with practically “win-win” in
implementing new material feeding method and importantly the project seeing WOCT
reduction and retaining high customer OTD at all time are doable project.
Through this project, all team members are further strengthen their work relationship
within cross functional matrix and also enhance their knowledge in lean and TPS
concept, one of the world class successful system in automobile industry. This project
also making significant saving in machine cost, material cost and labor cost in general.
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Notes
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Final project report submitted in partial fulfilment of the requirements for the Degree of Master of Business Administration (CeMBA)
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Publisher/Year
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Penang : School of Business and Administration, Wawasan Open University, 2010
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Physical Description
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51p.; 30 cm.
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Subject
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Wawasan Open University -- Dissertations
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Subject
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Performance technology
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Subject
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Lean manufacturing
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