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Call Number (WOU) SP CEMBA 2010 8
Author Leong, Kam Min
Title An evaluation of selected material feeding methodologies on work order cycle time (WOCT) improvement : a case study / Leong Kam Min
Abstract 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.
Notes Final project report submitted in partial fulfilment of the requirements for the Degree of Master of Business Administration (CeMBA)
Publisher/Year Penang : School of Business and Administration, Wawasan Open University, 2010
Physical Description 51p.; 30 cm.
Subject Wawasan Open University -- Dissertations
Subject Performance technology
Subject Lean manufacturing

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