centercenter18A1HP051 Gunalan Anush Kumar 18A1HP090 Siddharth Sehgal 18A2HP411 Saurav Dineshpratap Singh 18A2HP450 Mohammad Imad Shahid Khan 18A3HP645 Leela Sai Bharadwaj SakeDonner companygRoup-m sec-b882009090018A1HP051 Gunalan Anush Kumar 18A1HP090 Siddharth Sehgal 18A2HP411 Saurav Dineshpratap Singh 18A2HP450 Mohammad Imad Shahid Khan 18A3HP645 Leela Sai Bharadwaj SakeDonner companygRoup-m sec-bIntroductionDonner Company was founded in 1985. It produced circuit boards called “soldermask over bare copper (SMOBC)”. Circuit boards were produced by Donner Company for pilot production runs and experimental devices. Managers of Donner Company had enough experience in electronic industry and they all were engineers. Donner Company was known for its innovation as well as for introducing new designsProcess flow diagram left46990Step 1Step 168580095250Estimate Labor and material cost for biddingEstimate Labor and material cost for biddingcenter48260 If bid accepted deliver promised within deadline00 If bid accepted deliver promised within deadlineleft10160Step 2Step 2left286385Step 3Step 372390019685 Factory order and detail material specification should prepare Factory order and detail material specification should prepare57150267335Step 4Step 4center48260Order details sent to purchase agentOrder details sent to purchase agent5715010795Step 5Step 5center48895Enter the order in log and send a blue printEnter the order in log and send a blue print3810010795Step 6Step 6center48895Schedule the workSchedule the workIn preparing a bid to customer order, Plummer, President, Altmeyer, and Design Engineer Estimated Labor and material cost.
Order of boards up to 1000 will be deliver in three weeks and if it is more than 1000 then delivery will take for five weeks, if customer accept the bid.Preparation of detailed data of no of circuits, material specifications, factory order material specifications, delivery date and sequence of specificationsFor procuring raw materials at low price in about 4 days of normal order, order details should send to purchase agentEnter the order in log and send a blue printBased of the estimation of labor, raw materials, worker shift we have to schedule the orderOrder size should be considered for the CNC routerPUNCH PRESS CNC RouterSetup time 150 50Run Time for 1 Circuit Board 0.5 1Order size X XTotal setup time and Run time 150+(0.
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5*X) 50+(1*X)To find the breakeven point, both must be equal.150+(0.5*X)=50+(1*X)X= 200.So if the order size is more than 200, then only Donner should take the decision of changing to CNC. Or else, the company should not consider the CNC option.As per Exhibit 2, following is the time efficiency that is achieved by the process depending on the order size and the process of manufacturing:center255270Stage Set Up Time Run Time Time takenBoard Order size 8 Board Order Size 800Preparation Artwork Generation 29 0 29 29Inspect & Shear 20 0.5 20.
5 70Punch tooling Holes 10 0.5 10.5 60Image Transfer (Drill Holes) Manual Drill 15 0.08 335 -CNC Drill 240 0.004 – 1840Metallization 10 0.75 10.
75 85Image Transfer (DFPR) a. Panel Prep 5 0.2 5.2 25b.
Laminate & Expose 20 2 22 220c. Develop 20 0.2 20.2 40Electroplate 25 8.
5 33.5 875Strip DFPR 5 0.2 5.2 25Etch & Tin Strip 10 0.
2 10.2 30Fabrication Soldermask45 1.5 46.5 195Solder dip 30 0.5 30.5 80Punch Press Punch Press Profile 50 1 58 -CNC Router Profile 150 0.
5 – 550Inspect, Test, Pack 45 1.5 57 1245Total (mins) 694.05 5369Minutes per Board 86.
75625 6.7112500Stage Set Up Time Run Time Time takenBoard Order size 8 Board Order Size 800Preparation Artwork Generation 29 0 29 29Inspect & Shear 20 0.5 20.5 70Punch tooling Holes 10 0.5 10.
5 60Image Transfer (Drill Holes) Manual Drill 15 0.08 335 -CNC Drill 240 0.004 – 1840Metallization 10 0.75 10.75 85Image Transfer (DFPR) a. Panel Prep 5 0.
2 5.2 25b. Laminate & Expose 20 2 22 220c. Develop 20 0.2 20.
2 40Electroplate 25 8.5 33.5 875Strip DFPR 5 0.2 5.2 25Etch & Tin Strip 10 0.2 10.2 30Fabrication Soldermask45 1.
5 46.5 195Solder dip 30 0.5 30.5 80Punch Press Punch Press Profile 50 1 58 -CNC Router Profile 150 0.5 – 550Inspect, Test, Pack 45 1.5 57 1245Total (mins) 694.
05 5369Minutes per Board 86.75625 6.71125Steps to decrease the flow time of the jobsThe desk was 18″ away from plating tanks. It was found that 15% of the time was spent walking between them. So the plater can be placed near to the plating tank to reduce the walking time.Designate workers into different processes depending on the type of the job.This will reduce the time wastage and hence making the process more efficient.
Almost 1/4th of the jobs get delayed due to the telephone calls. So to the tackle this situation we can either employ a separate team to take those calls or employ from the existing employees. This would increase the productivity and reduce the job delayDonner is accepting more orders what they can accommodate in their workshop.Effect on Shop floor: Every order has a different design and different order size that leads workers to be assigned randomly in different activities depending on work load. This will lead to inefficiency and scheduling problems.Workers who are handling manual drilling will run out of work. The reason is due to large order size where CNC drilling is being used.
The drilling process requires less man power and many workers will remain idle. Finally, it will lead to loss in productivity. Incomplete of operations has led to return of circuits and it has increased to 3% from 1%. This shows the company is incapable of handling bulk orders. Rise in return of orders leads to reprocessing and shipping of the same order.
It will require employees to repeat the same process with will affect the productivity and operational efficiency will be reduced of the firm.Senior employees keep a watch on small orders and it leads to a smoother operation compared to bulk orders.Workers don’t have a clarity on what work is expected from them which leads to time wastage and its extremely difficult to assess their performance based on type of work and duration of work.Thank You
