Q1. was done on an informal basis by

Q1. How
is Donner company doing? If there are any problems, what are the causes for these?

 

Donner Company manufactured printed circuit
board and within 2 years had specialized in circuit board manufacturing for
experimental devices & for pilot production. They produced circuit boards known
as ‘soldermask over base copper’ (SMOBC) which became popular in early 1980’s.
It chose a production layout such that it minimized installation cost,
preserved life of expensive machines and isolated operations. It faced
difficulties around productivity, quality and delivery problems.

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Following are some of the problems faced by
Donner Company:

–         
Production
bottleneck: Bottleneck shifted almost every day from one operation to another.
As there was no pattern, it was difficult to bring process changes. As each
individual order demanded varying operations and hence it was difficult to predict
which process would have more load.

–         
Delay in delivery:
As customer’s engineer change the design because of design problems, this
lead to delay in delivery.

–         
Productivity:
As the workers shifted from job to job, it affected their productivity.

–         
Quality: Quality
standards varied from customer to customer and from order to order. Also, there
was no formal quality checking process, it was done on an informal basis by the
workers when it moved through the process.

–         
Shipping
policy: They were following a policy of clearing all the work before the
end of the month, which lead to fewer shipment in the start of the month and because
of this policy shipments were delayed.

Q2.
What orders will you schedule on the CNC drill? On the CNC router?

 

Let number of boards be
‘N’

 

CNC
Drilling:

From the Exhibit 2,

            Total time for CNC drill = 240 + 0.004*500*N (Number of
boards)           

            Total time for Manual drill = 15 + 0.08*500*N (Number of
boards)

 

To use CNC drill,

            Total time for CNC drill = 225

            N >= 5.92

 

This implies, if number
of boards are greater than or equal to 6, CNC drilling would be used, else
Manual drill would be used.

 

CNC
Router:

From the Exhibit 2,

            Total time for CNC router = 150 + 0.5*N (Number of
boards)        

            Total time for Punch press = 50 + 1*N (Number of boards)

 

To use CNC router,

            Total time for CNC router = 100

            N >= 200

 

This implies, if number
of boards are greater than or equal to 200, CNC router would be used, else
Punch press would be used.

 

 

Q3.
What is the standard labour time for an order of 1 board? 8 boards? 200 boards?

 

 

Operation

Setup Time (min.)

Run Time (min.)

Total Time (min.) (Boards – 1)

Total Time (min.) (Boards – 8)

Total Time (min.) (Boards – 200)

Preparation

Artwork Generation

29

0

29

29

29

Inspect and Shear

20

0.5

20.5

20.5

32.5

Punch tooling holes

10

0.5

10.5

10.5

22.5

Image Transfers

Manual Drill

15

0.08

55

NA

NA

CNC Drill

240

0.004

NA

256

640

Metallization

10

0.75

10.75

10.75

28.75

Panel Prep

5

0.2

5.2

5.2

10

Lamination and Expose

20

2

22

22

70

Develop

20

0.2

20.2

20.2

25

Electroplate

25

8.5

33.5

33.5

237.5

Strip DFPR

5

0.2

5.2

5.2

10

Etch and Tin strip

10

0.2

10.2

10.2

15

Fabrication

Solder Mark

45

1.5

46.5

46.5

82.5

Solder Dip

30

0.5

30.5

30.5

42.5

Punch Press

Punch press

50

1

51

58

NA

CNC router

150

0.5

NA

NA

250

Inspect and pack

45

1.5

46.5

57

345

 

Total

 

 

396.55

615.05

1840.25

a

8 boards

b

500 holes

c

prep of comp control

d

per circuit board

 

x

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