CO
t o *y i
o o:
o UJ
co : _ i : Uu < ;
> ' to i
_j :•
5~ uj ,:
7- Q i
O o •
i n
', Oi 'I in
i M i
( «
; m m
5-
o
UJ O
o
i; X :
j r
APPENDIX 2
Process data
Process time [source: Siti Internship Programme]
Aishah Fadilullah, 2006, Logbook, Student Industrial
No Process Minimum
time (sec)
Maximum
time (sec)
Average time (sec)
Activity
allocation
1. CRT Rising 1 6.06 7.55 6.98 Transfer
2. Input Beznet + CRT 25.9 30.8 28.73 Value added
3. Install tube + DGC + DY
29.9 35.7 33.19 Value added
4. Prepare speaker 23.2 30.1 26.52 Value added
5. Screw speaker 23.9 27.1 25.13 Value added
6. Screw CRT 27.2 33.5 30.25 Value added
7. Chassis 1 30.9 36.2 33.68 Value added
8. Chassis 2 30.6 37.1 33.69 Value added
9. Docking 1 33.5 35.9 34.6 Value added
10. Docking 2 30.4 37.9 33.2 Value added
11. G2 +HV check 33.9 36.4 35.05 Value added
12. Landing + Convergence
39.6 42.2 40.89 Value added
13. Corner landing 35.6 38.8 37.77 Value added
14. White balance +
Geometry
12.7 17.6 15.02 Value added
15. Convergence 2 27.5 33.7 31.33 Value added
16. Touch-up 1 25.6 32.1 28.87 Value added
17. AGC 32.5 38.8 35.29 Value added
18. Touch-up 2 32.5 39 35.41 Value added
19. Inward check 32.7 39 35.61 Value added
20. Rear cover 27.8 32.4 30.54 Value added
21. Video check 25.9 30.2 27.7 Value added
22. Inspection 1 18.6 25.6 21.9 Value added
23. Inspection 2 27.2 32.5 30.15 Value added
24. Inspection 3 32 35.5 33.89 Value added
25. Insulation 24 29.5 26.98 Value added
26. CRT Rising 2 6.06 7.55 6.98 Transfer
27. Rework 586.80 3378 1764 Non value added
28. CRT Rising 3 6.06 7.55 6.98 Transfer
29. Prepare carton 27.1 32.6 29.87 Value added
30. Input TV set 25.1 30.9 28.11 Value added
31. Packing 1 18.6 22.1 20.57 Value added
32. Direct vanning 10.4 13.2 12.20 Value added
TRANSFER + VA TIME 782.98 929.05 887.08 28 VA
APPENDIX 3
Nested model
APPENDIX 4
List of distribution
List of input distribution
No Process Distribution
1 Input Beznet + CRT 25.4 + 5.56 * BETA(0.929, 0.641)
2 Install tube + DGC + DY 29.3 + 6.73 *BETA(1.19, 0.877)
3 Prepare speaker 23 + WEIB(3.82, 1.43)
4 Screw speaker 23.6 + LOGN(1.56, 1.5)
5 Screw CRT & Set rising UNIF(27, 34)
6 Chassis 1 TRIA(30.3,34,36.7)
7 Chassis 2 TRIA(30, 33.3, 37.8)
8 Docking 1 NORM(34.6, 0.765)
9 Docking 2 30 + GAMM(2.53, 1.27)
10 G2 +HV check TRIA(33.5, 35.1, 36.7)
11 Landing 1 39.5 + 2.88 * BETA(0.766, 0.856)
12 Conv. 1 Corner landing 35.3 + 3.7 *BETA(1.49, 0.891)
13 White balance + Geometry TRIA(12.2, 14.7,18)
14 Convergence 2 27 + 7*BETA(1.14,0.754)
15 Touch-up 1 25 + GAMM(1.73,2.24)
16 AGC TRIA(32,35.5,39)
17 Touch-up 2 TRIA(32,35.3, 39)
18 Inward check NORM(35.6,2.11)
19 Rear cover 27.3 + 5.55 * BETA(0.94, 0.685)
20 Video check 25.4 + WEIB(2.52, 1.63)
21 Inspection 1 TRIA(18,21.7,26)
22 Inspection 2 27 + 5.98 *BETA(0.727, 0.656)
23 Inspection 3 32 + 3.88 * BETA(0.442, 0.623)
24 Insulation UNIF(24, 30)
25 Prepare carton UNIF(27, 33)
26 Input NORM(28.1,1.86)
27 Packing 1 UNIF(18.3, 22.4)
28 Direct vanning 10.1 +3.4 *BETA(0.894, 0.511)
29 CRT rising 1 TRIA(6, 7.23,7.7)
30 CRT rising 2 TRIA(6, 7.23, 7.7)
31 CRT rising 3 TRIA(6, 7.23, 7.7)
32 Rework 9 + WEIB(22.3, 1.45)
33 Machine failure uptime TRIA(12, 12, 13)
APPENDIX 5
Production output (Animation for Model 2)
£ftTR£SXN£ "-KHKB
APPENDIX 6
Production output (Animation for Model 3)
1-CHECK •-ftjaft;
CRTftX&EMG mm@TmmQE* IMTtHUvy-^BEZHeT-;••''•"DCCins.spkr.SCREWSPKftSCREWCRT
fl 1CHASSISt PC3 ™S m 0ma:QsS3tmm Q T-tmaflGCt-uM*iCOMV2flUTOGEOCOIWti&mmGi.;'"Gt'+.m Q a_-j SIMQ PACKINGMRDCTVANHIHG 0V»irep.iIHSP.2IftSP3MSUlATHMt CflftTOH
CQtJWjER CHftfiSKZ &0CKMK1 WKKIWG2 iTECM OLE REWHJftK FRDBUCtltfBQtTEPtJT
APPENDIX 7
VBA codes
1. VBA code for input process time user form.
Private Sub CommandButtonl_CIick()
Dim in As Model Dim theModl As Module Dim theMod2 As Module Dim theMod3 As Module Dim theMod4 As Module Dim theMod5 As Module Dim theMod6 As Module Dim theMod7 As Module Dim theMod8 As Module Dim theMod0 As Module Dim theModlO As Module Dim theModl 1 As Module Dim dieModl2 As Module Dim theMod 13 As Module Dim theMod 14 As Module Dim theMod 15 As Module Dim theMod!6 As Module Dim theMod 17 As Module Dim theMod 18 As Module Dim theMod 19 As Module Dim theMod20 As Module Dim theMod21 As Module Dim theMod22 As Module Dim theMod23 As Module Dim theMod24 As Module Dim theMod25 As Module Dim theMod26 As Module Dim theMod27 As Module Dim theMod28 As Module Dim a As Long
Dim b As Long Dim c As Long Dim d As Long Dim e As Long Dim f As Long Dim g As Long Dim h As Long Dim i As Long Dim j As Long Dim k As Long Dim 1As Long Dim n As Long
Dim o As Long Dim p As Long Dim q As Long Dim r As Long Dim s As Long Dim t As Long Dim u As Long Dim v As Long Dim w As Long Dim x As Long Dim y As Long Dim z As Long Dim aa As Long Dim ab As Long Dim ac As Long
Set m = ThisDocument.Model
a = m,Modules.Find{smFindTag, "Processl") Set theModl = m.Modules(a)
theModl. Data("Value") = TextBoxl. value b = m.Modules.Find(smFindTag, "Process2") Set theMod2 = m.Modules(b)
theMod2.Data(" Value") = TextBox2. value c = m.Modules.Find(smFindTag, "Process3") Set theMod3 = m.Modules(c)
theMod3.Data(" Value") = TextBox3. value d = m.Modules.Find(smFindTag, "Process4") Set theMod4 = m.Modules(d)
theMod4,Data(" Value") = TextBox4. value e = m.Modules.Find(smFindTag, "Process5") Set theModS = m.Modules(e)
theMod5.Data(" Value") = TextBox5. value f = m.Modules.Find(smFindTag, "Process6") Set theMod6 = m,Modules(f)
theMod6.Data(" Value") = TextBox.6. value g = m.Modules.Find(smFindTag, "Process7") Set theMod7 = m.Modules(g)
theMod7,Data(" Value") = TextBox7. value h = m.Modules.Find(smFindTag, "ProcessS") Set theMod8 = m.Modules(h)
theMod8.Data("Value") = TextBoxS. value i = m,Modules.Find(smFindTag, "Process9") Set theMod9 = m.Modules(i)
theMod9,Data("Value") = TextBox9. value j = m,Modules.Find(smFindTag, "ProcesslO")
theModl O.Data("Value") = TextBoxl0.value k = m.Modules.Find(smFindTag, "Processl 1") Set theMod 11 = m.Modules(k)
theModl 1,Data("Value") = TextBox! 1.value I = m.Modules.Find(smFindTag, "Processl2") Set theMod 12 = m.Modules(l)
theModl2.Data("Value") = TextBoxl2, value n = m.Modules.Find(smFindTag, "Processl3") SettheModl3 -m.Modules(n)
theModl 3.Data("Value") = TextBoxl 3.value o = m.Modules.Find(smFindTag, "ProcessM") Set tlieModl 4 = m.Modules(o)
theMod 14.Data("Value") = TextBox 14.value p = m.Modules.FindfsmFindTag, "Processl5") Set theModl 5 = m.Modules(p)
theModl5.Data("Value") = TextBoxl5. value q = m.Modules.Find{smFindTag, "Processl6") Set theModl6 = m.Modules(q)
theMod 16.Data("Value")= TextBox] 6,value r = m.Modules.Find(smFindTag, "Processl7") Set theMod 17 = m.Modules(r)
theModl7.Data("Value") = TextBoxl7.value s = m.Modules.FindfsmFindTag, "Processl8") Set theModl 8 = m.Modules(s)
theModl 8.Data("Vaiue") = TextBoxl8.value t = m.Modules.Find(smFindTag, "Processl9") Set theModl 9 = m.Modules(t)
theModl9.Data("Value") = TextBoxl9.value u = m.Modules.Find(smFindTag, "Process20") Set theMod20 = m.Modules(u)
theMod20.Data("Value") = TextBox20.value v = m.Modules.Find(smFindTag,"Process21") SettheMod21 = m.Modules(v)
theMod21.Data("Value") = TextBox21.value w = m.Moduies.Find(smFindTag, "Process22") Set theMod22 = m.Modules(w)
theMod22.Data("Value") = TextBox22.value x = m.Modules.Find(smFindTag, "Process23") Set theMod23 = m.Modules(x)
theMod23.Data("Value") = TextBox23.value y = m.Modules. Find(smFindTag, "Process24") Set theMod24 = m.Modules(y)
theMod24.Data("Value") = TextBox24.value z = m.Modu!es.Find(smFindTag, "Process25") Set theMod25 = m.Modules(z)
theMod25.Data{" Value") = TextBox25.value
aa = m.Modules.Find(smFindTag, "Process26") Set theMod26 = m.Modules(aa)
theMod26.Data("VaIue") - TextBox26.value ab = m.Modules.FindfsmFindTag, "Process27") Set theMod27 - m.Modules(ab)
theMod27,Data("Value") = TextBox27, value ac = m.Modules.Find(smFindTag, "Process28")
Set theMod28 = m.Modules(ac)
theMod28.Data{"Value") - TextBox28.value Me.Hide 'to hide the userform after click ok
End Sub
2. VBA code for welcome form and abort simulation form.
Private Sub CommandButton l_Click() Dim m As Model 'Define variables used in DimsAsSIMAN 'the VBA logic.
Set m = ThisDocumentModel 'm is defined 'as this particular
'model.
Set s = m.SIMAN
UserForm2.hide 'Get rid of the User Form 'when the abort button is 'clicked.
m.End 'End the model run.
End Sub
Private Sub CommandButton2_CHck() Dim m As Model 'Define variables used in Dim s As SIMAN -'the VBA logic.
Set m = ThisDocumentModel ' m is defined Set s = m,SIMAN 'as this particular
'model.
UserForm2.hide 'Get rid of the User Form 'when the abort button is 'clicked.
m.Go 'Continue the model run End Sub
Private Sub Labell_Click()
End Sub
Private Sub UserForm_Click()
End Sub
APPENDIX 8
Exported data and charts at Microsoft® Excel
UJ Q O
UJ
I- 111 _J o
>- o
t - CO CD CO Is- CD 1** LOt-COCDCOCON. r a r o co co cd co o) s
cq ^ ^ ^ cop jo
-^ CO CO CO CO LO S
t- CO CO CO g
•gLOCOOCDOOtO cDr^iri^rcM^-^S .ccocococococog
C l O C O C O C O C O O t O
cjcNddddco'S
Dl t -
C CO T3 U5 w 1*-
Docki
34.5
1 3
b *"
en co co cm co cd r - fviCO^CMCMCMCMh- cd in -<fr cd h- r-- (*-
. in © © t - co w to
IN in
— COCOCOCOCOCO^
co in
OrOOif)ifi<B
— CMCMCDCNddS
g'CN t- CM CN CM j£
9-COLOCMCNCMCM2-'cocococococojj
a 9 "y O
CO M Zt TJ- £ o
•^ CO o «o CO CM
O H 0.
CD CO CD CN CO LO tO en en m in w if) s CO W t - r- CD i - CO
t - CD CD in CD CO CO CN CM N CO N N (D O CI T~ T- Oi T- CO
. locdco'c6kcoS2
>CNCNCNCNCNCN£j
I- CO
^cdcOCNCOCNdcO LO ID 00 ^T CO CO JS
CO CO CO CO CO CO jg
lOCOCOCOCOCOCOCO CO
CO TO JZ
o
O °! = 2
< ° C CM
05 CO CO CO CD (M N t - CM CM t - LO CN m r-LOCOCDmCDCOh-
gcooiocoinifiio
t - co co m v- cm t o cn m m cn co t - o
. r^ cd cd d cm cd J£
HcNCNCMCOCOCMg
TT CO
•^ N N ^ W CN ^ tcdr^cNcocsicNJS
CDCMCNCOCNCOCOg
*-COCMCMCOCNCOa>
Q. M
o K rt 0 O
rew
29.4
. c CO <•
o Q. O
u CD CO
o o c.
C/} L - a.
. CD CO CO CO CN CO U> -..CO'sfCDCOCD'^-CO
^cOLOcococomco
CO CO CO CO CO CO CO
^CDv-^-^^^lO
•^iriiriLOiriNifiU)
CD Ln CD CD LO O) CO
g^r^co'^co'r-Q
gCOCNCOCOCOCMJ^ CD d CD CD CD (D 1^
JOcNCNCNCNCMCNCM
CO
CN CN CN CN CM CN CM
cd co c
CD U> o
> o CO
£ C CO ZJ
o o
(/> o c
^ ^ - m c N ^ C N T - N
0CMt-LO^CDCNCO 00 CN CO CN CN CO N
CN CN CO CN ^- CN CM
lO O N O ^ C M C O m in cd m o t - cm
•^co'dcDLriLo'coSS JgCNCOCNCNCNCNjg
CO "tf
r^ in lo to -^ lo IS
T- «- T- 1- f- T- Ig COLDin^iricNCM^
ccococococococo
O to o
_ r^ CD <*
CD
CO lO O U) Q.
W N Zt CO
c < c
CO CO CD CD CO CD ua JSior-h-LomLON
ccd^^cocdcdjg
cocor~-r-cococoS
E? CO CO g
fviCOCDLncococoeo
lN CO LO •*; CO CM CO ^_
ntodcNcbNcocri
^h-h-coT-r~-cort
TiriLOCo'co'io'cDrt
L_COCOCNCOCOCNCO — CNCOCOCMCNCNCM
cu in u
CD Q.
CO o 59 (0
c o M c
CO CO ^1- CO CM CN lO h- CD r1- CD Oi CD N _ c o T - c n o i c o c o c o
^CONCDOJCDCOP)
^io'oiddcdcd2 .ycNCNCMCNvT-j^
r-- cd o r- p o ••* ^- co r» o o o to
co iri oi co 6 d N. t-cNOCDdddScn^- ^ CO •* -^ <*• S
CM CM CM CM CO CO CO
•5J CM
c
C T- u to
=5 «? CDQ- CM—
N C o
CD CO <t*
CO _ l
u> ^ ( O m i f i T ^ ^ S ^mcOCOCDNCOS
-gCNCNCNCO^LOCO ajNodwcMcdiS
r cn oo co cn cn z:
° «
9 CO
> CM
cd o COcOCDOCN^-^-CO
^^^iriiricDCD*
1
o
^cocococococoj,
x •*
1 LO
CN CO
< o Q
LO N CN to cn (D CO s m t v- t - in ^ h-
*• inLOCDCOCOOQCO
;: ^ CN 6 O N N S^co n co co co co }S
^OLO^^-omcD
>CNdcNCNCM'dSg OcOcOCOCOCOCOjg
CO
E
2 O CO CD t -
CD O CO CD CO
Q OC
Cycletime(Model1) Process Takttime•Allowance•InputBeznet•InstallTubeMPreparespeakernScrewspeaker ScrewCRTDChassis1DChassis2•Docking1•Dockimg20G2_HVIeak Landing1•Convergence1•AutoGeoBConvergence2ElTouchup1•AGC Touchup2DInwardcheck•InstallrearcoverDDVDcheck•Inspection1aInspection2 Inspection3Elinsulation•PreparecartonDInputTV•Packing•Directvanning
CYCLETIME+DOWNTIME(MODEL1) TakttimeAllowanceBeznetInstallTubeInstallspeakerScrewspeakerScrewCRTChassis1Chassis2Docking1 31.1237.2227.0825.8732.6636.5935.8936.92 30.7636.8226.9925.8733.1536.8935.6136.92 30.0836.8227.425.8732.6636.8935.8936.66 30.0836.7828.1326.5432.6636.9235.7536.92 30.7636.8227.0825.8732.1936.5935.7536.94 31.0836.7828.1326.1332.6636.8935.7536.66 4540.530.646666736.873333327.4683333326.02532.6633333336.79535.77333336.83666667 Docking2G2__HVleakLanding1 37.3638.9745.86 37.2939.3645.49 36.9839.3645.49 36.9839.0545.49 37.2939.0545.49 37.2938.9745.49 37.19833339.12666745.5516667 RearcoverDVDcheckInspection1 31.4731.7723.97 31.8332.0123.97 31.4731.7724.05 31.4731.5324.05 31.8331.5324.01 31.1131.5324.05 31.5331.6924.0166667
ConvergenceAutoGeo. 42.0417.44 42.0417.44 42.0417.12 42.0417.12 42.0417.44 42.0416.8 42.0417.22666667 Inspection2Inspection3 33.1537.75 33.5137.75 33.5137.64 33.5137.75 33.3337.75 33.1537.75
Convergence2Touchup1AGC 33.7133.1539.89 33.2432.7739.89 33.2433.1539.55 34.1832.9639.89 33.7132.7739.89 34.1832.9639.89
Touchup2Inwardcheck 39.4639.74 40.0439.82 40.0439.66 39.4639.82 39.7539.74 40.0439.74 33.71 Insulation 30.23 30.07 30.23 30.07 29.91 30.23
32.9639.833333339.79833339.75333333 Preparecarton 32.23 31.89 31.89 31.89 32.23 32.06 33.3637.7316666730.1233333332.03166667 InputTV 31.49 30.75 31.49 31.49 31.49 31.12 31.305
Packing 21.71 21.71 21.71 20.99 21.71 21.71 21.59
Directvanning 14.32 14.32 14.17 14.32 14.47 14.47 14.345
o
•a o
CD
E
+3 C o Q + CD
£
u
>
O
<•;',, 'b-'""$wi
CM CD
a cm
to CO co JZ
o o
• m •
i -
K- 6
O &
* u
CD O
O CO
• m •
3
<
cz o
"•5
CD Q.
CO C
CZ
CD Q.
CO IZ
CD co CD a . to
CD O c CD
CD
V c
o c
CD cn
„C7 >
5 g O
o o
CO O
• a
CD J*
CO CD
tz c CO - J
•
CO
>
X
§ I
Q Q
• •
o o
CD C CO CD
O CO
a: o_
• o
O CD
O >
•P H
I 3
CO CM
B O S S
• El • •
CD C N CD -Q 3 a .
= a P o_
• • • •
CM O) tz o o
C CD
6 o
c o
CM CO
a 3 JZ
o 3 O
_ O 3
O CD «
< a < =
• • • m
CO
CO CD CM a . i z
,_ COCD CD CD CD CO <D
2$ CO CO co co CO CO
XL O O Q
CD CD CO
CO CO
CD CO
OI CD
en cn CD CO
1"
Cfl CO x :
O CO CO
CO CO
CO CO
CO CO
CO CO CO CO
CO CD
«S3
CO CO
CO CO
CO CO
CO CD
CO 00 CD tO CO
CO CO CO
CO CO
CO CO
CO CO CO CO to
to CO j r O
LO
H co DC O
o
I
CO
in m m
•* ^r ^>
^r -^ ^
CO CO CO
l o i n in
•* ** *r
••t ^ Tf
CO CO CO
o o o o o o o
CD
^t:
CO CD Q.
«
S>
o (/)
0 XL CO CD Q.
Cfl
CD CO CD CD CD CD CO CO CO CO CO CO
•<t Tf •* •*•*•*• *t
CO CO CO CO CO CO CO
(ucocococococort -QLoin'iriiriLoiriio 3COCOCOCOCOCOCO
TO
CI) 1 N CI)
^ ^ OJ
CN _J
LU CD
M r
o 5
o LU <r S
H CD
III c-
l •*->
O 2
m
(J t-
CO 00 CO CO CO CO O) Oi CO CO CD CO CO CO CO CO CO CO CO CO CO CO CO CO
U)
©
w
^
^CpCpCpcpcpCDtD iri in lo iri lo lo in"
CO CO co CO CO CO co
•«t ^ "*•
§• in lo in
o 3
^ - t ^- St
lo lo in u>
CO CO CO CO CO CO CO
cn cn cn CN CM CN in in lo CO CO CO o
CD
<
r~- h- h-
cq CO CO cd cd cd
CM CM CN Q.
3 SZ
O 3 O I- CN CD U c CD
E>
CD
>
o o
CO CO CO CO CO CO
0 ) 0 3 0 ) 0 CM CM CM CM
iri in lo to
CO CO CO CO
r^- r-- r—
CO CO CO CO CO CO CN CN CN
CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO
CO CD CD r~- r^ h- CM CM CM CO CO CO o
CD
CD
3
<
0 r^ r» r--
O CD CO CO
m CM CN CM
J-j, CO CO CO
CD
>
c o o
CO CD CD Is- h- h- CN CN CN CM CO CO CO CO
h- i-^ r~- h- CO CO CD tO CN CM CN CO CO CO
CO CD CD CO CD CO tD
T— T— 1— V - T— T— t -
c o c o c o c o c o c o c o c o E
c to
( O t ~ ^ - V - T - T - T — ^
^oicjJcjJoiaJoioS
^CNCNCNCNCNCNCM
X
CM'
CD
CN
_ CO CO CO CO CO CO
g1 CO CO CO CO CO CO
„
o o Q
CM CM CM CM CM CM CM CO CO
cn c
Ecn
CO o m
o in m lo lo to o o o o o
> oo CO
CN
CO CO CO CO CO CN CM CM CN CN CD
a
o o o o o o o
en c
'XL O CO a.
1
COCN COCN] CM CNCO CO COCM COCM COCM3 Q.
C
l — ™
r*- h- r» Is- h- h- r - C
o tz
CO
CO CO CO CO CO cq 00
O) oi oi oi ai oS o>
CM CN CM CM CN CN CM o
CDi _
CO Q.
0
i—
Q.
CO oo 00 oo CO CO 00 cn O) o O) CO o a>
CD CD CD CO CO CO t o CN CN CN CN CM CM CN c
o '*->
CO 3 (fl c
0) O) CO CO CO CO CO CO CO CO CO °°. CO CO
CO CO CO CO CO CO CO CO
c CO CO CO CO CO CO CO
o
tj
0 a . to c:
m m m LO LO LO U)
CN T ~ T ~ T ~ T ~ * ~ i r -
* ~
c o o o o o o o OCOCOCOCOCOCOCO
"5
0 Q.
Cfl
, - 0 ) 0 ) 0 ) 0 ) 0 ) 0 1 0 ) OCNCNCNCMCNCMCM
o 0 D_
_CCfl
l - - r * - h - f - - l * - r - r - 0CMCMCMCNCNCNCM JZ
o Q
>
a
^inmLnLOLotoin q t i d d d d o d
OcOCOCOCOCOCOCO
i _
CO 0 DC
2 up1 3
•Allowance •Docking1 •AGC •Insulation
Cycle Time (Model 2)
Process• Input Beznet • install DGC • Install speaker • Screw speaker H Screw CRT • Docking 2 EG2JHVIeak • Landing 1 • Convergence 1SAuto Geo • Touch up 2 • Inward check • Rear cover • DVD check • Inspection 1 • Prepare carton • Input TV • Packing • Direct vanning
•Chassis1 •Convergence2 •Inspection2
O) c XL
O O Q
lo in cn
<*> <? 00
in lo i n to o co co n CO CO CO
CO CO co cd cd 1
CO CO CO CO CO
^ ^ CO LO O CN
•>t -»• cn en O LO CM CM
n n n
CO CO CO
h- r*. r^ is.
CO CO CO CO CM
to to to CO JZ
o CO CM
» CO
CO CO CO JZ o
m o 00 H co DC o
o
i - CO CO CO CO
•<- CM CM CM CM
r^ r~^ r--' r^ r^
CO CO CO CO CO
-r- O) t - n CO CO to CM
|s^
CO IO o
( D O N M N »
CO CO CO CO CO CO
o o o o o o o
0 x :
CO 0 D_
Cfl
1
CJ COO) 0 XL CO 0 D_
to
O) T- O) T— O) x - O) v- O) t - N CD N CD N CO CO CO CO CO
N CO t o t o t o to o>
o N CO
CO LO CO CO CO LO 00
d j c n q c i c a a j q c n
^ N C O N N N O N 3C0COCOC0C0C0CO TO
Cfl
CM c
_ l CO -jj- -3- •4- ^" ^ N.
111 CM CO CO 00 00 co to
Q N N N-' N N N t o
t o O t o
"CD
CO CO CO CO CO CO
c Is.
LU N
0 CO
N
£ CO
H lO
2
5 0o d
o cCO
a 5
+ o
LU <
2 LO
H 0 Tt
LU £
_l ♦J
a V
>- CO
o 1-
XL cj
® LO cj T
O) CM CM CM CN CM CN CM CN CM CN CM
K co d d d d d oi
CO CO CO CO CO CO CO
5
c
^ ~
3 °>
~S CO
JZ o
LO O) CN O) CM CM CM O) O) t "
d CO d CO d d
CO CO CO CO CO CO 3
o H
T— O) , — , — , - O) Ti
q CO o o o
CO to
d CO d d d CO d
-q- •sr ^r •^ CO O
CD
<
N CO N CO CO CO 00 CD CN CO •sf CM ^" •*
CM CN CM CM CM CM CM CO CO CO CO CO CO CO a .
3 JZ
o 3 o H CM
0 CJ c 0 cn 0
>
C o o
O) O) T- m cn -«r
CO CO CO CO CO CO CO CO CO CO CO CO
N N N t - N N" "^ N" CO **
CD CO CO CO CO CO to CO CO CO CO CO CO CO
6
0 CD
o 3
<
0 ^ f CO LO CD - t CO w o
c 0 CO
N m CO m N LO CO
cb d d d d d t o
CO CO CO CO CO CO to
u . CO
0
>
c o O
o
^~ d coco c TD
c CO XL CO 0
>
X I CM CD
CO O) O) O) CO t - CO 00 CO v -
ffl N N NCO
CO CO CO CO CO
T - t D r - CO CN CO
CO
CO t - CD CO t - CO CM CO
,_: ,-:«*>
co co g
o
CO _. CN CO CO CN O) CO cn
cfincocomcocDco
.E co co co co
XL o o
D) C
N« i n LD LO CD m lO
m cj) 0) CO CD CO O) CO
> <D IT) d d d d °?
•QCM
0
CM CM CM CN CM tn CM
o o o o o o o
CO c o CO 0.
LO LD
CO CO
CO CO
CN N
Oi 00
CN Is.
N CO
f 5 CO CO CO CO
•i-i 3 Q.
C
rs.
io
CO
o N co
m CO
in CO
O) LO N
co ,_:
V
co CO CO CO t - CO CO
2
CO a . 0
N N N O l r N O
LO LO LO CD 00 LO tO
oi oi oi oi oi oi ai
CN CN CN CM CM CN CM
lo lo m in in o cn io in m m Ln n lo
co co co co co co co
73 0 a .
jzto
•>* ^t CD •^• 'sT CD CO CM CO CO 00 Oi Oi CO CO C CM CM CN CM CN CM J5
CO «
O CO CO CO CO CO
tj T "
0 0)
Q. CM
(0
c CO
T- ^ i n •^r •^r CO "3" CO
IS
N CD CD m CO CO
•"if ^r •^r TT
*e
CN CM CM CM
o LO
0
a . to
to Tf
c CM
, tN CN , _ ^ CM CN IO
XL Tt
CD CO j- CM
^r in LT) -tf
^ TT
d d d d d d
CN CM CN CN CM CM o
Q
>
Q CD «> T_
in ^1- in LO ^t CO
T— co v - X— CO CO
o ^r ^J- N" ^> TJ
sg
o CO
1_
co co CO CO
CO •^
0 CO
DC
Cycletime+Downtime(Model2) time , AIjwance
St
*-- .. I 1SSj. lliill
'-•" ••
811
5®S£7< Process •TakttimeaAllowance•Beznet•InstallTube•'InstallspeakerDScrewspeakerEDScrewCRTQChassis1 •Chassis2•Docking1aDocking2QG2_HVleakDLanding1•Convergence1OAutoGeo.•Convergence2 OTouchup1•AGCDTouchup2OlnwardcheckEIRearcoverDDVDcheckDlnspectionl•ilnspection2 OInspection3EllnsulationDPreparecartonOInputTVDPackingDDirectvanningCYCLETIME(MODEL3) TakttimeAllowanceBeznetInstallTubeInstallspeakerScrewspeakerScrewCRTChassis1Chassis2Docking1Docking2 29.0429.8625.4425.1327.1933.6833.4633.5537.86 27.8832.0126.5224.7933.5233.5233.4634.637.86 28.7335.7325.4425.6633.5233.6833.6934.633.2 28.7333.2127.8824.1329.2232.9633.6935.8830.66 28.7332.0123.2125.6632.1633.5233.6935.8830.66 28.7332.0123.2125.6629.2232.9632.6533.5532.52 4540.528.6432.471666725.2833333325.1716666730.80533.38666733.4434.6766733.79333 G2_HVleakLanding1ConvergenceAutoGeo.Convergence2Touchup1AGCTouchup2InwardcheckRearcover 34.8641.5335.6212.7230.2231.2138.7538.9634.8532.05 34.9540.8938.0914.9531.3332.1235.0235.8837.5532.41 35.2140.8937.7714.9531.6828.8732.5234.4534.0327.8 35.2140.8937.7712.7227.5428.8732.5235.8838.9632.05 35.2140.8935.6214.9530.2231.2134.8535.8832.6630.54 36.4442.1737.7712.7233.5231.2134.8534.4538.9632.05 35.31333341.2137.106666713.83530.7516666730.5816666734.7516666735.91666736.1683333331.15 DVDcheckInspection1Inspection2Inspection3InsulationPreparecartonInputTVPackingDirectvanning 27.721.5430.5635.5224.0327.0630.8521.5710.36 27.721.5427.2333.8925.6728.8830.8521.5710.36 30.2322.7132.4532.1226.9829.8730.8520.5712.98 30.2320.9928.8834.6326.9832.5628.1122.0912.2 25.8921.5431.8935.5229.5329.8726.9520.5712.53 25.8920.9929.8535.5225.6729.8726.9519.0412.2 27.9421.55166730.143333334.533333326.4766666729.68529.0933333320.90166711.77166667
Cycletime(Model3) - Takttime Alljwance - - '.t<mi- - - -..: - - Process time•Allowance•Beznet•InstallTube^Installspeaker•Screwspeaker•ScrewCRT•Chassis1 2•Docking1•Docking2•G2_HVleak•Landing1•Convergence1OAutoGeo.ElConvergence2 up1•AGCDTouchup2Dlnwardcheck•Rearcover•DVDcheck•Inspection1•inspection2 3•InsulationnPreparecarton•InputTV•Packing•Directvanning
CYCLETIME(MODEL4) TakttimeAllowanceBeznettInstallTubeInstallspeakerScrewspeakerScrewCRTChassis1Chassis2Docking1 37.5338.7537.78037.0937.237.1538.21 37.3238.7337.78037.0937.1837.338.21 37.3238.8137.99037.1837.237.2138.13 37.3238.7337.78036.9537.237.338.14 37.3238.7537.99037.1837.237.1538.14 37.3238.7337.78036.9537.237.2138.21 4540.537.35538.7537.85037.0733333337.19666737.2238.17333 Docking2G2_HVleakLanding1Convergence1AutoGeo.Convergence2Touchup1AGCTouchup2Inwardcheck 36.6732.7937.7336.2636.433.1431.5438.9139.1339.11 36.8132.7837.7136.2736.4533.1431.5538.9339.1539.15 36.7332.8937.6836.2436.4533.1431.5438.9639.1339.16 36.7132.8237.836.2736.433.1431.5238.9639.0839.16 36.7332.8937.836.1936.4533.1431.4738.9639.1339.14 36.8132.7937.7136.2736.3833.1231.5238.9339.1239.16 36.74333332.826666737.73833336.2536.4216666733.1366666731.5233333338.94166739.12333339.14667 RearcoverDVDcheckInspection1Inspection2inspectionsInsulation 33.75 33.75 33.74 33.75 33.75 33.74 34.07333331.238333322.00333333.74666667
PreparecartonInputTVPackingDirectvanning 34.0731.2421.98 34.0731.2521.98 34.0431.2322 34.1131.2322 34.1131.2422.06 34.0431.2422
36.5127.8533.4430.81 36.5127.8533.4130.75 36.5127.8533.4430.72 36.5127.8633.4230.81 36.527.8333.4430.72 36.5827.8533.4230.81 36.5227.8483333333.4283333330.77 030.68 030.68 030.68 030.73 030.7 030.68 030.69167
Cycletime(Model4) Process TakttimeaAllowance•BeznetnInstallTubeE3Installspeaker•Screwspeaker•ScrewCRT Chassis2DDocking1DDocking2OG2_HVleak•Landing1•Convergence1•AutoGeo. Touchup1PAGC•Touchup2DInwardcheck•Rearcover•DVDcheck•Inspection1 Inspection3•insulation•Preparecarton•InputTV•Packing•Directvanning
•Chassis1 •Convergence2 •Inspection2
APPENDIX 9
WIP and resource utilization monitoring screen
tniLtzifiiii^
•" 1^Ut;Be^et;";•vY>x'^M^'^.;^^a^as>t^^^..•:,'-."'6v.-'.:>-'•-.'..-.,..••Ons^p^VV^^
^9>Ck":.:YChassis"2>:;•;.::.yJv'No""- ;Y;,i:Xh^-d;y',-\-YlMck^IvYI-'-•";6".\-,i';''-";-•'/- .:5cre^*.sp'safei:;.\,•.'.'•-f\:\;:-.;•ptjt^g'^v•'"•••"-.,-.-)$.-'.4-..-"'" ^5cr?W"GRB^-1,^•V"->'*".-'7--.":';.^cdjL^N§nt^
Landing'l'-;.V:^?•.'C£mvergencev:i-- .Q',.-Av:-,"---.V .Convergence27"'•<r'.3''/-}-•':.;•;-Vkjeociieck;.";-"--""^-""ti-^""-""' ./•:"Tpuch:up^v:w"'•-y'jr\V.'v.^'-'-^lnsfttt^fm^:"'^;'0.'V§•.'-•$•;*-'- ;>-;-;yk;inspection2>;.;.;.•v-??.-4-;.-;V---! ;-vfQgcHm2;;.;".-;;;;/-::-^."";a-^--/•.^•lDspecfeii3rv3s,";;."-.--".t>i~.A"..V-;•;•' check.-'."-;':a;v;;vv;]hs0iafefoay-""f•:-^$-'-:<•'•- .&ear-£oyer;..,;>..Y--" 5ac&|n£; Prepare-cartonPaddhg:"• ;.Directvandirig-"
'^m^-'^-vlV-f &ss&mbliv "'•-inputBezhetv;;;-.;;•;--•:••'ei^ssisi;.-. ":".-"'lostaH.JD'SC-;.:"",Chassis2. '^InWall'speaker"'_'"--—\Docfebgvl;-'". ',-.'Screwspeaker.Docking2'; "-•'5crew.CRT'•-'.""- •A'djustmemt- -G2_HVleakv vLanding.;!-"-.;;
Convergencei Auto.geometry .inspection;.;.;. ,..-.Convergence2.Videocheck;. '-:'-'touch.up1.-.;''.'•!irispectioFi1' AGC••••••.Inspection2 .Touch-iip2.;Inspection-3.. Inwardcheck:-"Insulation• ...RearcoveYy Packing Preparecarton InputTV
Packing Directvanning. TotalWIP Model2monitoringscreen
m-
::••'. vt ''"W '-;D> ; CJ*:.
"'.<0,,',':;'9'•';.•«-; .y»
•-JE' j5'^vo-,.-0 v
-Y.U-Q'.'.Q.'O'"
•.:':-2^:
'^•;§':>%^'-••"flV'^';!;.;
o
3
>•
E
<
•..'•'•i"-j» •W. .• .flJ'Y'Ll"
«#I.S
-.CO.";(ft w Oi O"
u
^ 12
O Q
no 1)
a a & & 5
Q. Vi Vi J-j J-
. (B •'•'''C'".
^st^yy
!#*•
:.*&'•. '.••-•"•:
<
*<?•
C p
05 (5
a) a1
> o
O ZJ
U <
-1C
CT
I "2
s 5
7V^- '.'^•,'"t\J..',CO'.'''1
''•••^•>'g>#v'gV."&
;s "EYO. •&•;• CL =!•
.••;i"--3fi[--;E'"a--:-s.
Ys-'Yu.
'•T3.
'.3."
31
••>
••:•{£
o UJ
. - * w cn
r r rr c
u u o a
u u
« •w
a . a. a . ZJ
Ui Irt VI
c o
CD >
D U
s
CM a zi
1 to
3 5- <0
-J » a>
& i -3 "J- i •w
n i (- r r iTl n* •>
c j j
V U
a . a
U a.
(0 a . m
§CO t-l o cfl
a
a
m
O
'&.:
i_4'..;,(\j;., *^":-.;ftl.
ffi' '^IQ -Q'i'.'.b'.
Wi-' .&'•''&"•"•'&<-•
;w vv •;£- 'jg;
-jz;'-,.S-,''0';
ft
YQ'' .
^YY'^Y^':
..•g;;-';i-i'./^'N-,fl?-
CQ4J _
:*J'-:.."(D''.'''.T5- :t>-J , 'JO-
]IY-Y£lYviT w , n . f-j
jn Y/£,/#:.£ •-.&;&
a:;
*۩^
O
P
3JZ JZ
Hi C
n i n
£ 5
*( 19
_£r c U
W
:;&-:.
.-•-£Y
c c
as as t
a. a. p-.
L'l i/l KJ 3: 5
ID OS
(->';••• (0
•"C ;;• ; p . ,fflr'.:.S;<
ijg-:
•'as.,;- ..
-O-- ».-'ZJ<
U; <t
u l:
D as ill U>
>
U i i
c
5 ^ g
C CO 3
•,;u:
•..ID'
•jr.
• o
*-•"-« Yt*v OcY.c. •-«••
-•.2.' -;S'Y.;a;- .<ta -tj •,u\;
ID ID: .as
• p.'-.Q.'.-a-;
„ ,.'.,v>..-w> ;w.
£•< •:£= ••:.-.£:' ",e.
•'-2
'•si;
-'«•/', -;
•*—. . ( j - ;
•"43•'•..a* 9-
:f;f;.i;
G,: ;S;t:3'' Y'-CJ ':;':-'Cl••;•". 3..
- j r
j r
u D
CM 1.1
43o
O
u c
Q.
Z) 3
ID
>
r JZ
u
M^
frt o o ^5 o
•a::
<D
m -c
'R<Tf
•nt >
'C/'
V
• <n- Q. •a
c r r in m >
r j=£
.^s
LL D
s© O 1/3
•c
I
I
APPENDIX 10
Resource utilization charts at Process Analyzer
UtilizationforAssemblyProcessArea —i- /• •', > :,-i• * _$'«• ' - -i 1f „ - j ; „, w i _ t- , "ii *
~"" 1 -.•• , • i 1r1-r ASA*(Y^ •.,-A ac^'
jBezhetResource.Utilization r™chassis1ResourceJJIilization |~~Chassis2Resouree.Ulilization IDGCResource.Utilizaiicn IDockingiResource-Utilization |Docking2Resourae.Utilisatiori IPrepareJnstallSpeakerResourceiUiilJzaliori r™"S&rewCRTResour&e.Uilizstiori [ScrewSpeakerResource-Utilization
ResourceUtilizationforAdjustmentProcessArea sszm ,0;'; *K>A£?
F!~AutoGeoJUUhiteBalanceResouree.Utilizaition F"ComerLandingResouree.Uiilisaiion iG2_HVCheckResoiaree.Utiliaation {Landing1ResourceJUHIization M&daltv»s
ResourceUtilizationforInspectionProcessArea •
r~ r~ r i™
AOCResource.Utilization Convergence2Resource.Utilization inspectioniResource.Utilization Inspetfion2Resounee.Utilisation Inspection3Resounee.Utilization InstallRearCowerResource.Utilisation InsulationTestResource.Utilization VideoCheckResource.Ub'lisation TouchUp2Resource.Utilization Touchup1Resource.Utilization InwardCheckResource.Utilization
ResourceUtilizationforPackingProcessArea iYtodeltyp>:
f!DirectVanningResource.Utilization IInputSetResource.Ufilization IPackingResource.Ufilization r"PrepareCartonResource.Utilisation
APPENDIX 11
Production output (Animation for Model 4)
•m-
~v; ^W!
E
in
fi= fte
i
t t
«==s i V
\*4
M
6 1
~*1 f<*
*t*
r
1
r *
**
;«
*•••» MMMWHWI
II
N «
<v
I
- .
e
o
Air
•*.
*==4
^ ^ j
m ID
Mt
« w 4
S3 a
?F
APPENDIX 12
Cycle time comparison (Model 2 & Model 3)
•fSSt o"a. coCouCDCOsz3 t-NCOIfllDlOCOOJtOClrttDOJOncOrCMNCMOJOOlOCOtOOOO^-CO^-COr-h-C33CDN.O)T;rr(ooJodNoisdifl^oiocdrioiNdfflNOJri^cNi^oiiririr1COT-CMCMCOCOcOCOCOCOCMCOCMCMCMCOrsJCO^-v-CMCOCOCMCMCOCO'r-00O)O)C)(OCOCO00CO00tO00COO)COCOa}COCOaiO)O)C0O)CDCOCOCO $ T-"COT—COo3 ID00o^J-mtoCOOo
CMCM
CMCO ntnwoncocmt-o>cor-coot-t-in-r-•*rrp«ncmcocmirir^ooin h-lOCMOCOCDwoicor-^cDcococoooso)T-COv-T-CDCOCOOOOCOorootmoo-" OCMOSCOOOSWOS"rCMrOW_.OOCOCMt-ooocoincoocoo Tfcmcmr-00CMOOOCDCOCMCOt-
OlOCOCOCOCMCMCOCOCOCMCOCOCMCOCMt-CMCOCMCMCO h-cowcmo>oCMCMCMCMCMCOCMt-
o1o1o1oI•*1*o1CO172g
^1"tc61,a_i—1Q.1o155I
<=»i«jo1ra
<=>1 re
oI><CMIO"1"*"1 o -^(DCMCDooeocomincDtCOrNCOlOOOTfCOf-.©commoocMT-__OOOSCOOOOOOJOSCOCDCOCOOSCOCOOSOSOSCDCOpcOCM
t-CSWCOCMCOCOCMCOCOCOCOOOCDCOOOCOCM'tCOCDCMj*r1010fl)^^CDLDCDCOh-or-h- CDCO CMomr-mmn-ooCOOS00COCOCOCO^•Or-C-^-lfiCDCDW-rz.:r--coooocoosr^peD
3*2
3 CDCMr-CO,^-h-^OCO0mmCOccSCOOOCD^_-^00COCOCOu>I--CO0OiCMT—0T"^CMwiocMcMcMTfCMtninm'tf
tncd00cooCD•*~-ooCO10 ^N»(OrSO)0)NO)0
CMC5CMCOOh»•*...-h-cocMioor-CDocqr-oN-TrcoTr^-^cor^ooiiriT^r^T-'cMcocMosh-^- r*-h-r*-min_p*.<o-*•*-*-CD1-OSh-CMCO
COh-OCMCOWCMCOCON.COx-eOCOCOCO-*COCOCOCOCOCOCMCOCOCOCO-<J-CMCMCOCOCMCOCOCOT-
I-
•t:in
0OS asECDEEP-£
COasCDCOtoaOS cuE CDE CDEas$8
I
PCO CDE1
EEECO82CL CO82CL EEPFFEEas\-CO82CL PCOCOCDOP Pas as£ P8
i
F 0EP Pcoen PCflCO(0 PCOCO
i
asE 88 COCO8 COCO8 0EP PCOCO ECfl 2CLasE8 COCO8 CDE ECOf-CDU20. us« CDu8CM8 as0P£L_2220CO8COas2CP2 i_2PCO82 wCO0) (0as8 to8S0_ 2Q_ 2CL8c 8C 2CL 2a. (0COCD FCOCO8 COCO0 0-CLCM CLCO 2CL CO8 282 COtoCO82 CLCOas CLCLCM COCO82 02 0as0.OS CM CO CD2>h 02*CO CMCO
g 1
c,0 c.2 c0 COCL r—CO CLOS COasO a.CO a.3 CL3 CLOS as-> CLO.2 C'<0CACO CACO1 1
cXLO c'xi0 CLO 2CL a.3asa. t5CDa. "5CDa. ""8
Z3 •2i cc cxla a.2 Q_\—CO
1 1
03 O3 CLas c"cc 0O3COJ=jC00O0>CMa.CO(0COCOCOCOasO00O3CO-E—*5<m00O00aQaCDcccccc_!D_a.DCCOCOH-P1—> CM