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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)

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APPENDIX 6

Production output (Animation for Model 3)

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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

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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

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APPENDIX 9

WIP and resource utilization monitoring screen

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Production output (Animation for Model 4)

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