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Activity report for year 2000 Manufacturing Unit Notebooks and Servers

Activity report for year 2000 Manufacturing Unit Notebooks and Servers. JP CABRERA, MUNS Manager, 03/01/2001. MUNS Production Chart. Our Team Values. Polyvalence, Flexibility, Motivation, Involvement Autonomy, Professional integrity, Enthusiasm Presenteism, Punctuality

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Activity report for year 2000 Manufacturing Unit Notebooks and Servers

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  1. Activity report for year 2000 Manufacturing Unit Notebooks and Servers JP CABRERA, MUNS Manager, 03/01/2001

  2. MUNS Production Chart

  3. Our Team Values • Polyvalence, Flexibility, Motivation, Involvement • Autonomy, Professional integrity, Enthusiasm • Presenteism, Punctuality • Rigor, Method, Serious, Pro Activity • Dexterity, Rapidity, Agility, Reactivity • Competence, Knowledge, Confidence, Reliability • Communication, Respect for others, Welcome • Frankness, Team work, Competition • Innovation, Quality, Energy, Customer facing

  4. Global process Engineering Purchasing Shipping Marketing Material Planning Quality Packing sales Order Admin Burn-in & Preload On Line Repair Production Planning Customers Brands NEC PBELL BULL US Assembly Maintenance Kitting Industrial Engineering Stockrooms Human Resources & Facilities Receiving

  5. Production for Year 2K • 113511 notebooks • 20000 in December 2K (25000 in full year 1998) • average of 25 units per manufacturing order • 14282 servers • 15 models, racks and tower • 10 new product introductions • 2 units per manufacturing order (ATO) • 140000 accessories • for servers, notebooks and desktops • 10,5 M$ of stocks, 17500$ adjustment ie 0,0016%

  6. Quality internal audit Y2K • Servers ( 30/03/2000) : Satisfaction : 95% • Remarks : • FA & security instruction not written : done • Notebooks (18/12/2000) : Satisfaction : 85% • Remarks and status : • procedure is not up to date : in progress • torque of screw drivers not calibrated : tool must be replaced, 19KF, Investment proposal to be done • ESD rules not respected : verify that everybody conforms the ESD rules • working instruction list not up to date : in progress

  7. BUDGET Y2K : • Stockroom : • Actual (November) : 474729$ • Budget : 427719$ • Servers : • Actual : 402213$ • Budget : 641095$ • Notebooks : • Actual : 771892$ • Budget :611998$

  8. Investments Y2K : • Stockroom : • Increase stockroom capacity in order to shorten the servers lead time : shelves + receiving • Amount = 48630$ • Notebooks : • Increase production capacity from 600/day to 900/day in order to achieve the target for end of the year : new layout + 6 trolleys for preload • Amount = 138000$

  9. METHODS : • Quality measurement on the lines : • Acceptable Quality Level : cosmetics & docs • On Line Repair ratios • KAIZEN : the processes are always improved by the operators, in brainstorming meetings, controlled by leads or supervisors, • Progress group at receiving • Weekly meeting for OLR Quality improvement • Daily meeting for business & material management • New operators:2 days training + 3 (practice servers)

  10. Capacity calculation : on Wednesday, 11:00 Capacity required by order admin Material availability Capacity calculation parameters = number of working hours or number of people Wednesday, 12:00 Mail : working hours & capacity for the following week

  11. METHODS : 5S or Housekeeping • Quality can only grow in a clean workshop • Seiri = to throw away useless things • Seiton = everything at its place • Seiso = to clean • Seiketsu= to be methodical, organized • Shitsuke= to learn rigor

  12. METHODS : New product Introduction Production: operator training, quality, routing times, efficiency, productivity, practice Purchasing Material planning Production planning MOs 1 unit for FA test Marketing Engineering Tests & support FA team : assembly method working instructions test process Products FCS dates roadmaps

  13. Mission for the server production team • To produce servers • with Excellence in quality, • delivered in time to the customer, • and with respect of the budgeted costs. • This must be done with well trained people, in respect of the working conditions and environment, and continuously searching for improvement of the process.

  14. Layout : Servers

  15. Process for servers Packing 1 work station Shipping Burn-In 180 entry points Entry = 6 hours High = 12 hours Quality On Line Repair Nationalization kits Stockroom Assembly 10 work stations 45 mn (Average) Kitting Max Capacity : 300/day/3 shifts

  16. Objectives and results for servers • Quality : • On Line repair, Objective : 6.7 % current : 6.8% • Non conform products • Process issues • assembly errors • DOA, Objective 1 % , current : 0.1% • Lead times : Objective : 4 days from order placed to FOB • current lead time : 10 days (average) • production cycle time : 3 days (average) • Costs : • productivity : Objective :4/day/operator, current 3,35

  17. Production cycle for servers • J = order is placed in SOPSYS • J+1 = MO is planned at J+2 • J+2 = production, pretest, burn-in, • J+3 = delivery to shipping

  18. QUALITY Y2K : Servers

  19. QUALITY Y2K : Servers

  20. QUALITY Y2K : Servers

  21. Manpower Y2K : Servers

  22. Productivity Y2K : Servers

  23. Efficiency Y2K : Servers

  24. Mission for the notebooks production team • To produce notebooks • with Excellence in quality, • delivered in time to the customer, • and with respect of the budgeted costs. • This must be done with well trained people, in respect of the working conditions and environment, and continuously searching for improvement of the process.

  25. Layout : Notebooks

  26. Process for notebooks Packing Shipping Pretest/Preload 192 entry points 3,5 hours Quality On Line Repair Nationalization kits Stockroom Assembly 12 work stations 10 mn (Average) Kitting Max Capacity : 900/day/3 shifts

  27. Objectives and results for notebooks • Quality : • On Line repair, Objective : 2.7 % current : 2.7% • Non conform products • Process issues • assembly errors • DOA, Objective 2 % , current : 1% • Lead times : Objective : 3 days from order placed to FOB • current lead time : 10 days (average) • production cycle time : 3 days (average) • Costs : • productivity : Objective :4/day/operator, current 3

  28. Production cycle for notebooks • J = order is placed in SOPSYS • J+1 = MO is planned at J+2 • J+2 = production, pretest, preload, • J+3 = delivery to shipping

  29. QUALITY Y2K Notebooks

  30. QUALITY Y2K : Notebooks

  31. QUALITY Y2K : Notebooks

  32. Manpower Y2K : Notebooks

  33. Mission for the warehouse team • To receive and stock each component • with Excellence in inventory accuracy, • delivered in time to the productions or to the other warehouses, • and with respect of the budgeted costs. • This must be done with well trained people, in respect of the working conditions and environment, and continuously searching for improvement of the process.

  34. Layout : Stockroom

  35. Process for warehouse Prod. Planning Max Capacity : 900 notebooks or 50 MOs/day/3 shifts + 300 servers or 100 Mos/day/3 shifts + 50 Mos for accessories Office : following up of MOs Manufacturing Orders & picking lists Inventory Resupply Goods Docks Receiving Mass Stockroom Picking Stockroom Picking warehousemen Prekit preparation Protected Stockroom Production Shuttles

  36. Manpower Y2K : Warehouse

  37. Inventory Adjustments Y2K 1999 2000 Transfer from St Sylvain

  38. Efficiency Y2K : picking & delivery to production

  39. Weakness and axes of improvement • Global : • supply chain : forecasts accuracy, bids not taken in account, specific components with low volumes => suppliers not flexible • dependence of engineering on Boxborough • production planning : launch of production with components arriving the same day => shortages • too many temporary people => low skills level • Stockroom : • not enough space on the docks and shelves • no software for picking list nor MO grouping

  40. Weakness and axes of improvement • Notebooks: • Quality management must be improved by 10 points • Floor and walls to be repaired • Servers : • Packing becomes very hard because of the weight of servers : a handling tool has to be developed, in progress • Not enough light on the line : budgeted, IP to be done • both Nb & Sv: • compressed air screw drivers : budgeted for 2001 • On Line working instructions : budgeted for 2001

  41. Training : proposal for 2001

  42. END

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