การลดเวลานำของการผลิตตัวกรองสัญญาณรบกวนโดยใช้การผลิตแบบลีน

Abstract

This research aims to solve an issue regarding a production lead time which is higher than a production cycle time the customer need. Therefore, in the process of electrical interference suppression filter production of a case study, the organization cannot manufacture products to meet the customer demand. The target cycle time satisfying the customer request is 3.10 minutes per piece, yet the actual cycle time is 4.30 minutes per piece. Furthermore, the researcher uses a lean manufacturing technique to reduce lead time of production lots of 520 pieces. There are three production improvements consisting of printed circuit board assembly, resin injection process and product final electrical test combined with packing. The methods used in this study were quantitative and qualitative data including time measurement in order to calculate standard time of each process. Moreover, a value stream mapping was created both before and after improvements by adopting lean techniques ECRS and motion and time study techniques. The U-shaped layout technique also helped reduce lead time and increase productivity. As for the evaluation of results, lead time, output and efficiency before and after improvement for a period of two months were compared to each other. The solution of this problem is to develop the manufacturing process by reducing bottleneck’s cycle time. In other words, the soldering work stations should be increased. Besides, monitoring tools, methods of copper wire by using a semi-automatic winding machine and pouring resin by an automatic machine XY should be improved. The waiting time during the process, in addition, was shortened by using U-shaped layout technique. The results of this independent study could achieve the goal. The lead time was reduced to 94.12% and the output was increased to 100.90%. Furthermore, the cycle time process was decreased to 2.15 minutes per piece and the performance efficiency was improved to 83.57% without adding a number of employees. The production process was also continuously and smoothly flowing and the waiting period during the process was lessened.