Toshihiro Nakamura, manufacturing engineering section manager, is examining the prototype assembly process sheet (shown in Exhibit 6.8) for the newest subnotebook computer model. With every new model introduced, management felt that the assembly line had to increase productivity and lower costs, usually resulting in changes to the assembly process. When a new model is designed, considerable attention is directed toward reducing the number of components and simplifying parts production and assembly requirements. This new computer was a marvel of high-tech, low-cost innovation and should give Toshiba an advantage during the upcoming fall/winter selling season.

Production of the subnotebook is scheduled to begin in 10 days. Initial production for the new model is to be 150 units per day, increasing to 220 units per day the following week (management thought that eventually production would reach 300 units per day). Assembly lines at the plant normally are staffed by 10 operators who work at a 14.4-meter-long assembly line. The line is organized in a straight line with workers shoulder to shoulder on one side. The line can accommodate up to 12 operators if there is a need. The line normally operates for 7.5 hours a day (employees work from 8:15 A.M. to 5:00 P.M. and regular hours include one hour of unpaid lunch and 15 minutes of scheduled breaks). It is possible to run one, two, or three hours of overtime, but employees need at least three days' notice for planning purposes.

The Assembly Line At the head of the assembly line, a computer displays the daily production schedule, consisting of a list of model types and corresponding lot sizes scheduled to be assembled on the line. The models are simple variations of hard disk size, memory, and battery power. A typical production schedule includes seven or eight model types in lot sizes varying from 10 to 100 units. The models are assembled sequentially: All the units of the first model are assembled, followed by all the units of the second, and so on. This computer screen also indicates how far along the assembly line is in completing its daily schedule, which serves as a guide for the material handlers who supply parts to the assembly lines.

Exhibit 6.8: Notebook Computer Assembly Process Sheet