Resources Optimization and Capacity Analysis in Electronics Manufacturing Industry
September 8, 2023
Resources Optimization and Capacity Analysis in Electronics Manufacturing Industry
mbawankar |
Client Organization is the service leader in the electronic interconnect industry. It is a privately held, global supplier of interconnects, cable assemblies, and design solutions. Products include high-speed board-level interconnects, high-speed cable assemblies, optical systems, mid-board and panel optics, glass core technology, and the industry’s largest variety of board-to-board interconnects.
Key Points
- Current Facility monthly volume can be completed in 15 days.
- Scope to reduce machines and work only 8 hour shifts.
- Capacity expansion of up to 3 times with current equipment.
- Scheduling has less impact with current SKU variants.
Client’s Challenge
- Varied Product Demands
- Upper production limit from current facility
- Shift patterns to be followed
- Bottleneck areas
- Storage between production areas
- Batch based lead time
PMI's Approach
The study was organized in a 6-stage process:
- Data Verification and Static analysis
- Conceptualization
- Model Building and verification
- Validation
- Testing Scenario’s
- Results and Conclusion
Data Verification and Static analysis – Check data provided by client, analyse information and theoretically estimate the possible utilization and output from the system.
Conceptualization – Understand all parameters, rules and possible changes in the manufacturing system. Come up with a flexible model building method to quickly accommodate possible changes.
Model Building and Verification – Using Simulation software, build and check behaviour of model against static analysis.
Validation – Test simulation model with past performance data from facility.
Testing Scenario’s – Tweak parameters and analyse the model to bring value to current facility.
Results and Conclusion – Optimization of machines, shifts. Tabulate all scenario’s tested for client reference.
Involvement of Associates –
- PMI – 1 Project Manager, 1 Engineer.
- Client – 1 Project coordinators.
Static Analysis -
- Analyze machines considering details of monthly target volume cycle time, batches and yield.
- Summarize possible shift patterns to be tested.
- Machines Utilization.
Finding & Recommendations
After doing analysis and evaluation following results were obtained –
- In existing condition, monthly target is completed in 15 days.
- Machines Utilizations studied.
- We can produce up to 3 times the required volume by changing shifts.
- Detailed tracking of lead times, WIP and batch wise information at every stage is done to get a more holistic understanding of the system.
- Model is flexible to add more machines, change shifts and variants to quickly study all required variable parameters (Cycle times, downtimes and changeovers).
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Client Organization is the service leader in the electronic interconnect industry. It is a privately held, global supplier of interconnects, cable assemblies, and design solutions. Products include high-speed board-level interconnects, high-speed cable assemblies, optical systems, mid-board and panel optics, glass core technology,
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