Alternate Title

Improving the Throughput of an Assembly Line

Contributor(s)

Lee, Shiwoo

Abstract

Power One is a leading manufacturer of customized DC/DC converters. The converters are composed of transformers, inductors and PCB. However, the focal point of this project is the manufacturing process of transformers and inductors. Currently, Power One is experiencing complications in their assembly line. Results from our extensive data collection and analysis shows that among other problems, such as poor tools and unorganized layout design, the assembly line is unbalanced. This generates large numbers of work in process, low efficiencies and higher operational expenses. Our approach included analyzing the high running transformers and inductors that would impact the performance of the system and taking time studies for each operation. We identified the bottlenecks in the station and recommended transforming the most common bottleeneck station into a non bottleneck one. We proposed the introduction of a more efficient tool, the fixture that increased production capabilities to 12.77 percent. We also proposed to balance the line that would in effect reduce work in process and cut production time and costs associated with it. Outsourcing some parts of the process that Power One is not specialized in, that takes a lot of time and effort, to vendors also reduced costs of production by 15 percent. Our recommendations increase the efficiency and throughput of the manufacturing process, reduce cost of production and cut down on production time. In effect our recommendations all led to an improvement in the overall performance of the manufacturing process.

Notes

Capstone Design Course

Keywords

manufacturing processes, transformers, inductors, assembly lines

Publication Date

2007

Permanent URL

http://hdl.handle.net/2047/d10010701


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