Exhibit $8\mathrm{.}15$: Notebook Computer Assembly Process Sheet

Task Task Time $($Seconds$)$ Tasks That Must Precede

$1.$ Assemble Cover $75$ None

$2.$ Install LCD in Cover $54$ Task $1$

$3.$ Prepare Base Assembly $21$ None

$4.$ Install M$-$PCB in Base $35$ Task $3$

$5.$ Install CPU $22$ Task $4$

$6.$ Install Backup Batteries and Test $40$ Task $4$

$7.$ Install Accupoint Pointing Device and Wrist Rest $33$ Task $4$

$8.$ Install Speaker and Microphone $45$ Task $4$

$9.$ Install Auxiliary Printed Circuit Board $($A$-$PCB$)$ on M$-$PCB $25$ Task $4$

$10.$ Prepare and Install Keyboard $25$ Task $9$

$11.$ Prepare and Install Digital VideoDrive $($DVD$)$ and Hard Disk Drive $($HDD$)58$ Task $10$

$12.$ Install Battery Pack $8$ Task $11$

$13.$ Insert Memory Card $5$ Task $12$

$14.$ Start Software Load $8$ Tasks $2,5,6,7,8,13$

$15.$ Software Load $291$ Task $14$

$16.$ Test Video Display $46$ Task $15$

$17.$ Test Keyboard $44$ Task $16$

The daily schedules are shared with the nearby Parts Collection and Distribution Center $($PCDC$).$ Parts are brought from the PCDC to the plant within two hours of when they are needed. The material supply system is very tightly coordinated and works well.

The assembly line consists of a $14\mathrm{.}4-$meter conveyor belt that carries the computers, separated at $1\mathrm{.}2-$meter intervals by white stripes on the belt. Workers stand shoulder to shoulder on one side of the conveyor and work on the units as they move by$.$ In addition to the assembly workers, a highly skilled worker, called a $$supporter$,$ is assigned to each line. The supporter moves along the line, assisting workers who are falling behind and replacing workers who need to take a break. Supporters also make decisions about what to do when problems are encountered during the assembly process $($such as a defective part$).$ The line speed and the number of workers vary from day to day, depending on production demand and the workers$$ skills and availability. Although the assembly line has $12$ positions, often they are not all used.

Exhibit $8\mathrm{.}16$ provides details of how the engineers who designed the new subnotebook computer felt that the new line should be organized. These engineers designed the line assuming that one notebook would be assembled every two minutes by six line workers.

Exhibit $8\mathrm{.}16$: Engineers' initial design of the assembly line

Assembly Line Position Tasks Workstation Number Labor Time $($Seconds$)$

$11.$ Assemble Cover $(75)175$

$22.$ Install LCD in cover $(54)254+21=75$

$23.$ Prepare Base Assembly $(21)$

$34.$ Install Main Printed Circuit Board

$($M$-$PCB$)$ in Base $(35)335+22+40=97$

$35.$ Install CPU $.(22)$

$36.$ Install Backup Batteries and Test $(40)$

$47.$ Install Accupoint Pointing Device and

Wrist Rest $(33)433+45+25=103$

$48.$ Install Speaker and Microphone $(45)$

$49.$ Install Auxiliary Printed Circuit Board $($A$-$PCB$)$ on M$-$PCB $(25)$

$510.$ Prepare and Install Keyboard $(25)525+58+8+5+8=104$

$511.$ Prepare and Install Digital Video Drive $($DVD$)$ and Hard Disk Drive $($HDD$)(58)$

$512.$ Install Battery Pack $(8)$

$513.$ Insert Memory Card $(5)$

$514.$ Start Software Load $(8)$

$615.$ Software Load $(104)$

$715.$ Software Load $(104)$

$815.$ Software Load $(83)$

$916.$ Test Video Display $(46)646+44=90$

$917.$ Test Keyboard $(44)$

$10$ Empty

$11$ Empty

$12$ Empty

The following is a brief description of what is done at each workstation:

Workstation $1$: The first operator lays out the major components of a computer between two white lines on the conveyor. The operator then prepares the cover for accepting the LCD screen by installing fasteners and securing a cable.

Workstation $2$: The second operator performs two different tasks. First, the LCD screen is installed in the cover. This task needs to be done after the cover is assembled $($task $1).$ A second independent task done by the operator is the preparation of the base so that the Main Printed Circuit Board $($M$-$PCB$)$ can be installed.

Workstation $3$: Here the M$-$PCB is installed in the base. After this is done, the Central Processing Unit $($CPU$)$ and backup batteries are installed and tested.

Workstation $4$: The Accupoint Pointing Device $($touchpad$)$ and wrist rest are installed, the speaker and microphone is installed, and the Auxiliary Printed Circuit Board $($A$-$PCB$)$ is installed. These are all independent tasks that can be done after the M$-$PCB is installed.

Workstation $5$: Here, tasks are performed in a sequence. First, the keyboard is installed, followed by the DVD and Hard Disk Drive $($HDD$).$ The battery pack is then installed, followed by the memory card. The computer is then powered up and a program started that loads software that can be used to test the computer. Actually loading the software takes $291$ seconds, and this is done while the computer travels through positions $6,7,$ and $8$ on the assembly line. Computers that do not work are sent to a rework area where they are fixed. Only about $1$ percent of the computers fail to start, and these are usually quickly repaired by the supporter.

Workstation $6$: