Toshlba's Notebook Computer Assembly LIne The dally schedules are shared with the nearby Fujlhashi Parts Collection and Distribution Center. Parts are brought from Fujhashi to

the plant within two hours of when they are needed. The materlal 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 decislons 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 avallability. Although the assembly line has $12$

positions, often they are not all used.

Exhibit $6\mathrm{.}9$ provides detalls of how the engineers who designed the new subnotebook computer felt that the new line should be

organized.

Exhibit $6\mathrm{.}9$: Engineers' Initial design of the assembly line

In words, 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 Processina Unit $($CPU$)$ and backuo batterles are 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 i

Toshihiro Nakamura, manufacturing engineering section manager, is examining the prototype assembly process sheet $($shown in

Exhibit $6\mathrm{.}8)$ 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 $255$ units per day the following week $($management thought that eventually production would reach $324$ units per day$).$

Assembly lines at the plant normally are staffed by $10$ operators who work at a $14\mathrm{.}4-$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 $7\mathrm{.}5$ hours a day $($employees work from $8$:$15$ A$.$M$.$ to $5$:$00$ P$.$M$.$ and regular hours include one hour of unpald 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 dally 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 sequentlally: 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

materlal handlers who supply parts to the assembly lines.

Exhibit $6\mathrm{.}8$: Notebook Computer Assembly Pr