Design of process layout for deflection yoke process : a case study of a cathode ray tube indusry

Abstract

This thesis study relates to analysis of existing Deflection Yoke assembly line so as to reduce bottleneck problems and design new process layouts in order to be the alternatives for the company to make decision for implementation in the future. To overcome the bottleneck problems, many subjects such as product description, process system, and market product demand are analyzed the possibility to improve line efficiency and productivity of the assembly line in details. The study starts from analysis of operation improvement, especially bottleneck operation. After the operations are improved, standard operation and time are set, new workstations are designed based on the required capacity by using assembly line balacing technique, and manpower is appropriately allocated into the new system. To design new process layout, the proposed alyouts are designed in order reduce materials handling, increase effective space utilization, and improve quality of the product. In this thesis, three proposed layouts are designed and evaluated their effectiveness by using both quantitative and qualitative approaches in order to compare the advantage and disadvantage of each proposed layout. The evaluation will help the company to make decision for implementation the propoer layout to suit to specific situation in the future. After implementing the operation improvement, the supply method of inspection (bottleneck) operation is changed which results in 10% reduction of its standard time. The equipment in subassembly operation is relocated which results in 19% its productivity improvement. In implementing the new assembly line balacing, the bottleneck problems are eliminate which results in average 12% line efficiency improvement and 15.5% productivity improvement in the assembly line.