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DL headcount sizing_Rev0.1

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Approver(SHHYeo
DistributionListRevRev0.1

DLheadcount&stationsizingcookbook
Revision
Rev0.1
ReleasedDate
11/07/08
DesignationGOSIEDirectorDateofApproval11/07/08
GlobalIEManager,SiteFunctionalIEmanager

ChangeDetailsInitialRelease
Date
11/07/08

Originator(sSheTeeTan

1.Purpose

Thiscookbookwillintroduceamethodologyforanalyzing,assessingandcalculatingtheDLandstationrequirementforthemechanicalassemblyoperation.

2.Scope

Intoday’scompetitiveenvironment,customersdemandeverythingbetter,fasterandcheaper.Toremain
competitiveJabilmustcontinuetoimprovetheirmanufacturingprocessesandoperation.OneofthekeyfocusareainmanufacturingoperationistheDLoptimization.It’sthetaskofIndustrialEngineersandtheManufacturingtoidentifyopportunitiesandcontinuousdrivingoptimizationinthisarea.
Inthesubsequentsectionoftheprocedure,we’lldiscusstheapplicationofthetemplateandhowit’susedtocompute#ofDLandstationrequirement.
3.Definitions/Terminology

TAKT-Therateofcustomerdemand,calculatedbydividingtheavailableproductiontimebythequantityMOST-MaynardOperationSequenceTechniquePFD–personal,fatigueanddelay
Standardtime-isthetimerequiredbyanaverageskilledoperator,workingatnormalpacetoperformthetaskusingaprescribedmethod,allowingtimeforPFDOLE–Overalllaborefficiency

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4.Responsibility
4.1

DLheadcount&stationsizingcookbook
Revision
Rev0.1
ReleasedDate
11/07/08
ItistheresponsibilityofMEor/andIEtoupdatetheassumptions,standardtime,demandtoanalyzetheDLandthestationrequirementwheneverthere’rechangesinanyofthevariables.

5.Documents
5.1
Referencedocuments5.1.1
DLandstationsizingtemplate
6.Process
6.1

Sizinginputsandprocesssteps
3.Standardtime
2.Assumptions
4.Customerdemand
1.Processmatrix
5.DLandStationsizingtemplate
6.Datasharingwith
Workcell
7.QuarterlyDLforecastsizing
8.OLE%monitoringandcontinuousimprovement

Input:Processmatrix

6.1.1
ProcessmatrixwiththeassemblysequencestartingfromstationafterSMTuntilpackingwillneedtobeincludedinthetemplate.Thisincludesthemainassembly,sub-assemblyandthecomboprocess.Offlineactivitiessuchasrework/debug,materialhandling,RMAandotherofflineprocessarenotmandatoryforthissizing.(TemplatecanbeusedfortheofflineDLrequirementestimationifthestandardtimeisavailable

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6.1.2

DLheadcount&stationsizingcookbook
Revision
Rev0.1
ReleasedDate
11/07/08
Input:Assumptions
#ofshift/day
Productivehr/shift
PFD(personalfatigueanddelayYield
Input:Standardtime
TheworkmeasurementtechniquesthatnormallyusedinJabil:
••
MOST–Jabilstandardtooltoestablishthetimestandard,applicabletoallmanualoperation
TimeStudy–establishtimestandardformachinetime,testtimeandinspectiontime••••
6.1.3

6.1.46.1.5

6.1.6
6.1.7
6.1.8
Input:Customerdemand
Customerdemandshallbeobtainedfromtheplanner,intheformofMPS.

DLandStationsizingtemplate
Afterallvariablesandassumptionsareinsertedintothetemplate,theoutputwillbepresentedasbelow
•Requirements–total#ofrequirementthatgothroughtheprocessinaday,itwillbe
usedtocomputetheTAKToftheprocess
•TAKT–insec,calculatedbydividingtheavailabletime/daytotheRequirements
•Weightedtime–computedbytakingtheweightedaverageofthestationstandardtime
andtherequirementthatgothroughtheprocess
•#ofmachineorstationandDLrequirement–WeightedtimedividedbytheTAKTtime•Roundup–thisistheroundupoftherequirement.Roundupwillberequiredforthe
station/machinebutnotnecessaryontheDL.ThefractionofDLrequirementwillindicateanopportunityofprocessmergingandlaborflexingtoupstreamordownstreamstation.
Datapublishing
Theoutputoftherequirementwillthenbesharedwiththeworkcellfunctionalteam.Finalbuyofffromworkcellmanagerisrequired.
MPCDLforecast
The#ofDL(manualoperationincludingtheSMT,offlineheadswillthenbeusedfortheMPCDLforecast.
OLE%monitoring&continuousimprovement
OveralllaborefficiencyisanindicatortotellhowefficiencytheDLsarestaffedvs.theactualrequirement.Thechallengeofmaintainingtheindicatoratthecompetitivelevel(eg:>85%willbethedemandfluctuation,changesinmix,soit’skeytohaveDLcrosstrainedtoenablemobilizationwithintheorganization.

7.0Records

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