Manufacturing Strategy – Lean Lot Sizing

Capacity Optimization with Lean Lot Sizing for high-volume assemblies

RT

SMT Run-rate = 0.375 mins per piece.

SMT Operations Run-rate

Consider a 20hrs run per day. Number of units produced at SMT = 20*60/0.375 = 3200 pcs

HLA Operations Run-rate

HLA Run-rate = 0.333 mins per piece.

Consider a 20hrs run per day. Number of units produced at HLA = 20*60/0.333 = 3600 pcs

Lean Lot Sizing to optimize capacity at ATE for assemblies

Average ATE capacity per day ~ 2400 pcs

SMT capacity per day = 3200HLA capacity per day = 3600

Lean Lot Size = 3000 (minimum)

When you feed 3000pcs per day into the ATE Testers, you ensure Full Efficiency is achieved at the ATE Test each day of the week.

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Negative Effects of non-optimized Manufacturing Line

Quality: Rush jobs on weeks with high-loading affecting quality of PWAs.

On-Time-Delivery (OTD): Uneven load-leveling means no shipment during some weeks and affects delivery commitments to customers.

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