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Carcass Assembly
Oct /2014 ~ Jan/2015 Performance Review
Sponsored by: Mr. Bob Harold (EXEC)
Project team: Mr. Nguyen Khac Hai (CI Manager)
Mr. Tong Viet Lam (Department head)
And team members (5S team and Line)
And the support of QC and Mr. Dario
1

Team members
5S team and Conveyor Assembly Line
2

Improvements have been made
1) Implementation of 5S – better workplace
organized.
2) Jigs for drawer assembly.
3) Pre-fitting of drawer stoppers at frame
assembly step.
4) Layout and install conveyor assembly line.
5) Test of products on the line for the next line
(continual).
3

7.5% target increased
Reported throughput increases 13%
~300 CBM surplus pre-assemble in
Dec in hot box.
4

5.2 hours / CBM at end of Dec
Estimate 10,000 hrs on payroll reduction in Dec against Aug
(~US$35,000 saving with $1.68 rate)
5

34.19
29.45
30.88 31.00 31.12
17.49
16.40
13.70
25.21
18.32
10.00
15.00
20.00
25.00
30.00
35.00
40.00
WK47 WK48 WK49 WK50 WK51
Dept (Hrs/CBM)
Line (Hrs/CBM)
6

Conveyor Assembly line & Payroll gain hours
Cell Assembly Conveyor Assembly line
Actual hrs/STD hrs
ratio
1.73 0.85
Absolute Payroll hours gain against STD hours are 1,116 hrs,
=> Compare with cell, payroll gain is 6,800 hrs,
or US$11,400 saving in 6 weeks (~US$100,000/year)
with entire conveyor line capacity
7* STD = Standard labour hours

8
1. Material is ready at point of use
2. Utilize of labor
3. Using of jig and template
4. More control and direct from team leader
5. On line QC as mistake proofing

How is the Assembly Line performance
9

Test of products on conveyor line
10

Next steps
• Complete test the line for more different item
constructions, by end of Jan-2015 estimated.
• Better layout for material flow for the line.
• Adding new conveyor assembly line.
• Review sanding process for a flow connection.
• Production scheduling system for assembly and
sanding.
• …
17

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Carcass assembly project performance review

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Carcass assembly project performance review