Lean Transformation for Server Manufacturing Environment

摘要

In the wake of globalization, companies are beginning to emphasize becoming cost competitive. This trend is also prevalent in server manufacturing industries that feature leading edge technologies. Within these industries, there is the challenge to incorporate automation into production areas in order to eliminate human error and ensure the accuracy of data. The ultimate objective is to reduce the production cycle time by eliminating any wastes from production area activities. An effective way to accomplish this is to undertake Lean Transformation (LT) initiatives by developing a Lean Culture, which is a widely recognized method of successful Lean change. In this study, an initiative was taken at the assembly area of a server manufacturing plant to minimize the time taken for the Certificate of Authenticity (COA) label activities. Moreover, efforts were made to integrate automation with the implementation of a Java Graphical User Interface application and the development of a database. Several Lean tools including fishbone diagram, process map, time study analysis, and customer satisfaction surveys were utilized to understand and improve the COA label activities. The LT initiative was successful in minimizing the COA label tracking and rework activity time by 42.7% and 36.7%, respectively, with an expected yearly savings of about $4,000. Furthermore, the study was successful in eliminating the use of paper and in developing a database system to secure the COA label activities. The sustainability of the LT initiatives was insured through employee training, user manual preparation, and a documentation of the LT activities.