Transcript Activity report for year 2000 Manufacturing Unit Notebooks and Servers JP CABRERA, MUNS Manager, 03/01/2001 NEC Computers International MUNS Production Chart Jean-Pierre CABRERA Manufacturing Manager P7150 Babin Veronique Assistant Manager.

Activity report for year 2000
Manufacturing Unit Notebooks and Servers
JP CABRERA, MUNS Manager,
03/01/2001
NEC Computers International
1
MUNS Production Chart
Jean-Pierre CABRERA
Manufacturing Manager
P7150
Babin Veronique
Assistant Manager Production
P4779
Philippe MESLET
Warehouse Supervisor
P7137
Etienne ALLAIRE
Servers Supervisor
P5066
Benoit Heriteau
Notebooks acting as supervisor
P5098
Manufacturing Technicians
Guillaume Quemener
Jérôme Guedon
Stock Leads
P7074
Jean-Marc PALMIER
Shift Leads
P5097
Bruno Leroux
Y Hamon G. Lepage
Shift Leads
P5096
Frédéric Benoit
FA,ISO,Methods
P4631
Stéphane Cognolato
Receiving Lead
P7069
Rémy Lecomte
Kitting
P7067
Daniel Martin
FA, Methods
P7293
Antony Boudaud
Office
P4980
Alain Bureau
Prekits/Accessories
P4857
Bernard Sauvaget
Notebooks OLR
P7014
Cedric Liau
Jérémie Brun
CPU stockroom
P7183
Franck Manseau
Servers OLR
P4015
Melin Michel
Stock Inventory
P7142
NEC Computers International
2
Our Team Values
•
•
•
•
•
•
•
•
•
Polyvalence, Flexibility, Motivation, Involvement
Autonomy, Professional integrity, Enthusiasm
Presenteism, Punctuality
Rigor, Method, Serious, Pro Activity
Dexterity, Rapidity, Agility, Reactivity
Competence, Knowledge, Confidence, Reliability
Communication, Respect for others, Welcome
Frankness, Team work, Competition
Innovation, Quality, Energy, Customer facing
NEC Computers International
3
Global process
Engineering
Marketing
Purchasing
Shipping
Material Planning
Quality
sales
Customers
Brands
NEC
PBELL
BULL
US
Order Admin
Production Planning
Packing
Burn-in & Preload
On Line Repair
Assembly
Maintenance
Industrial Engineering
Human Resources & Facilities
NEC Computers International
Kitting
Stockrooms
Receiving
4
Production for Year 2K
• 113511 notebooks
– 20000 in December 2K (25000 in full year 1998)
– average of 25 units per manufacturing order
• 14282 servers
– 15 models, racks and tower
– 10 new product introductions
– 2 units per manufacturing order (ATO)
• 140000 accessories
– for servers, notebooks and desktops
• 10,5 M$ of stocks, 17500$ adjustment ie 0,0016%
NEC Computers International
5
Quality internal audit Y2K
• Servers ( 30/03/2000) : Satisfaction : 95%
– Remarks :
• FA & security instruction not written : done
• Notebooks (18/12/2000) : Satisfaction : 85%
– Remarks and status :
• procedure is not up to date : in progress
• torque of screw drivers not calibrated : tool must be
replaced, 19KF, Investment proposal to be done
• ESD rules not respected : verify that everybody
conforms the ESD rules
• working instruction list not up to date : in progress
NEC Computers International
6
BUDGET Y2K :
• Stockroom :
– Actual (November) : 474729$
– Budget : 427719$
• Servers :
– Actual : 402213$
– Budget : 641095$
• Notebooks :
– Actual : 771892$
– Budget :611998$
NEC Computers International
7
Investments Y2K :
• Stockroom :
– Increase stockroom capacity in order to shorten
the servers lead time : shelves + receiving
– Amount = 48630$
• Notebooks :
– Increase production capacity from 600/day to
900/day in order to achieve the target for end of
the year : new layout + 6 trolleys for preload
– Amount = 138000$
NEC Computers International
8
METHODS :
• Quality measurement on the lines :
– Acceptable Quality Level : cosmetics & docs
– On Line Repair ratios
• KAIZEN : the processes are always improved by the
operators, in brainstorming meetings, controlled by
leads or supervisors,
• Progress group at receiving
• Weekly meeting for OLR Quality improvement
• Daily meeting for business & material management
• New operators:2 days training + 3 (practice servers)
NEC Computers International
9
Capacity calculation : on Wednesday, 11:00
Capacity required
by order admin
Material availability
Capacity calculation
parameters =
number of working hours
or number of people
Wednesday, 12:00
Mail : working hours & capacity for the following week
NEC Computers International
10
METHODS : 5S or Housekeeping
•
•
•
•
•
•
Quality can only grow in a clean workshop
Seiri
= to throw away useless things
Seiton = everything at its place
Seiso = to clean
Seiketsu= to be methodical, organized
Shitsuke= to learn rigor
NEC Computers International
11
METHODS : New product Introduction
Purchasing
Material
planning
Production
planning
MOs
Engineering
Marketing
Products
FCS dates
roadmaps
NEC Computers International
1 unit for
FA test
Tests &
support
Production:
operator training,
quality,
routing times,
efficiency,
productivity,
practice
FA team :
assembly method
working instructions
test process
12
Mission for the server production team
•
•
•
•
To produce servers
with Excellence in quality,
delivered in time to the customer,
and with respect of the budgeted costs.
– This must be done with well trained
people, in respect of the working
conditions and environment, and
continuously searching for improvement
of the process.
NEC Computers International
13
Layout : Servers
NEC Computers International
14
Process for servers
Packing
1 work station
Shipping
Quality
Nationalization
kits
On Line
Repair
Burn-In
180 entry points
Entry = 6 hours
High = 12 hours
Stockroom
Kitting
NEC Computers International
Assembly
10 work stations
45 mn (Average)
Max Capacity :
300/day/3 shifts
15
Objectives and results for servers
• Quality :
– On Line repair, Objective : 6.7 % current : 6.8%
– Non conform products
– Process issues
– assembly errors
– DOA, Objective 1 % , current : 0.1%
• Lead times : Objective : 4 days from order placed to FOB
– current lead time : 10 days (average)
– production cycle time : 3 days (average)
• Costs :
– productivity : Objective :4/day/operator, current 3,35
NEC Computers International
16
Production cycle for servers
•
•
•
•
J = order is placed in SOPSYS
J+1 = MO is planned at J+2
J+2 = production, pretest, burn-in,
J+3 = delivery to shipping
NEC Computers International
17
QUALITY Y2K : Servers
NEC Computers International
18
QUALITY Y2K : Servers
%QUALITY OUTGOING SERVER
8,00%
7,00%
6,00%
5,00%
4,00%
3,00%
2,00%
1,00%
NEC Computers International
déc-00
nov-00
oct-00
sept-00
août-00
juil-00
juin-00
mai-00
avr-00
mars-00
févr-00
janv-00
1999
0,00%
19
QUALITY Y2K : Servers
RMA (12 month rolling)
2,00%
1,50%
% other (12 month)
% NDF(12 month)
1,00%
% Failed(12 month)
0,50%
goal
19
9
jan 9
v-0
0
fév
r-0
ma 0
rs00
av
r-0
0
ma
i-0
0
jui
n-0
0
jui
l-0
ao 0
ût0
se 0
pt00
oc
t-0
0
no
v-0
0
dé
c-0
0
0,00%
NEC Computers International
20
ai
Se ne
1
m
ai
n
e
Se
3
m
ai
Se ne
5
m
ai
n
e
Se
7
m
a
Se ine
m
9
ai
n
e
Se
11
m
ai
n
e
Se
13
m
ai
n
Se
e
1
m
ai 5
n
e
Se
17
m
ai
n
e
Se
19
m
ai
Se ne
21
m
ai
n
e
Se
23
m
ai
n
Se
e
2
m
ai 5
Se ne
27
m
ai
n
e
Se
29
m
ai
Se ne
31
m
ai
n
e
Se
33
m
ai
n
Se
e
3
m
ai 5
Se ne
37
m
ai
n
e
Se
39
m
ai
Se ne
41
m
ai
n
e
Se
43
m
ai
n
Se
e
4
m
ai 5
Se ne
47
m
ai
n
e
Se
49
m
ai
ne
51
Se
m
CDI CDD TEMPS
Manpower Y2K : Servers
JP CABRERA
21/12/2000
NEC Computers International
Effectif par semaine, SERVEURS
45
40
35
30
25
INT
CDD
20
CDI
15
10
5
0
Semaine
21
04
/0
1/
20
00
19
/0
1/
2
03 000
/0
2/
20
00
18
/0
2/
2
04 000
/0
3/
20
00
19
/0
3/
2
03 000
/0
4/
20
00
18
/0
4/
2
03 000
/0
5/
20
00
18
/0
5/
2
02 000
/0
6/
20
00
17
/0
6/
20
00
02
/0
7/
2
17 000
/0
7/
20
00
01
/0
8/
2
16 000
/0
8/
20
00
31
/0
8/
2
15 000
/0
9/
20
00
30
/0
9/
2
15 000
/1
0/
20
00
30
/1
0/
2
14 000
/1
1/
20
00
29
/1
1/
2
14 000
/1
2/
20
00
29
/1
2/
20
00
Productivity Y2K : Servers
40
Productivité
36
32
28
24
20
16
12
8
4
0
UNITS/DAY/OPERATOR
objectif
NEC Computers International
Nbre de personnes présentes
Polynomial (UNITS/DAY/OPERATOR)
22
04
/0
1/
2
19 000
/0
1/
2
03 00
0
/0
2/
20
18
00
/0
2/
2
04 00
0
/0
3/
20
19
00
/0
3/
2
03 00
0
/0
4/
20
18
00
/0
4/
2
03 00
0
/0
5/
20
18
00
/0
5/
2
02 00
0
/0
6/
2
17 00
0
/0
6/
2
02 00
0
/0
7/
2
17 000
/0
7/
2
01 00
0
/0
8/
2
16 00
0
/0
8/
2
31 000
/0
8/
2
15 00
0
/0
9/
20
30
00
/0
9/
2
15 00
0
/1
0/
20
30
00
/1
0/
2
14 00
0
/1
1/
20
29
00
/1
1/
2
14 00
0
/1
2/
20
29
00
/1
2/
20
00
Efficiency Y2K : Servers
Efficience Assemblage Serveurs
200
NEC Computers International
120
100
150
80
100
60
40
50
20
0
0
Efficience
heures perdues
Heures non productives
Polynomial (Efficience)
23
Mission for the notebooks production team
•
•
•
•
To produce notebooks
with Excellence in quality,
delivered in time to the customer,
and with respect of the budgeted costs.
– This must be done with well trained
people, in respect of the working
conditions and environment, and
continuously searching for improvement
of the process.
NEC Computers International
24
Layout : Notebooks
NEC Computers International
25
Process for notebooks
Packing
Shipping
Quality
Nationalization
kits
On Line
Repair
Pretest/Preload
192 entry points
3,5 hours
Stockroom
Kitting
NEC Computers International
Assembly
12 work stations
10 mn (Average)
Max Capacity :
900/day/3 shifts
26
Objectives and results for notebooks
• Quality :
– On Line repair, Objective : 2.7 % current : 2.7%
– Non conform products
– Process issues
– assembly errors
– DOA, Objective 2 % , current : 1%
• Lead times : Objective : 3 days from order placed to FOB
– current lead time : 10 days (average)
– production cycle time : 3 days (average)
• Costs :
– productivity : Objective :4/day/operator, current 3
NEC Computers International
27
Production cycle for notebooks
•
•
•
•
J = order is placed in SOPSYS
J+1 = MO is planned at J+2
J+2 = production, pretest, preload,
J+3 = delivery to shipping
NEC Computers International
28
QUALITY Y2K Notebooks
% OLR NOTEBOOK
5,00%
4,50%
4,00%
3,50%
3,00%
2,50%
2,00%
1,50%
1,00%
0,50%
0,00%
Process
Assembly
Suppliers
NEC Computers International
déc-00
nov-00
oct-00
sept-00
août-00
juil-00
juin-00
mai-00
avr-00
mars-00
févr-00
janv-00
1999
1998
Goal
29
QUALITY Y2K : Notebooks
% OUTGOING QUALITY CHECK NOTEBOOK
2,00%
1,80%
1,60%
1,40%
1,20%
1,00%
0,80%
0,60%
0,40%
0,20%
NEC Computers International
déc-00
nov-00
oct-00
sept-00
août-00
juil-00
juin-00
mai-00
avr-00
mars-00
févr-00
janv-00
1999
1998
0,00%
30
NEC Computers International
déc-00
nov-00
oct-00
sept-00
août-00
juil-00
juin-00
mai-00
avr-00
mars-00
f évr-00
janv-00
1999
avr-0
mars-0
2,00
1,50
1,00
juil-0
juin-0
mai-0
avr-0
mars-0
f évr-0
janv-0
199
199
déc-0
nov-0
oct-0
sept-0
août-0
juil-0
juin-0
mai-0
QUALITY Y2K : Notebooks
RMA (ARR) repartition
3,00
2,50
other
NDF
Failed
goal
0,50
0,00
31
ai
Se ne
1
m
ai
n
e
Se
3
m
ai
Se ne
5
m
ai
n
e
Se
7
m
ai
ne
Se
m
9
ai
Se ne
11
m
ai
n
e
Se
13
m
ai
Se ne
1
m
ai 5
n
e
Se
17
m
ai
Se ne
19
m
ai
n
e
Se
21
m
ai
Se ne
23
m
ai
n
Se
e
2
m
ai 5
n
e
Se
27
m
ai
n
e
Se
29
m
ai
n
e
Se
31
m
ai
Se ne
33
m
ai
n
Se
e
3
m
ai 5
Se ne
37
m
ai
n
e
Se
39
m
ai
Se ne
41
m
ai
n
e
Se
43
m
ai
n
Se
e
4
m
ai 5
n
e
Se
47
m
ai
n
e
Se
49
m
ai
ne
51
Se
m
CDI CDD TEMPS
Manpower Y2K : Notebooks
JP CABRERA
21/12/2000
NEC Computers International
Effectif par semaine, NOTEBOOKS
70
60
50
40
INT
CDD
30
CDI
20
10
0
Semaines
32
Mission for the warehouse team
• To receive and stock each component
• with Excellence in inventory accuracy,
• delivered in time to the productions or to the
other warehouses,
• and with respect of the budgeted costs.
– This must be done with well trained
people, in respect of the working
conditions and environment, and
continuously searching for improvement
of the process.
NEC Computers International
33
Layout : Stockroom
NEC Computers International
34
Process for warehouse
Prod.
Planning
Office :
following up
of MOs
Max Capacity :
900 notebooks or 50 MOs/day/3 shifts
+ 300 servers or 100 Mos/day/3 shifts
+ 50 Mos for accessories
Manufacturing Orders
Inventory
& picking lists
Resupply
Goods
Mass
Prekit
preparation
Docks Stockroom Picking
Receiving
Stockroom Picking
warehousemen
Protected
Shuttles
Production
Stockroom
NEC Computers International
35
ai
Se ne
1
m
ai
n
e
Se
3
m
ai
n
Se
e
5
m
ai
n
e
Se
7
m
a
Se ine
m
9
ai
n
e
Se
11
m
ai
n
e
Se
13
m
ai
Se ne
1
m
ai 5
n
e
Se
17
m
ai
Se ne
19
m
ai
n
e
Se
21
m
ai
Se ne
23
m
ai
n
Se
e
2
m
ai 5
Se ne
27
m
ai
n
e
Se
29
m
ai
Se ne
31
m
ai
n
e
Se
33
m
ai
Se ne
3
m
ai 5
n
e
Se
37
m
ai
Se ne
39
m
ai
n
e
Se
41
m
ai
Se ne
43
m
ai
n
Se
e
4
m
ai 5
Se ne
47
m
ai
n
e
Se
49
m
ai
ne
51
Se
m
CDI CDD TEMPS
Manpower Y2K : Warehouse
JP CABRERA
21/12/2000
NEC Computers International
Effectif par semaine, STOCK
35
30
25
20
INT
CDD
15
CDI
10
5
0
Semaine
36
Inventory Adjustments Y2K
Valeur ajustement
25000
20000
19.198,78
1999
2000
15000
10000
Transfer from St Sylvain
4.026,84
5000
2.283,621.829,22
0,00
672,46
0,00
-1.068,71
61,48
326,54
0
-1.413,66
-1.795,00
-382,84 -720,90 -546,53
-1.387,92
-1.764,44
-2.347,63
-3.011,60
-5000
-4.123,44
-7.788,69
-7.190,33
-10000
-11.104,25
NEC Computers International
Décembre
Novembre
Octobre
Septembre
Aout
Juillet
Juin
Mai
Avril
Mars
Février
Janvier
Décembre
Novembre
Octobre
Septembre
Août
Juillet
Juin
Mai
Avril
Mars
Février
-15000
37
Efficiency Y2K : picking & delivery to production
NEC Computers International
38
Weakness and axes of improvement
• Global :
• supply chain : forecasts accuracy, bids not taken in
account, specific components with low volumes =>
suppliers not flexible
• dependence of engineering on Boxborough
• production planning : launch of production with
components arriving the same day => shortages
• too many temporary people => low skills level
• Stockroom :
• not enough space on the docks and shelves
• no software for picking list nor MO grouping
NEC Computers International
39
Weakness and axes of improvement
• Notebooks:
• Quality management must be improved by 10 points
• Floor and walls to be repaired
• Servers :
• Packing becomes very hard because of the weight of
servers : a handling tool has to be developed, in
progress
• Not enough light on the line : budgeted, IP to be done
• both Nb & Sv:
• compressed air screw drivers : budgeted for 2001
• On Line working instructions : budgeted for 2001
NEC Computers International
40
Training : proposal for 2001
Cost Center
3500
3500
3530
3530
3530
3530
3530
3530
3530
3530
3530
9373
9373
9373
9373
9373
9373
9373
9373
9373
9373
9373
9383
9383
9383
9383
9383
9383
9383
3530-9373-9383
9373-9383
Name
Training Heading
Babin V
Anglais individuel
Babin V
Finance
Guedon J
Anglais classique
Quemener J
Anglais classique
Cognolato S
Anglais classique
Meslet P
L' Entretien Annuel d'activité
Guedon J
Douane + Transport
Quemener J
Douane + Transport
Cognolato S
Douane + Transport
Cabrera J
Douane + Transport
3 pers
Outlook
Taconne. A
réseau
Allaire. E
Anglais classique
Benoit. F
Anglais classique
Juret. A
Anglais classique
Leger. C
Anglais classique
Pilard. J
Anglais classique
Cabrera J
Anglais individuel
Palmier JM Construire, Animer et gérer son équipe
Lecomte R Construire, Animer et gérer son équipe
Allaire. E
L' Entretien Annuel d'activité
Cabrera J
Manager un centre de responsabilité
Heriteau B
Anglais classique
Leroux B
Anglais classique
Martin D
Gestion de temps
Heriteau B
Perfectionnement gérer son équipe
Leroux B
Perfectionnement gérer son équipe
Sauvaget B
Certification Multiplatforme
Geffard P
L' Entretien Annuel d'activité
6 pers
Formation Secouriste
8 pers
Technique Servers
NEC Computers International
Date
Cost
6.500 F
3.200 F
1.850 F
1.850 F
1.850 F
1.300 F
0F
0F
0F
0F
0F
5.000 F
1.850 F
1.850 F
1.850 F
1.850 F
1.850 F
8.000 F
2.100 F
2.100 F
1.300 F
44.000 F
1.850 F
1.850 F
1.400 F
715 F
715 F
16.500 F
1.300 F
0F
0F
Total Training Cost
6.500 F
9.700 F
11.550 F
13.400 F
15.250 F
16.550 F
16.550 F
16.550 F
16.550 F
16.550 F
16.550 F
21.550 F
23.400 F
25.250 F
27.100 F
28.950 F
30.800 F
38.800 F
40.900 F
43.000 F
44.300 F
88.300 F
90.150 F
92.000 F
93.400 F
94.115 F
94.830 F
111.330 F
112.630 F
112.630 F
112.630 F
Total Cost center
9.700 F
6.850 F
71.750 F
24.330 F
41
END
NEC Computers International
42