Q1. Howis Donner company doing? If there are any problems, what are the causes for these? Donner Company manufactured printed circuitboard and within 2 years had specialized in circuit board manufacturing forexperimental devices & for pilot production. They produced circuit boards knownas ‘soldermask over base copper’ (SMOBC) which became popular in early 1980’s.

It chose a production layout such that it minimized installation cost,preserved life of expensive machines and isolated operations. It faceddifficulties around productivity, quality and delivery problems.Following are some of the problems faced byDonner Company:-         Productionbottleneck: Bottleneck shifted almost every day from one operation to another.

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As there was no pattern, it was difficult to bring process changes. As eachindividual order demanded varying operations and hence it was difficult to predictwhich process would have more load.-         Delay in delivery:As customer’s engineer change the design because of design problems, thislead to delay in delivery.-         Productivity:As the workers shifted from job to job, it affected their productivity.-         Quality: Qualitystandards varied from customer to customer and from order to order. Also, therewas no formal quality checking process, it was done on an informal basis by theworkers when it moved through the process.

–         Shippingpolicy: They were following a policy of clearing all the work before theend of the month, which lead to fewer shipment in the start of the month and becauseof this policy shipments were delayed.Q2.What orders will you schedule on the CNC drill? On the CNC router? Let number of boards be’N’ CNCDrilling:From the Exhibit 2,            Total time for CNC drill = 240 + 0.

004*500*N (Number ofboards)                        Total time for Manual drill = 15 + 0.08*500*N (Number ofboards) To use CNC drill,            Total time for CNC drill <= Total time for Manualdrill            240 + 0.004*500*N <= 15 + 0.08*500*N            38N >= 225            N >= 5.92 This implies, if numberof boards are greater than or equal to 6, CNC drilling would be used, elseManual drill would be used.

 CNCRouter:From the Exhibit 2,            Total time for CNC router = 150 + 0.5*N (Number ofboards)                     Total time for Punch press = 50 + 1*N (Number of boards) To use CNC router,            Total time for CNC router <= Total time for Punchpress            150 + 0.5*N <= 50 + 1*N            0.5N >= 100            N >= 200 This implies, if numberof boards are greater than or equal to 200, CNC router would be used, elsePunch press would be used.  Q3.What is the standard labour time for an order of 1 board? 8 boards? 200 boards?    Operation Setup Time (min.) Run Time (min.) Total Time (min.) (Boards – 1) Total Time (min.) (Boards – 8) Total Time (min.) (Boards – 200) Preparation Artwork Generation 29 0 29 29 29 Inspect and Shear 20 0.5 20.5 20.5 32.5 Punch tooling holes 10 0.5 10.5 10.5 22.5 Image Transfers Manual Drill 15 0.08 55 NA NA CNC Drill 240 0.004 NA 256 640 Metallization 10 0.75 10.75 10.75 28.75 Panel Prep 5 0.2 5.2 5.2 10 Lamination and Expose 20 2 22 22 70 Develop 20 0.2 20.2 20.2 25 Electroplate 25 8.5 33.5 33.5 237.5 Strip DFPR 5 0.2 5.2 5.2 10 Etch and Tin strip 10 0.2 10.2 10.2 15 Fabrication Solder Mark 45 1.5 46.5 46.5 82.5 Solder Dip 30 0.5 30.5 30.5 42.5 Punch Press Punch press 50 1 51 58 NA CNC router 150 0.5 NA NA 250 Inspect and pack 45 1.5 46.5 57 345   Total     396.55 615.05 1840.25 a 8 boards b 500 holes c prep of comp control d per circuit board  

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