Stapler
1. Existing Design
i) Design efficiency = (number of functional component / total ) x 100
Major component: superstructure x2, loading component, pin holder, flexor, spring, pin
No. functional component = 6
Total no. component = 9
Design efficiency= (6/9)x100 = 66.67%
ii) Suitability
A breakdown of how the unit is currently manufactured and associated costs
a) Sequence of assembly:
1. Flexor + top superstructure + PVC holder
2. Bottom superstructure + PVC holder
3. Loading compartment + Pin holder + Spring
4. Step 1 + Step 2 + Step 3 + Pin
b) Assembly process
1. The assembly process for the bottom and top superstructure is almost similar which they used hot stamping machine to assemble the PVC holder to the superstructure. The hot stamping machine use pressure and heat to imprint the PVC holder to fit on the superstructure.
2. To assemble the loading compartment, pin holder and spring, manpower is used.
3. After the above is done, the stapler is to be assembled to be one which a pin is fixed.
c) Labour cost
Example: production: 1 million unit of stapler per month
- 3 shift
- time taken to assembly 1 unit 2 minutes
- RM1500 per month per worker
- 26 working days
- 3 shift (20 hours) 1 person per shift = 6.67 hours = 400.2 minutes 2 minutes per unit, 1 shift = (400/2) = 200 units - 3 shift 600 units/day 26 days 15600 unit/worker 1 million units = (1 million/15600) = 64 workers Labour cost = (64 X RM1500) / 1 million = RM0.096/unit = RM0.10/unit
To reduce the labour cost, the assembly time per unit needs to be reduced. The assembly time per unit can be reduced to 1.5 minute. To reduce the time, one of the sequences of the assembly process need to be reduced and hence the number of parts of the stapler need to be reduced. Therefore, with the time reduce to 1.5 minute, the labour cost per unit is reduced to RM0.75.
i) Design efficiency = (number of functional component / total ) x 100
Major component: superstructure x2, loading component, pin holder, flexor, spring, pin
No. functional component = 6
Total no. component = 9
Design efficiency= (6/9)x100 = 66.67%
ii) Suitability
A breakdown of how the unit is currently manufactured and associated costs
a) Sequence of assembly:
1. Flexor + top superstructure + PVC holder
2. Bottom superstructure + PVC holder
3. Loading compartment + Pin holder + Spring
4. Step 1 + Step 2 + Step 3 + Pin
b) Assembly process
1. The assembly process for the bottom and top superstructure is almost similar which they used hot stamping machine to assemble the PVC holder to the superstructure. The hot stamping machine use pressure and heat to imprint the PVC holder to fit on the superstructure.
2. To assemble the loading compartment, pin holder and spring, manpower is used.
3. After the above is done, the stapler is to be assembled to be one which a pin is fixed.
c) Labour cost
Example: production: 1 million unit of stapler per month
- 3 shift
- time taken to assembly 1 unit 2 minutes
- RM1500 per month per worker
- 26 working days
- 3 shift (20 hours) 1 person per shift = 6.67 hours = 400.2 minutes 2 minutes per unit, 1 shift = (400/2) = 200 units - 3 shift 600 units/day 26 days 15600 unit/worker 1 million units = (1 million/15600) = 64 workers Labour cost = (64 X RM1500) / 1 million = RM0.096/unit = RM0.10/unit
To reduce the labour cost, the assembly time per unit needs to be reduced. The assembly time per unit can be reduced to 1.5 minute. To reduce the time, one of the sequences of the assembly process need to be reduced and hence the number of parts of the stapler need to be reduced. Therefore, with the time reduce to 1.5 minute, the labour cost per unit is reduced to RM0.75.