The document discusses using lean lot sizing to optimize capacity for high-volume assembly manufacturing. It calculates the daily production capacities for surface mount technology (SMT) and hand-load assembly (HLA) operations, finding they can each produce over 3,000 units per day. The average automated test equipment (ATE) capacity is 2,400 units per day. To fully utilize the ATE capacity each day, a lean lot size of 3,000 units per day is recommended to feed into the testing process. Not optimizing the manufacturing line through uneven loading can negatively impact quality and on-time delivery commitments due to rush jobs and weeks without shipments.

1. Manufacturing Strategy – Lean Lot Sizing
Capacity Optimization with Lean Lot Sizing
for high-volume assemblies
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2. SMT Run-rate = 0.375 mins per piece.
SMT Operations Run-rate
Consider a 20hrs run per day.
Number of units produced at SMT = 20*60/0.375
= 3200 pcs

3. HLA Operations Run-rate
HLA Run-rate = 0.333 mins per piece.
Consider a 20hrs run per day.
Number of units produced at HLA = 20*60/0.333
= 3600 pcs

4. Lean Lot Sizing to optimize capacity at ATE for assemblies
Average ATE capacity per day ~ 2400 pcs
SMT capacity per day = 3200
HLA capacity per day = 3600
Lean Lot Size = 3000 (minimum)
When you feed 3000pcs per day into the ATE Testers, you ensure
Full Efficiency is achieved at the ATE Test each day of the week.

5. Thank You

6. Negative Effects of non-optimized Manufacturing Line
Quality: Rush jobs on weeks with high-loading affecting quality of PWAs.
On-Time-Delivery (OTD): Uneven load-leveling means no shipment during
some weeks and affects delivery commitments to customers.

7. Thank You