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SME 3813

INDUSTRIAL ENGINEERING
PROJECT
ON
COAXIAL CABLE ASSEMBLY
IMPROVEMENT

GROUP MEMBERS
1)
2)
3)
4)

VASU DEVAN
SHATKUNAM
RAJWINDER
AZRI KHAIRY

Letcurer: Prof.Dr.Mohd Izman Sudin

COMPANY PROFILE
EMS is involved in 4 keys industries:
Computer
Telecommunications
Consumer Electronics
Automotive

Fabricated wires which include cutting, stripping, twisting, tinning,


crimping, terminating, -------connector insertion, forming, loam wiring
and assembly jobs.
Insulated Displacement Connector (IDC) assembly.
Data cables for networks, multimedia and signal cables.
Over mould components.

ASSEMBLY OVERVIEW

ANTENNA PLUG
SIDE

COAXIAL SIDE

RG174 CABLE

SALES ORDER SUMMARY


Coaxial Cable Assembly

ORDER QTY

SAS NO

COMPLETION DATE

6689

MAY 2011

200

7328

JUNE 2011

1000

7627

JULY 2011

3000

7681

AUGUST 2011

2000

7791

SEPTEMBER 2011

3000

8005

OCTOBER 2011

2000

8159

NOVEMBER 2011

5000

(PCS)

INFORMATION PROVIDED FROM SALES SERVER OUTSTANDING LIST

PROBLEM STATEMENT
IDENTIFIED THREE PROCESSES
THAT HAVE CAPABILITY TO
REDUCE CYCLE TIME FROM 190
SECONDS, REJECTS & COSTS.

DATA COLLECTION
CURRENT PROCESS DATA PER PIECE ASSEMBLY

PROCESS

NOTES

CUTTING CABLE

TIME /

ESTIMATED

(SEC)

QTY/ HOUR

1.5

2400

WIRE CUTTING MACHINE

TOOLING

NO. OF
OPERATOR

STRIP OUTER CABLE JACKET

BOTH SIDES

45

80

MANUAL

CUTTING HEATSHRINK TUBE

ANTENNA PLUG SIDE

2.5

1440

WIRE CUTTING MACHINE

STRIP INNER CABLE JACKET

BOTH SIDES

20

180

MANUAL

FOLD BACK CABLE BRAID

ANTENNA PLUG SIDE

720

MANUAL

TRIMMING BRAID

COAXIAL SIDE

15

240

MANUAL

CRIMPING COAXIAL TERMINAL

COAXIAL SIDE

514

CRIMPING MACHINE

INSERT HOUSING & RETAINER

COAXIAL SIDE

514

MANUAL

TWIST & TINNING

ANTENNA PLUG SIDE

450

MANUAL

SOLDERING ( 2 SIDES)

ANTENNA PLUG SIDE

10

360

MANUAL

CRIMPING CLAMP

ANTENNA PLUG SIDE

12

300

MANUAL

HEAT UP SHRINK TUBE

ANTENNA PLUG SIDE

720

MANUAL

FIX ANTENNA COVER

ANTENNA PLUG SIDE

720

MANUAL

720

MANUAL

12

300

TESTING JIG & VISUAL

1.2

3000

MANUAL

APPLY LABEL
TESTING AND CHECKING
PACKING

BOTH SIDES

LEGEND:
Identified Potential Process
Improvement

CURRENT PROCESS OVERVIEW


1)

CABLE CUTTING & OUTER JACKET STRIPPING

OLD PROCESS
NOTE:
KM-3100 MACHINE DOES NOT HAVE
THE ABILITY TO STRIP CABLE JACKET
PROCESS :

A - CABLE CUTTING

1 PC

1.5 SEC

OUTPUT ( 1 HOUR)

3600 SEC / 1.5 SEC

2400 PCS

PROCESS :

B - STRIP OUTER CABLE JACKET

1 PC (2 SIDES)

45 SEC

OUTPUT ( 1 HOUR)

3600 SEC / 45 SEC

80 PCS

PROCESS :

A+B

1 PC (2 SIDES)

1.5 SEC + 45 SEC = 46.5 SEC

OUTPUT ( 1 HOUR)

3600 SEC / 46.5 SEC

77 PCS

CURRENT PROCESS OVERVIEW


2)

TRIMMING BRAID FOR COAXIAL SIDE

CURRENT PROCESS

PROCESS :

CABLE BRAID TRIMMING FOR COAXIAL SIDE

1 PC

15 SEC

OUTPUT ( 1 HOUR)

3600 SEC / 15 SEC

240 PCS

THANK YOU