Task: A manufacturer of headphone speakers has a production process that involves assembling purchased components and subassemblies. The production process is being analyzed to identify ways to produce the headphones more efficiently. It is expected that a process chart and assembly chart will help to better understand the current processes and assist to develop improvement ideas.
Current Component List
|
Component Description
|
Component Code
|
Predecessor Component Code(s)
|
Quantity Required
|
|
1. Left speaker frame
|
P14L
|
-
|
1
|
|
2. Right speaker frame
|
P14R
|
-
|
1
|
|
3. Speaker
|
S37
|
P14L, P14R
|
2
|
|
4. Wire assembly
|
W25
|
S37
|
1
|
|
5. Faceplate
|
F12
|
W25
|
2
|
|
6. Foam earpiece cover
|
C44
|
F12
|
2
|
|
7. Metal center connector
|
M11
|
C44
|
1
|
Current Assembly Tasks for Headphone Speakers
|
Task Description
|
Distance Moved (feet)
|
Worker time (minutes)
|
|
1. Get components kit
|
12
|
0.2
|
|
2. Inspect that kit contains all parts
|
-
|
0.1
|
|
3. Insert one speaker into left frame
|
3
|
0.1
|
|
4. Insert one speaker into right frame
|
-
|
0.1
|
|
5. Attach wire to left speaker
|
4
|
0.1
|
|
6. Attach wire to right speaker
|
-
|
0.1
|
|
7. Inspect wire connections
|
4
|
0.1
|
|
8. Test sound quality
|
-
|
0.1
|
|
9. Snap faceplate on each frame
|
4
|
0.2
|
|
10. Put foam cover over each earpiece
|
4
|
0.2
|
|
11. Insert connector into both frames
|
4
|
0.2
|
|
12. Final inspection
|
4
|
0.2
|
Required to answer:
Q1. Prepare an assembly chart for the headphone assembly
Q2. Prepare a process chart for the headphone assembly
Q3. How might an assembly chart and process chart be helpful in identifying improvements? Provide details.