Shortening the Cycle Time of the Fiber Ribbon Orientation Process for Wavelength Selective Switch Production using Design for Assembly and Disassembly Concepts

Abstract

The primary objective of the research was to shorten the cycle time of a particular process used in producing a new Wavelength Selective Switch (WSS) product by a multinational electronic manufacturing corporation. In recent years, the case study company has encountered difficulties with process cycle time exceeding predefined takt time when establishing a new production process for the freshly launched item. To identify areas for improvement, the study leveraged industrial engineering techniques, such as the Yamazumi Chart, line balancing (workload leveling) analysis, and method time measurement. After the production process data was thoroughly analysed, cycle time reduction opportunities emerged. After that, the jig design used in the present investigation was developed based on the highly effective and widely recognized mechanical engineering concepts of Design for Assembly (DFA) and Design for Disassembly (DFD). The aim was to confidently eliminate non-value-added processes in the fiber ribbon orientation step, resulting in increased efficiency and improved outcomes. The study reported a significant reduction of 87% in the cycle time required. The results also demonstrated that implementing certain methodologies could reduce the cycle time. In addition, this finding held significant importance for the industry, as it could lead to increased efficiency and productivity, ultimately leading to cost savings of 12% of its total production.