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Assembly and process chart

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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

Tasks
1. Prepare an assembly chart for the headphone assembly
2. Prepare a process chart for the headphone assembly
3. How might an assembly chart and process chart be helpful in identifying improvements? Provide details.

Attachments
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Solution Summary

1. Assembly chart for the headphone assembly
2. Process chart for the headphone assembly

Solution Preview

1. Prepare an assembly chart for the headphone assembly
Attached Microsoft excel file: process charts_Head phone assembly.xls contains the assembly chart.
Note: When you open the file, you will get a message to enable or disable macros. Click on the enable macros button to see all the details in the file.

2. Prepare a process chart for the headphone assembly
Attached Microsoft excel file: process charts_Head phone assembly.xls contains ...

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