Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics
The study is aimed at improving productivity and quality, increasing revenue and reducing rejection cost of the manual component insertion (MCI) lines in a printed circuit assembly (PCA) factory. Subjective assessment (through questionnaire), direct observation method, and archival data were used. L...
| Main Authors: | , |
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| Format: | Article |
| Language: | English |
| Published: |
2006
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| Subjects: | |
| Online Access: | http://shdl.mmu.edu.my/1987/ http://shdl.mmu.edu.my/1987/1/1337.pdf |
| _version_ | 1848789932268584960 |
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| author | Yeow, Paul H.P. Nath Sen, Rabindra |
| author_facet | Yeow, Paul H.P. Nath Sen, Rabindra |
| author_sort | Yeow, Paul H.P. |
| building | MMU Institutional Repository |
| collection | Online Access |
| description | The study is aimed at improving productivity and quality, increasing revenue and reducing rejection cost of the manual component insertion (MCI) lines in a printed circuit assembly (PCA) factory. Subjective assessment (through questionnaire), direct observation method, and archival data were used. Live experiments were conducted on production lines. Eleven problems were identified, i.e., long search for materials from the stores, unproductive manual component counting, obstructions during insertions, component fall-off while the PCA board was traveling on a U-shaped conveyor, etc. Interventions were made to rectify the problems, i.e., to have only one central store to eliminate confusion of the materials' whereabouts, use weighing scale for component counting, modify the MCI sequence and the bin arrangements to avoid obstructions, and use straight conveyor to reduce handling. As a result, there was a tremendous increase in productivity and yearly revenue (US$4,223,736) and a huge reduction in defects and yearly rejection costs (US$956,136). |
| first_indexed | 2025-11-14T18:04:34Z |
| format | Article |
| id | mmu-1987 |
| institution | Multimedia University |
| institution_category | Local University |
| language | English |
| last_indexed | 2025-11-14T18:04:34Z |
| publishDate | 2006 |
| recordtype | eprints |
| repository_type | Digital Repository |
| spelling | mmu-19872011-09-23T02:55:00Z http://shdl.mmu.edu.my/1987/ Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics Yeow, Paul H.P. Nath Sen, Rabindra TA Engineering (General). Civil engineering (General) The study is aimed at improving productivity and quality, increasing revenue and reducing rejection cost of the manual component insertion (MCI) lines in a printed circuit assembly (PCA) factory. Subjective assessment (through questionnaire), direct observation method, and archival data were used. Live experiments were conducted on production lines. Eleven problems were identified, i.e., long search for materials from the stores, unproductive manual component counting, obstructions during insertions, component fall-off while the PCA board was traveling on a U-shaped conveyor, etc. Interventions were made to rectify the problems, i.e., to have only one central store to eliminate confusion of the materials' whereabouts, use weighing scale for component counting, modify the MCI sequence and the bin arrangements to avoid obstructions, and use straight conveyor to reduce handling. As a result, there was a tremendous increase in productivity and yearly revenue (US$4,223,736) and a huge reduction in defects and yearly rejection costs (US$956,136). 2006-04 Article NonPeerReviewed application/pdf en http://shdl.mmu.edu.my/1987/1/1337.pdf Yeow, Paul H.P. and Nath Sen, Rabindra (2006) Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics. International Journal of Industrial Ergonomics, 36 (4). pp. 367-377. ISSN 01698141 http://dx.doi.org/10.1016/j.ergon.2005.12.008 doi:10.1016/j.ergon.2005.12.008 doi:10.1016/j.ergon.2005.12.008 |
| spellingShingle | TA Engineering (General). Civil engineering (General) Yeow, Paul H.P. Nath Sen, Rabindra Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics |
| title | Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics |
| title_full | Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics |
| title_fullStr | Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics |
| title_full_unstemmed | Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics |
| title_short | Productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics |
| title_sort | productivity and quality improvements, revenue increment, and rejection cost reduction in the manual component insertion lines through the application of ergonomics |
| topic | TA Engineering (General). Civil engineering (General) |
| url | http://shdl.mmu.edu.my/1987/ http://shdl.mmu.edu.my/1987/ http://shdl.mmu.edu.my/1987/ http://shdl.mmu.edu.my/1987/1/1337.pdf |