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.