Elektronik sanayiinde endüstri mühendisliği uygulamaları

Abstract

Bu çalışmada, elektronik sanayinde faaliyet gösteren bir firmanın, maliyet düşürme ve verimlilik arttırma açısından en önce düzenlenmesi gereken stok kontrol, giriş kalite kontrol ve üretim bölümlerinde, ORCA adlı ürün için sistem kurma ve iyileştirme çalışmaları yapılmıştır. ilk olarak giriş bölümünde. Endüstri Mühendisliği ile ilgili genel bilgiler ve temel kavramlar verilmiştir. Zaman ve metot etütleri, yöneylem araştırması ve işbilim bunlardan bir kısmıdır. ikinci bölümde ise, uygulama yapılan şirket ve ürün tanıtılmıştır. Komtel, NETWORK GROUP HOLDINGS PLC adlı bir İngiliz şirketler topluluğunun üyesidir ve Network Electronic Industries Ltd. 'ye bağlı olarak çalışmaktadır. Şirket, Network 'ün fason üretim yaptırdığı şirketlerde kalite takibi yapmak amacıyla kurulmuş daha sonra, kendisi de Network 'ün küçük bir modeli olarak çalışmaya başlamıştır. ORCA adlı ürünü de bu şekilde ÖZAK adlı fason üretici firmada yapılmak tadır. üçüncü bölümde, ORCA için bir hat dengeleme çalışması yapılmıştır. Bu amaçla sıralı pozisyon ağırlık metodu kulla- kullanılmıştır. öncelikle elemanların öncelikleri belirlenmiş, daha sonra bu elemanlar istasyonlara bu sıra ile yerleştirilmiştir. Çalışma sonucunda dizgi bandının 6 iş istasyonu ile kurulabileceği belirlenmiştir. Dördüncü bölüm. Stok kontrol sisteminin belirlenmesi ile ilgilidir. önce tüm stok kontrol sistemleri hakkında genel bilgiler verilmiş daha sonra ORCA için en uygun sistem araştırılmıştır, ilk olarak stoklar yerli ve ithal diye ikiye bölünmüş ve her biri için bir sistem geliştirilmiştir. Yapı lan çalışmalar sonucunda, her iki mal grubu için de en uygun sistemin basit stok kontrol sistemi olduğu belirlenmiştir. Elde edilen maliyetlere göre de ithal malzemeler için optimum sipariş miktarı 4000 adet/ay, yerli malzemeler için ise 2000 adet/ay olarak hesaplanmıştır. Beşinci bölüm, ORCA için giriş kalite kontrol ve kabul örneklemesi sisteminin oluşturulduğu bölümdür. Burada konu ile ilgili genel bilgiler verildikten sonra, ORCA için en uygun kalite kontrol sistemi seçilmiştir. Bu sistem, Geçerli Kalite Seviyesi (GKS) Sistemidir. örnekleme planları bu sisteme göre yapılacaktır. Daha sonra ise bu sistemin uygulanabilme si için en önemli kısım, yani kalite standartları belirlenerek, sistemin uygulanabilir hale getirilmesi sağlanmıştır.

Chapter 1: Introduction In this chapter, basic concepts and fundamentals of industrial engineering have been examined. First of all we must investigate how this engineering branch came out. In the begining of 20th century, people dealing with planning and control activities of the companies were electronic, chemical or other engineers from social branches of universities. After industrial revolution quantity of companies have increased. Of course, this meant that a company should have to be managed professionally. So a new branch of engineering came out. Especially. in last few decades, industrial engineers made more effective studies by help of job sociology, job physiology and job psychology. Industrial engineers make below studies : -Time sharing -Motion Study -Salary evaluation -Plant Location -Building type selection -Manufacturing planning -Production planning -Establishing and operating production control systems -Cost-control systems, budgeting -Material stock systems -Material requirement planning -Personnel management -Wage problems. Most interesting part of industrial engineering is Operational Research. This is a science which helps solution of many problems that can be met in a company. Its name and methods have been used since the 2nd World War. During the War, especially in the Britain Army, experts on their areas came together and investigated necessary solutins by using scientific method, technic and tools. Below are some areas that Operational Research can be used effectively: -Inventory control problems -Transportation problems, -Queue problems -Plant renewal problems, -Competition activities, -Personnel management. Chapter 2: Product and the manufacturer The company this study have been carried out is KOMTEL ELEKTRONİK SANAYİ VE TİCARET A. S. (Hereafter referred to as KOMTEL). Komtel is a part of an English holding named NETWORK GROUP HOLDINGS PLC. (Hereafter referred to as NG). NG is an electronic household products design, engineering and marketing company which activate in ECC. Some of their products are colour television sets, refrigerators, satellite receivers etc. These products are manufactured in a factory which is not a property of NG. NG make agreements with such factories to produce NG designs. BEKOTEKNIK SANAYİ VE TIC. A. S. is one of them. And KONTEL is repsesantative and inspector of NG. We can call KONTEL as small NG. Because they also do the same business with NG. One of KOMTEL products is ORCA REMOTE CONTROL CABLE TV ADAPTOR. ORCA is a product which convert nonremote control TV sets to remote control TV sets. It also increases channel quantity to 64. Additionally it enables TV to receive cable broadcasting. It covers nearly 200 components. 170 pieces of them are import, remainings are local parts. Below are production steps of ORCA: - Insertion, - Soldering, - Chassis control - Alignment - Cabinet mounting - Channel alignment, - Komtel quality control, - Beko quality control, - Packaging. ORCA is manufactured in a factory called OZAK. Ozak is a company with 200 worker which manufactures products for BEKO and KOMTEL. The product ORCA is manufactured there for KOMTEL. OZAK has GOO pieces/day audio product manufacturing capacity. Factory is located at Beylikduzu, Istanbul. xi Chapter 3; Line balancing A product is generally made from a lot of parts. Of course it is a company problem to design a mounting line for the product. In the begining of industrial revolution it has been realized that it was more effective and cheap to manufacture goods on a mounting line than an individual production. Process of balancing a mountig line with the minimized loss time is called line balancing. Line balancing is carried out to: - to minimize time losses - to minimize quantity of jobshops - to prevent to be on limits This study have been implemented for ORCA remote control converter in order to minimize labour cost and meet the order quantity placed by BEKOTEKNIK. It has been agreed with BEKO that KOMTEL will deliver 4000 units of ORCA to BEKO. So cycling time for ORCA line can be calculated as: 4000 units of ORCA / 20 working days = 200 units/day 8 hours x 60 minutes x £0 seconds / 200 = 144 seconds => cycling time = 144 seconds First» priorities of components must be specified in order to commence the study: - First priority is on mains tranformer. - Regulators with position numbers REG1 and REG2 must be inserted in last jobshop. - All other parts must be inserted with increasing volume order. - Tuner must be last inserted component. After specifying all positions and weights, final step is to place jobshops. It is possible to carry out this process with six jobshops and with 2% balance loss and it is in limits. xii Chapter 4: Stock control Today one of the most important problems of manufacturers is an effective inventory management, so an effective stock control management. In order to specify a stock control system for a company, all stock control systems must be examined. There are 2 main groups of stock control systems: 1- Continious stock control systems, 2- Periodic stock control systems. A decisionmaker must examine the parts and production carefully, and then he can choose the most effective system. Stock control system for ORCA: ?" As it has been mentioned before, there are two kinds of components used in ORCA: Import and local. So it will be very useful to examine these parts seperately. Optimum order quantity for import parts is nearly 4000 kits. This quantity is 2000 kits for local components. Above quantities have been obtained by the. help of below items: Import parts: Local parts: Annual demand = R = 50, 000 units Handling cost = Ch= 5, 000 TL/adet Obtaining cost= Co= 9,000,000 TL. Annual demand = R = 50, 000 units Handling cost = Ch= 4, 100 TL/adet Obtaining cost= Co= 2, 000, 000 TL. Purchase order point for import kit is 1700. It is 1250 units for local parts. During the decision phase for stock control system, decisionmaker must discuss it with sales and marketing department, and he must check all index and statistics. Chapter 5s Input quality control and sampling Quality of a product depends on: xiii - Design quality, - Component quality, - Labour quality, - Equipmet used in production. If it is an electronic product, then quality of components becomes very important. Because commponent quality directly effects the quality. So an electronic products manufacturer must built an effective Input Quality Control (IQC) to control materials supplied. Belov are some IQC tests: - Size control, - Functional control, - Weight control, - Flammability test, - Cosmetic control, etc. There are a lot of systems for above quality control process. One of them that will be used for ORCA IQC is Acceptable Quality Levels (AQL) system. All accept-reject values are specified in AQL tables. We are going to use AQL system for ORCA IQC. A Komtel inspector will carry out inspection after production and he will accept AQL level 2.5 for Major defects and 4.0 for minor defects. If a party is rejected he will carry out tightened inspection specifications for second control. But of course an IQC system without speified quality standards is nothing. Below are main standard defect groups for our product ORCA: - Packaging defects - Cosmetic defects - Alignment defects - Geometric defects - Colour defects - Audio defects - Connection defects - Working defects - Bad contact - Mechanic defects It will be very useful to implement this system for ORCA. Because quality is the most effective subject for marketing and sales.