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Donner Case

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Submitted By fux21
Words 1688
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Table of Contents

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Executive Summary ............................................................................................................................................... 1
Appendix I: Process Flow ..................................................................................................................................... 2
Appendix II: Break-even analysis for Drilling and Profiling processes ............................................................ 3
Appendix III: Standard operation times (setup and run time scaled per board) ............................................ 4
Appendix IV: Total operation time results for the order sizes 1, 8, 200 and 800 ............................................ 5
Appendix V: Capacity in the DFPR area ............................................................................................................ 6

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II!

Executive Summary
The Donner Company manufactures Soldermask over bare copper circuit boards. Meeting specifications of small and large electronic firms by a self-invented process making them one of the industry leaders. The routine process1 can be divided in three main stages - preparation, image transfer and fabrication (Appendix I).
In both, image transfer and fabrication, it is possible to choose between two alternate technologies (manual vs. automatic) leading to the same output in a sub-process while differing in a fixed setup time and run time per board. Therefore, a break-even quantity was calculated for both in order to configure a decision rule on which option to schedule customer orders to achieve the smallest total production time (Appendix III). As a result, for manufacturing orders of more or equal than six boards the CNC Drill should be the preferred technology in the drilling process. However, for orders greater than 200 boards the operation of choice should be the CNC Router in the fabrication stage.2 As of now, the first rule stated above clearly contradicts Donne Company’s current operating standards, since they use the CNC drill for orders greater than 100 boards.
Assuming it is possible to change the current shop floor policy, it was calculated how using the breakeven rules mentioned above affect the production of various order sizes. The total respective production times per order and per board were computed factoring in the drilling and profiling decisions as per quantity (Appendix
IV). It was noticed that as order size increases, the automatic technologies CNC drill and CNC router prove more beneficial when seeking short production times. Additionally, economies of scale with diminishing returns are also present in the production process, as the time per board decreases significantly for greater order sizes.
Another process that needs further attention is the Dry Film Photoresist area as it contains three suboperations. Examining each of the sub-processes while considering an 8-hour daily shift highlights Laminate &
Expose as the bottleneck process for the tested order sizes. Order quantities of 8, 200 and 800 result in a daily capacity constituting to 174, 960 and 1745 boards per day respectively. It is striking that the daily capacity increases significantly with an enlarged order size (Appendix V).
Besides implementing the results above, we recommend to change the current shipping policy to the effect that shipping should be executed as early as possible to overcome the current issue of procrastinated shipments which lead to an overhead in the end of the month. Additionally, current delays (e.g. in the procurement) and productivity losses due to idle machines need further investigation, whereas the quality control strategy needs to be adopted to monitor the manufacturing process more effectively. All in all, the Donner Company needs to tackle the mentioned inefficiencies in order to maintain its leading position in the long run.

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1
2

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The process flow represents the majority of orders, whereas special orders leading to different processes are excluded.
For an order equal to 200, the company is indifferent between both choices if time is the only decision basis.

1!

Artwork Generation
- Receive artwork
- Produce negative image
- Repeat images per panel

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Appendix I: Process Flow

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Inspect & Shear
- Inspect for visual defects
- Shear laminate into panels

Preparation!

CNC diskettes
- programme (X,Y) coordinates !
Punch tooling holes

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Manual

Drill

CNC Drill

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Metallization

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Panel Preparation

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- Wash
- Scrub
- Coat
Information for computer control

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Laminat & Exposure
- Apply film on top
- Expose to UV light

Image!Transfer!
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Develop Machine

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Electroplate
- Deposit additional copper
- Flashplate tin

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Strip DFPR

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Etch & Tin Strip
- Etch remaining copper
- Strip tin chemically

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Image!Transfer!
Fabrication!

Soldermask

Solder Dip

CNC routing Profile

Punch press Inspect, Test, Pack

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2!

Appendix II: Break-even analysis for Drilling and Profiling processes

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Assumption: Just one of the seven drilling machines at one time
Drill (Decision)

Manual
CNC Drill

Equation

Setup [min]
15.00
240.00

Run [min]
0.08
0.00

Unit (Run) per hole * typical circuit board has 500 drilled holes per hole

15 + 0.08 * 500 * X
(500 * X) * (0.08 - 0.004)
X * (0.076)
X

=
=
=
=

240 + 0.004 * 500 * X
240 - 15
225 / 500
0.45 / 0.076

X

=

with X = break even quantity (boards)

5.92

--> just integer numbers possible for X < 6: manual drilling for X >= 6: CNC drilling
Hypothetic: All of the seven drilling machines can be used parallel
New Break even quantity

for X < 42 boards (7 * 6) we use manual drilling for X >= 42 boards (7 * 6) we use CNC drilling

Profile (Decision)

Punch press
CNC Router

Equation

Setup [min]
50.0
150.0

Run [min]
1.0
0.5

Unit (Run) per board per board

50 + 1 * X
X * (1 - 0.5)
X * 0.5

=
=
=

150 + 0,5 * X
150 - 50
100.00

X

=

with X = break even quantity (boards)

200.00

for X < 200 Punch press for X = 200: Indifferent for X > 200: CNC router

Current Policy

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For orders smaller than 100 the manual drilling is used

3!

Appendix III: Standard operation times (setup and run time scaled per board)

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Assumption: One board needs the process time of one panel (and not 0.125)

Standard production times
Scaled for 1 board
Setup [min] Run [min]
Preparation
Artwork Generation
Inspecht & Shear
Ounch Tooling Holes
Image Transfer
Drill (Decision)
Manual
CNC Drill
Metallization
Dry Film Photoresit (Process)
Panel Prep
Laminate & Expose
Develop
Electroplate
Strip DFPR
Etch & Tin Strip
Fabrication
Soldermask
Solder Dip
Profile (Decision)
Punch press
CNC Router
Inspect, Test, Pack

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Scaled for >= 8 boards
Setup [min] Run [min]

29
20
10

0
0.5
0.5

29
20
10

0
0.0625
0.0625

15
240
10

40
2
0.75

15
240
10

40
2
0.09375

5
20
20
25
5
10

0.2
2
0.2
8.5
0.2
0.2

5
20
20
25
5
10

0.025
0.25
0.025
1.0625
0.025
0.025

45
30

1.5
0.5

45
30

0.1875
0.0625

50
150
45

1
0.5
1.5

50
150
45

1
0.5
1.5

4!

Appendix IV: Total operation time results for the order sizes 1, 8, 200 and 800

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Operation times [min]

Time of Operation

1 Board (1 panel) 8 boards (1 panel) 200 boards (25 panels) 800 (100 panels)
Preparation
Artwork Generation
Inspecht & Shear
Ounch Tooling Holes
Image Transfer
Drill (Decision)
Manual
CNC Drill
Metallization
Dry Film Photoresit (Process)
Panel Prep
Laminate & Expose
Develop
Electroplate
Strip DFPR
Etch & Tin Strip
Fabrication
Soldermask
Solder Dip
Profile (Decision)
Punch press
CNC Router
Inspect, Test, Pack
Time per order [min]
Time per board [min]

Observations:

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29
20.5
10.5

29
20.5
10.5

29
32.5
22.5

29
70
60

10.75

256
10.75

640
28.75

1840
85

5.2
22
20.2
33.5
5.2
10.2

5.2
22
20.2
33.5
5.2
10.2

10
70
25
237.5
10
15

25
220
40
875
25
30

46.5
30.5

46.5
30.5

82.5
42.5

195
80

51

58

46.5

57

250
345

550
1245

396.55
396.55

615.05
76.88125

1840.25
9.20125

5369
6.71125

55

Order size of 1:
Order size of 8:

We use manual drilling & the manual punch press
We use the CNC Drill & the manual punch press
We use the CNC drill. However, we are indifferent between
Order size of 200: using the manual punch press & the CNC Router
Order size of 800: We use the CNC drill & the CNC Router

5!

Appendix V: Capacity in the DFPR area

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Scaling
Order size = 8
DFPR (Process)
Panel Prep
Laminate & Expose
Develop

Production Time
Setup [min] Run [min]
Unit
5.00
0.20
per panel
20.00
2.00 per panel
20.00
0.20 per panel

Time per panel

Order size = 80
DFPR (Process)
Panel Prep
Laminate & Expose
Develop

Production Time
Setup [min] Run [min]
Unit
0.50
0.20
per panel
2.00
2.00 per panel
2.00
0.20 per panel

Time per panel

Order size = 800
DFPR (Process)
Panel Prep
Laminate & Expose
Develop

Production Time
Setup [min] Run [min]
Unit
0.05
0.20
per panel
0.20
2.00 per panel
0.20
0.20 per panel

Time per panel

5.20
22.00
20.20

0.70
4.00
2.20

0.25
2.20
0.40

Capacity Calculation
Order size = 8
DFPR (Process)
Panel Prep
Laminate & Expose
Develop

Capacities (panels)
Per hour
Per day
11.54
92.31
2.73
21.82
2.97
23.76

Capacities (boards)
Per hour
Per day
92.31
738.46
21.82
174.55
23.76
190.10

In orders

Order size = 80
DFPR (Process)
Panel Prep
Laminate & Expose
Develop

Capacities (panels)
Per hour
Per day
85.71
685.71
15.00
120.00
27.27
218.18

Capacities (boards)
Per hour
Per day
685.71
5485.71
120.00
960.00
218.18
1745.45

In orders

Order size = 800
DFPR (Process)
Panel Prep
Laminate & Expose
Develop

Capacities (panels)
Per hour
Per day
240.00
1920.00
27.27
218.18
150.00
1200.00

Capacities (boards)
Per hour
Per day
1920.00
15360.00
218.18
1745.45
1200.00
9600.00

In orders

92.31
21.82
23.76

68.57
12.00
21.82

19.20
2.18
12.00

Bottleneck explanation
The Laminate & expose process is always the bottleneck in this area
If the order size is 8 boards, a bottleneck arises if the quantitiy exceeds 21 orders
If the order size is 80 boards, a bottleneck arises if the quantitiy exceeds 12 orders
If the order size is 800 boards, a bottleneck arises if the quantitiy exceeds 2 orders

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6!

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