•Problem Statement:
Current insert production planning process is inefficient, labor intensive, and does not account for new equipment
constraints and capabilities
–Scheduling is only
partially automated
–Requires manual hopper
selection, assembly line mapping, and job
assignments
–Requires long
lead-times to produce schedules
•Collator operation has multiple inefficiencies
–Feeding FSIs into
collator is labor intensive
–Changing hopper
contents for the next IPC is time and labor intensive
–Takes up to 3 minutes
to change hopper contents
–Usually 250 - 300 IPCs
per Sunday
–Line must stop during
change-over causing labor loss
–
•Introduction of new collator requires process
change
–Current planning
process does not account for changeover implications of new collator machine
–New collator provides
physical performance enhancements