Title :
The effect of set management on just-in-time manufacturing
Author :
Federico, J.D. ; Waddle, C.A.
Author_Institution :
IBM Corp., Hopewell Junction, NY, USA
Abstract :
The authors describe the implementation of the set management concept at IBM in Hopewell Junction in 1990. Set management is designed to release a package of layers, which have been combined at the substock crib, into a substrate part number, significantly lowering material handling and inventory levels resulting in improved test yields. In the revolutionized set management approach, layer job release was triggered by a new software system which balanced sets. When completed each layer job was placed directly into the magazine from which it would be released into stocking, eliminating handling steps and kitting. Inventory reduction was immediately visible with inventory levels going from 30-40 days to less than 10 days. Implementation of set management led to a 7% improvement in yield, a 6× reduction in layer inventory, a 3× reduction in crib storage time, and multiple handling and inspection reductions. The savings to IBM amounted to over $12 million. Process change results are now seen on a real-time basis. Software was instituted to do daily inventory checks and ensure that the line is loaded with the correct mix of part numbers to meet the highest measure of serviceability possible
Keywords :
electronics industry; manufacturing computer control; production control; stock control; IBM; crib storage time; improved test yields; inventory reduction; just-in-time manufacturing; package of layers; set management; software system; substock crib; substrate part number; Ceramics; Glass; Inspection; Inventory management; Job shop scheduling; Laminates; Manufacturing processes; Packaging; Production facilities; Stacking;
Conference_Titel :
Electronics Manufacturing Technology Symposium, 1991., Eleventh IEEE/CHMT International
Conference_Location :
San Francisco, CA
Print_ISBN :
0-7803-0155-2
DOI :
10.1109/IEMT.1991.279762