a) Material Flow Process
Yield is the number of acceptable units at the end of the process divided by the number of starting pieces excluding scrap and rework.
Here we use the Material Flow Process to evaluate each individual process.
As per the given question the total unit is considered as X
Let us assume X as 100
It was provided in the question that the yield of processing station = 70%
Whereas the yield of Rework station = 30%
However, good parts from rework station is only 20%
Moreover,the cost of various process are given
such as processing = $30, Testing =15, Shipping =10, Rework = 20 ,Scrap =5 are also provided
We can draw process map using this information
Cost of each process is given in brackets
Yield equation
Yield = Process 1 +Process 4 - 10% or e-DPU Here DPU Means defective Product Units
b) If X = 2500
In Process 1 good yield = 70%
i.e., 2500* 70/100 = 1750 units
Then in process 4, 30% yield 2500 * 30/100= 750
out of 750 , 20% are good units hence 750*20/100 = 150 good units
So total Good PCB Units = 1750+150= 1900 units
c) Scrapped amount = Rework - Good units
Rework yield = 350
Out of that good units 150
Scrap = 350- 150 =200
Scrap value = 200 * 5 = 100
d) cost per PCB = Total unit/ Cost per unit
Cost per unit = $30+$15+$10+$20+$5 = $80
I.e., 2500/ 80 = 31.25
e) If recovery rate increased from 20 to 30 then yield will improve
from 1900 to 1975
i.e in process 4 30% yield of 2500 = 750 units
out of that 30% as good unit means 750*30/100 = 225
then total unit = 1750 + 225
= 1975
Problem 2 (50 points) (Quality-Yield-Costs) Consider a printer circuit board manufacturing process. After processing and electrical...
Pareto Chart and A report summarizing the costs, percent of total, and percent of sales by appraisal, prevention, internal failure, and external failure cost of quality categories.Cost of Quality Report for a Manufacturing Company The president of Mission Inc. has been concerned about the growth in costs over the last several years. The president asked the controller to perform an The study of employee effort and other business records to determine the cost of activities.activity analysis to gain a better...
Summary: A car part manufacturing company currently produce a suspension assembly for Toyota Motor Corporation. Figure 1 shows the breakdown structure of the suspension assembly and Figure 2 shows the final assembly and how to fit into a car. Table 1 shows the name of components, part numbers and number of components in each suspension assembly. Figure 1. Breakdown structure of Suspension Assembly Figure 2. Suspension Assembly Number in Figure 1 Part number Part name Amount per assembly 1 PA-T15-001...
How can we assess whether a project is a success or a failure? This case presents two phases of a large business transformation project involving the implementation of an ERP system with the aim of creating an integrated company. The case illustrates some of the challenges associated with integration. It also presents the obstacles facing companies that undertake projects involving large information technology projects. Bombardier and Its Environment Joseph-Armand Bombardier was 15 years old when he built his first snowmobile...