Implementation of Lean System on Erbium

Topics: Manufacturing, Lean manufacturing, Toyota Production System Pages: 22 (5962 words) Published: April 29, 2013
Implementation of Lean System on Erbium Doped Fibre Amplifier Manufacturing Process to Reduce Production Time T. Maneechotea and P. Luangpaiboonb
Industrial Statistics and Operational Research Unit (ISO-RU), Department of Industrial Engineering, Faculty of Engineering, Thammasat University, 12120, THAILAND. (email: Thiti.Maneechote@gmail.com) b Industrial Statistics and Operational Research Unit (ISO-RU), Department of Industrial Engineering, Faculty of Engineering, Thammasat University, 12120, THAILAND. (email: lpongch@engr.tu.ac.th) Abstract. A manufacturing process of erbium doped fibre amplifiers is complicated. It needs to meet the customers’ requirements under a present economic status that products need to be shipped to customers as soon as possible after purchasing orders. This research aims to study and improve processes and production lines of erbium doped fibre amplifiers using lean manufacturing systems via an application of computer simulation. Three scenarios of lean tooled box systems are selected via the expert system. Firstly, the production schedule based on shipment date is combined with a first in first out control system. The second scenario focuses on a designed flow process plant layout. Finally, the previous flow process plant layout combines with production schedule based on shipment date including the first in first out control systems. The computer simulation with the limited data via an expected value is used to observe the performance of all scenarios. The most preferable resulted lean tooled box systems from a computer simulation are selected to implement in the real process of a production of erbium doped fibre amplifiers. A comparison is carried out to determine the actual performance measures via an analysis of variance of the response or the production time per unit achieved in each scenario. The goodness of an adequacy of the linear statistical model via experimental errors or residuals is also performed to check the normality, constant variance and independence of the residuals. The results show that a hybrid scenario of lean manufacturing system with the first in first out control and flow process plant lay out statistically leads to better performance in terms of the mean and variance of production times. Keywords: Erbium Doped Fibre Amplifier, Lean Manufacturing, Computer Simulation, Flow Process Plant Layout, Analysis of Variance. PACS: 07.05.Tp a

INTRODUCTION
The excellent optical amplifiers are available in forms of erbium doped fibre amplifiers (EDFA) and their uses were firstly reported in 1987 [1]. Currently, the EDFA are the most widely used and therefore these are taken as standard amplifiers in ATTACHMENT I all optical communication systems. They can serveFIRST PAGE OF EACH PAPER in the both as booster amplifier CREDIT LINE (BELOW) TO BE INSERTED ON THE transmitter and as preamplifier in the receiver [2]. EDFA offers several advantages when compared. They are commercially available in both C (the original frequency CP1285, IAENG Transactions on Engineering Technologies Volume 5, Special Edition of the International MultiConference of Engineers and Computer Scientists 2010, edited by S.-I. Ao, A. H.-S. Chan, H. Katagiri, and L. Xu © 2010 American Institute of Physics 978-0-7354-0839-5/10/$30.00

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allocation used for communication satellites) and L (the frequency long range between 390MHz and 1.55GHz used for communication satellites) and offer high gain with relatively low noise figure. However, the EDFA adds some complexities, such as a pump laser, to a system. Integration with other components is also required as shown in Figure 1. For a schematic process of the EDFA focusing on many components need to be integrated with fibre optic, these make a module assembly process is complicated. Today various industries are highly competitive due to the increasing market demand as well as the current economic climates make impact to every industry around the world,...

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