Improving unbalanced workload between production shifts: a case study of Company J

Abstract

Company J in Vietnam is one of the most pivotal players in the international electronics supply chain for J Inc. However, in recent instances, the SE Work cell within the company appears to exhibit deteriorated performance levels. This manifests in three different symptoms: decreased gross margins excluding the cost of labor, incurring higher levels of overtime costs, along with fluctuating numbers of defects every shift. Using the Problem Solving in Organizations (PSO) framework, this study examined these issues through interviews with managers, engineers, and operators, supported by secondary operational data and benchmarking. Initial analysis pointed towards an inclusive combination of problem areas encompassing instability in the plan, issues pertaining to the capabilities of the workforce members, along with inadequacies in the manual processes. After bringing all the validation findings together, the evidence points to ineffective training as the central issue across the entire workflow. The current approach is informal, inconsistent, and depends too much on a small group of experienced operators. This leads to uneven skill levels, slower adaptation to process changes, and a growing reliance on overtime to keep operations running. Strengthening the training system within the Work cell is crucial for stabilizing operations and improving overall performance.