TESC Final Project for Productivity Measurement, Fall 2011. Note: The embedded video will not play unless I pay the web site, so follow the link in the references. -Roy & Ridhdhi

1. Lean Manufacturing the iPhone Plastic Case
By Roy Jones & Ridhdhi Upadhyay
(There are accompanying notes.)

2. Pillbox, Inc.
J & U Consulting
-Ridhdhi Upadhyaya – An experienced technologist
trained at the New Jersey Institute of Technology &
Thomas Edison State College. Worked on projects for
Rutgers and Mount Sinai Medical Center. Specialist in
outsourcing contract work to Western India.
-Roy Jones – An experienced project manager, led a team
of IT specialist upgrading 35 clients in 1999 for Y2K,
twenty years IT & healthcare experience. Experienced in
non-profits & Government Administration, trained at the
University of South Florida & Thomas Edison Sate
College.

3. Pillbox, Inc.
Issues to be Examined at Pillbox Inc.
-Low Morale of work force & management
-Lack of focus on quality
-Maintenance program to maintain quality
-Alternatives to current production scheme

4. Pillbox, Inc.
Are you ready for change?
-Phase I
-Week1 – Planning
-Site visit to Pillbox by J & U Consulting
to include staff interviews
-Development of Project Plan & Goals
-Commitment of resources
-Scheduling & Project Scope

5. Pillbox, Inc.
-Phase I
-Week2 – Planning
- Mr. Upadhyaya to do on site visits in
Western India.
-Mr. Jones to complete benchmarks of
existing production at Pillbox Inc.

6. Pillbox, Inc.
-Phase I
-Week3 – Planning
- Final Planning Meetings
- Resources, People, Schedules set
- Kick Off Meeting
Are you ready for change?

7.  -Phase II
 -Week4 – Pilot Project Begins
 - Streamlining the Design
Process
◦ - Design work in “Solid Works”
◦ - Test Kanban Strategy

8.  -Phase II
 -Week4 – Pilot Project
- Design Phase - 3D printed
prototype
- Testing the Mold Design, a video

 Click on this video

9.  -Phase II
 -Week5 – Pilot Project
◦ - Maintaining Quality with a
◦ Quality Maintenance Program
◦ - Confirm Kanban Strategy

10.  -Phase II
 -Week6 – Revised Pilot Project
 - The Need for Feedback & revisions
 to the Pilot Project
 - Test Production runs
 - Maintenance Quality Goals Set

11.  -Phase III
 -Week7 – Go Live
 - Move Changes to Production
 - Ramp up the Speed
 - Invoke Improved Maintenance
 - Post Live Feedback
 -Continuous Improvement

12.  -Phase III
 -Week7 – Post Go Live
◦ -”Final” Revisions
◦ - “Last” Benchmarks
◦ -Last Meeting with J & U
-But there is an alternative and it’s
motivational to all staff………….

13.  Why manufacturing iPhone cases in India is better
than at home.
 1) With many different looks and designs Indian
companies provide more marketing options.
 2) A company named Fommy carries an extensive
collection of cases for iPhones, Nokia phones, and
many others manufactured by Amzer.

14.  3) Another company named Pielframa makes only
pure leather cases for iPhones and many other
phones.
 4) They provide embossed lettering with different
information on the type and different colors.

15.  5) COST -Lowest price for an iPhone case in an
Apple store in USA is about $30-$35.
 In India, for the same case, it would cost less than
half of the cost here.
 The price by Fommy for the simplest case costs
about $3 USD = Rupees 199.00

16.  6) Company called Infocera in India is “the leading
manufacturer which supplies premium quality
cases and other necessary accessories for Apple
iPhones and BlackBerry kind of products” for Case-
Mate.
 7) Safety - Their new product “Bounce” is
specifically made for iPhone 4 and is said to reduce
radiation by 85%.

17.  8) Competition between different companies in
India results in lower market prices.
 9) Amzer, the manufacturer of the iPhone cases
and many others, provides cases which are made of
hybrid materials.
 Ex.: The manufacturer provides a case which is
made of silicone and metallic chromium, naming
the case - Hybrid Silicon.

18.  You have a choice to compete in the global
economy and keep all of the jobs where they are
now or to move production offshore and manage
the work from Pillbox Inc.
 What is your decision? Are you ready for change?

19.  References:
 http://blog.graftconcepts.com/2011/10/25/how-to-make-
an-iphone-case-part-2/#wpcom-carousel-33
 http://blog.graftconcepts.com/2011/10/24/how-to-make-
an-iphone-case-short-video/
 www.Fommy.co.in
 www.Pielframa.com
 www.Infocera.com (for) www.Cellularoutfitter.com
 www.Amzer.com

20. Lean Manufacturing the iPhone Plastic Case
By Roy Jones & Ridhdhi Upadhyay, J & U Consulting
777-555-1234, info@j&u.com