research paper: productivity improvement in a centralized warehouse

“You may delay, but Time will not”-Benjamin Franklin

IMPROVEMENT OF PRODUCTIVITY IN A CENTRALIZED WAREHOUSE THROUGH

APPLICATION OF MAYNARD OPERATION SEQUENCE TECHNIQUE (MOST)

Faizan Ali Sayyed, Rishabh Chaudhary,Lakshaman Suthar,Deevyasu Randive,

(Department of Industrial Engineering)

Outline• Abstract• Introduction• Literature• Maynard Operations Sequence Technique (MOST)• Case Study: Company Profile, Working• Case Study: Problems identified, Objective and

Methodology• Conclusion• References

Introduction• In today’s era- difficult to manage the resources and need

to optimize• Manpower utilization • Affect of manpower utilization on profitability• Work measurement• PMTS• History of Work

Literature ReviewYear Scientist Work

1760 Jean Rodolphe Perronet Extensive time studies

1820 Charles W. Babbage Time Study in manufacturing

1881 F. W. Taylor Origin of Time Study

1903 Refined Time Study

1920 F. Gilbreth Motion Study, Micro-motion Study

1938 J.H. Quick, W.J. Shea, R.E. Koehler Work Factor System

1948 H.B. Maynard, G.J. Stegermerten, J.L. Schwab

Methods-time measurement

1972 H.B. Maynard Maynard Operations Sequence Technique

• WFS adds factor to time value to give accurate time standard

• MTM analyzes different elements of manual work• Both are complex, require expertise and knowledge

• MOST: revolutionary, easy to use, faster, universal• Analyze variable factors and allocate appropriate time

values

MOST• Types of MOST:

1. Basic MOST2. Maxi MOST3. Mini MOST 1. 2. 3.

• Sequence of Actions in MOST• General Move (ABG ABP A)

Notations A B G P

Description Action Distance Body Motion Gain Control Placement

• Control Move (ABG MXI A)

• Tool Use (ABG ABP TU ABP A)

Notations A B G M X IDescription Action

DistanceBody

MotionGain

ControlMove

ControlledProcess

TimeAlignment

1 TMU = 0.00001 hour

1 hour = 100,000 TMU

1 TMU = 0.0006 minute

1 minute = 1667 TMU

1 TMU = 0.036 second

1 second = 27.8 TMU

CASE STUDYKomal Foods, Haldiram’s International Limited

Company Profile • Sweets and snacks• Established by Shivkisan Agrawal in 1970• Over 200 different types of products• 13 Plants in Nagpur, 1 central warehouse• Ranked 55th among India's most trusted brands (True Search Advisory)

• Established in 2007• Right next to the biggest Haldiram’s plant Kasana• Covers central India and exports• 120 workers, operates under 16 supervisors • 60,000 live stock daily

Komal Foods Warehouse

WORKING• Layout• Working Process• Techniques used

Layout

Layout for Warehouse, Komal Foods: (a) Ground Floor

• 3 Storey building, Allocation, Dispatch

Online conveyor from Kasana

DP1 DP2 DP3 DP4 DP5

Layout

Fig. Layout for Warehouse, Komal Foods: (a) First Floor

Online conveyor from Kasana

SC1

SC2 SC3 SC4

SC5

SC6

Working Process• Usually 5-6 workers are needed at each dispatch point• Variation in Carton Sizes and weights• Online Conveyor• Order Processing• Material Handling

Fig. a pallet jack, a belt conveyor, and a spiral conveyor 

Stocking

Palletizing

Cross check by supervisor

Material Description is checked

Unloading from truck/conveyor

Delivery note is checked

Loading

Quantity check by driver and worker

Material check by Supervisor

Palletizing and Moving stock to dispatch point

Registration (name, Qtty., Truck details, Invoice, etc.)Material

Description is checked

Delivery note is received

Loading and Unloading process at the warehouse

Techniques used

Techniques Used were: Stopwatch Time Study Maynard Operations Sequence Technique

Problems Identified• Occurrence of delay while loading and unloading of

pallets• More production than required• High frequency of accidents• Manual and Orthodox Working style• Lack of flow of information• Lack of training• Space Allocation• Ergonomics: Bend and Arise

OBJECTIVETo find out the problems associated with the delays in movement of goods and propose solutionsTo ensure smooth flow of goods and information

METHODOLOGYStopwatch StudyMOST Study

Stopwatch Study• A 80% rating factor was considered for all the operations,

under the supervision of Warehouse supervisors, and 4% fatigue allowance and 5% personal allowance was considered.

• Normal Time = Observed Time X Rating Factor• Standard Time = Normal Time + Allowances

1. Time study for loading a pallet:(66 observations, 1817 cartons, average weight 12.91 kg observed time 4.71 secs)

Standard time = 4.11 secStandard time for loading a pallet from conveyor (30

cartons) = 123.21

2. Time study for movement of the pallet: (100 observations, 2804 cartons, average distance 41.59 meters, observed time 93.68 average weight 12.68 kgs)

Standard time = 81.62 sec

3. Time study for loading material in a truck, at the dispatch point:

(80 observations, 2,144 cartons, average weight 12.55 kgs, observed time 4.49 seconds)

Standard time = 3.91 secStandard time for loading a pallet into the truck (30

cartons) = 117.3 secArranging the carton in truck requires additional

179.2 seconds Total Loading time = 296.5 sec

MOST Analysis

Activity MOST analysis TMU

Grasp a carton and place at the base of pallet

(A1B0G3 A1B3P3 A0)x6 660

Grasp carton and place above two layers

(A1B0G3 A1B0P3 A0)x6 480

Place with blindness/ obstruction by body adjustment

(A1B0G3 A1B16P6 A0)x3 810

    1850*0.036= 66.6 sec

1. MOST analysis for Loading of cartons (30 cartons) on the pallet from the long belt conveyor is as follows:

Activity MOST analysis TMU

Position tiger beneath the pallet and engage the pallet with it.

(A3B0G0 M16X0I1 A0) 200

Push 40m(6-9 steps) (A0B0G0 M16X0I0 A0)X8 1280

Disengage and place pallets

(A0B0G0 M1X0I0 A0) (A0B0G0 A6B0P1 A0)

80

    1560*0.036= 56.16 sec

2. MOST analysis for Movement of the pallet from the long belt conveyor to the point of storage is as follows:

(Consider 40m and 30 cartons)

Activity MOST analysis TMU

Get a carton from the top of pallet

(A1B0G3 A3 B0 P1 A1)*12(A1B3G3 A3 B0 P1 A1)*6(A1B6G3 A3 B0 P1 A1)*12

1080720

1800

Push 40m(6-9 steps) (A1B6G3 A6 B6 P1 A6)*16(A1B6G3 A6 B3 P1 A6)*8(A1B6G3 A6 B0 P1 A6)*6

464020801380

    (11700/2)*.036=210.6sec

3. MOST analysis for Loading of cartons from the pallet into the truck is as follows

CONCLUSIONComparative Study

Loading of cartons from conveyor

Movement of pallet Loading of cartons into the truck

0

50

100

150

200

250

300

350

Stop watchMOST

Fig. Comparative Graph for Improvement

Time(secs)

Conclusion• Reducing the gap between expected and observed time• Production Planning and Economic Production• Safety of workers as well as products• Flow of information• Automation• Training and Educating the labors

References1. Pramandra G. and Saurabh S.(2012). To improve work force productivity in a

medium size manufacturing enterprise by MOST Technique issuu.com/iosrjen/docs/b02103081

2. A.N.M. Karim, S. T. Tuan, “ Improvement of Workflow and Productivity through Application of Maynard Operation Sequence Technique (MOST)”, Department of Manufacturing and Materials Engineering International Islamic University Malaysia, International Conference on Industrial Engineering and Operations Management, Bali, Indonesia, January 7 – 9, 2014

3. A Pandey, V S Deshpande, “Application of Maynard Operations Sequence Technique”, Department of Industrial Engineering, Shri Ramdeobaba College Of Engineering and Management, Nagpur, Maharashtra, India, InternationalJournal of Innovations in Engineering and Technology

4. Maynard Operation Sequence Technique at https://en.wikipedia.org/wiki/Maynard_Operation_Sequence_Technique ( accessed on May, 2016)

5. Introduction to Work measurement at http://nptel.ac.in/courses/112107142/part1/lecture8.htm ( accessed on May, 2016)

THANK YOUAny Questions?