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PRODUCTIVITY ENHANCEMENT AND PROCESS WASTE ELIMINATION THROUGH THE USE OF MAYNARD OPERATION SEQUENCE TECHNIQUE BY SARAVANAN TANJONG TUAN A dissertation submitted in fulfilment of the requirement for the degree of Master of Science in Manufacturing Engineering Kulliyyah of Engineering International Islamic University Malaysia AUGUST 2014

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Page 1: PRODUCTIVITY ENHANCEMENT AND PROCESS WASTE …

PRODUCTIVITY ENHANCEMENT AND PROCESS

WASTE ELIMINATION THROUGH THE USE OF

MAYNARD OPERATION SEQUENCE TECHNIQUE

BY

SARAVANAN TANJONG TUAN

A dissertation submitted in fulfilment of the requirement for

the degree of Master of Science in

Manufacturing Engineering

Kulliyyah of Engineering

International Islamic University Malaysia

AUGUST 2014

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ABSTRACT

To sustain in business under the current fierce competition a company needs to

explore all avenues of improvement. In this respect, reduction or elimination of idle

and/or down time in operations and improvement of the working methods can play a

significant role. This research project is undertaken to address the problems and

challenges faced by an auto company in meeting the daily production target of a car

rear window assembly line. The operations performed in making this end product are

attributable to inefficient work methods with non-optimal capacity planning for

different workstations. In this respect Maynard Operation Sequence Technique

(MOST) is adopted to exploit the advantages of this PTS system in determining the

accurate work standard, analyzing job activity, planning capacity and manpower, and

designing workplace. This has helped in re-organizing and allocating jobs for work

balancing, and assessing the economic benefit through cost estimation of the existing

and proposed processes. Initial investigation shows that the whole assembly line has

been suffering from the absence of established standard time for activities carried out

by operators, the non-value added activities involved and the inefficient methods such

as manual screwing, unplanned aisle and walking distance, material wastages and

imbalance in the material flow. Subsequently, by application of MOST alternative

methods and work standards are developed which are conducive to capacity planning,

workplace layout design and manning analysis. Thus through the process flow

analysis, material handling and redistribution of activities among the four

workstations an improved process is designed and proposed. It has been revealed that

with this proposed method an enhanced workflow is achievable. Upon preliminary

introduction of the concept, it has been possible to reduce the production cycle time to

cater the higher level of demand with shorter takt time maintaining the current level of

manpower. As a result, the production rate is possible to be enhanced from the current

level of 54 units to 70 units per day with the suggested operational procedure. This

increased capacity is deemed to satisfy the daily production target of 66 units per day.

Thus this study also recognizes the effectiveness of the MOST technique to enable an

analyst to expose wastes and unproductive methods of work in a quicker manner and

help rectify problems at the workplace with an eventual improvement in productivity.

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(MOST) PTS

.

MOST

Takt

4507

66

MOST

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APPROVAL PAGE

I certify that I have supervised and read this study and that in my opinion, it conforms

to acceptable standards of scholarly presentation and is fully adequate, in scope and

quality, as a dissertation for the degree of Master of Science in Manufacturing

Engineering.

…………………………………..

A. N. Mustafizul Karim

Supervisor

I certify that I have read this study and that in my opinion it conforms to acceptable

standards of scholarly presentation and is fully adequate, in scope and quality, as a

dissertation for the degree of Master of Science in Manufacturing Engineering.

…………………………………..

Erry Y. T. Adesta

Internal Examiner

…………………………………..

A. K. M. Mohiuddin

Internal Examiner

This dissertation was submitted to the Department of Manufacturing and is accepted

as a fulfilment of the requirement for the degree of Master of Science in

Manufacturing Engineering.

…………………………………..

Md. Yusof Bin Ismail

Head, Advanced Engineering and

Innovation Centre

This dissertation was submitted to the Kulliyyah of Engineering and is accepted as a

fulfilment of the requirement for the degree of Master of Science.

…………………………………..

Md. Noor Bin Salleh

Dean, Kulliyyah of Engineering

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DECLARATION

I hereby declare that this dissertation is the result of my own investigation, except

where otherwise stated. I also declare that it has not been previously or concurrently

submitted as a whole for any other degrees at IIUM or other institutions.

Saravanan Tanjong Tuan

Signature…………………. Date …..................

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INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

DECLARATION OF COPYRIGHT AND AFFIRMATION

OF FAIR USE OF UNPUBLISHED RESEARCH

Copyright © 2014 by International Islamic University Malaysia. All rights reserved.

PRODUCTIVITY ENHANCEMENT AND PROCESS WASTE

ELIMINATION THROUGH THE USE OF MAYNARD

OPERATION SEQUENCE TECHNIQUE

No part of this unpublished research may be reproduced, stored in a retrieval system,

or transmitted, in any form or by any means, electronic, mechanical, photocopying,

recording or otherwise without prior written permission of the copyright holder except

as provided below.

1. Any material contained in or derived from this unpublished research may

be used by others in their writing with due acknowledgement.

2. IIUM or its library will have the right to make and transmit copies (print

or electronic) for institutional and academic purposes.

3. The IIUM library will have the right to make, store in a retrieval system

and supply copies of this unpublished research if requested by other

universities and research libraries.

Affirmed by: Saravanan Tanjong Tuan

……..……..…………… …………………..

Signature Date

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ACKNOWLEDGEMENTS

Thanks to God, with his will and blessings, I have been able to finish my dissertation

as the last module for the Master of Science in Manufacturing Engineering. I feel most

fortunate indeed, when given a chance and had a fruitful experience having done my

PG study at International Islamic University Malaysia. In this respect, first of all, I

would like to express my sincere appreciation and gratitude to my Supervisor, Prof.

Dr. A. N. Mustafizul Karim for his constant guidance, constructive suggestions,

encouragement, and his time in editing the chapters, during this long period in

preparation of this thesis. There are a number of people whose direct and indirect

support must be mentioned and in this regard I would like to extend my appreciation

to my co-supervisor Prof. Dr. A.K.M. Nurul Amin for his support and advice in ways

to improvise my studies and for having confidence in me throughout this period.

During the past few years, I have been through indescribable experience and it

would be difficult to achieve what I have today without the support from various

sources. I must recognize my lecturers who taught me the courses and transferred the

knowledge. My special thanks are due to Br. H. M. Emrul Kays and Br. Mekentichi

Abdesselam, PG students of MME department for being supportive in various phases

of this project. This study was conducted as a part of FRGS project (FRGS11-031-

0179) funded by Ministry of Higher Education (MOHE), Malaysia. I am grateful to

MOHE and RMC, IIUM.

Last but not least, I would like to thank my family members for their supports

and all my friends whom I have made from the beginning and along the way in IIUM.

Not forgetting all friends who gave me their sincere friendship. Thank you very much.

May God bless us all.

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TABLE OF CONTENTS

Abstract .................................................................................................................... ii Abstract in Arabic .................................................................................................... iii Approval Page .......................................................................................................... iv Declaration ............................................................................................................... v

Copyright Page ......................................................................................................... vi Dedication ................................................................................................................ vii

Acknowledgements .................................................................................................. viii List of Tables ........................................................................................................... xi List of Figures .......................................................................................................... xiii

List of Abbreviation ................................................................................................. xv

CHAPTER ONE: INTRODUCTION ................................................................. 1 1.1 General Background ............................................................................... 1 1.2 Productivity and Line Balancing ............................................................ 2 1.3 Brief Description of Most ...................................................................... 4

1.4 Problem Statement ................................................................................. 5 1.5 Aims and Objectives .............................................................................. 6 1.6 Scope of Work ........................................................................................ 7

1.7 Significance of the Study ....................................................................... 7

CHAPTER TWO: LITERATURE REVIEW .................................................... 9 2.1 Introduction ............................................................................................ 9 2.2 Work and Time Measurement Techniques ............................................ 9

2.2.1 Predetermined Motion Time System (PMTS) ............................. 10

2.2.1.1. MTM Method .................................................................... 11 2.2.1.2. MODAPTS Method .......................................................... 12 2.2.1.3. MOST Method .................................................................. 13

2.3 Advantages and Benefit of Most ............................................................ 26

2.4 Production Line Balancing ..................................................................... 27 2.5 Summary ................................................................................................ 30

CHAPTER THREE: RESEARCH METHODOLOGY ................................... 31 3.1 Introduction ............................................................................................ 31

3.2 Research Approach ................................................................................ 31 3.2.1 Approach in Implementation of MOST ....................................... 33 3.2.2 Method for Assembly Line Balancing ......................................... 36

3.2.3 Evaluation of production rate and Balancing Efficiency ............. 37 3.3.4 Economic Validation of the proposed modification .................... 38

CHAPTER FOUR: DATA COLLECTION AND ANALYSIS ........................ 40 4.1 Introduction ............................................................................................ 40 4.2 Company Profile .................................................................................... 40 4.3 Current Practices within the Rear Window Assembly Line .................. 41

4.3.1 Current Process Layout ................................................................ 41 4.3.2 Sequence of Operation ................................................................. 43

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4.4 Basic Steps of Assembling the Rear Window ........................................ 45

4.4.1 Workstation 1 ............................................................................... 45 4.4.2 Workstation 2 ............................................................................... 47

4.4.3 Workstation 3 ............................................................................... 49 4.4.4 Workstation 4 ............................................................................... 50

4.5 Work Element for Rear Window Assembly .......................................... 52 4.6 Overview of the Undertaken Assembly Line ......................................... 53 4.7 Takt Time of Rear Window Assembly (Present Situation) ................... 53

4.8 Line Balance Loss for Current Rear Window Assembly Operations .... 55 4.9 Summary of Current Situation Analysis ................................................ 56

CHAPTER FIVE: PROPOSED MODIFICATION IN AND ITS

IMPLICATION ...................................................................................................... 57 5.1 Introduction ............................................................................................ 57

5.2 Rear Window Assembly Operations ...................................................... 58

5.2.1 Workstation 1 ............................................................................... 58 5.2.2 Workstation 2 ............................................................................... 60 5.2.3 Workstation 3 ............................................................................... 63 5.2.4 Workstation 4 ............................................................................... 64

5.3 Possible Scope of Improvement ............................................................. 66 5.4 Proposed Modifications in the Assembly Line ...................................... 68

5.4.1 Proposed Plan for Tool use and Workflow .................................. 69 5.4.2 Proposed Changes for Layout Plan .............................................. 73

5.5 Assessment of Improvement in Productivity ......................................... 74

5.5.1 Proposed WorkStation 1 – Elemental Task Times ...................... 74 5.5.2 Proposed Workstation 2 – Elemental Task Times ....................... 75

5.5.3 Proposed Workstation 3 – Elemental Task Times ....................... 77 5.5.4 Proposed Workstation 4 – Elemental Task Times ....................... 78

5.6 Summary of the Resulting Improvements .............................................. 80 5.6.1 Demand Satisfaction .................................................................... 80 5.6.2 Production Rate Improvement ..................................................... 82

5.6.3 Line Balance Loss Evaluation ...................................................... 83

5.6.4 Economic Validation of Investment ............................................ 84 5.6.5 Summary ...................................................................................... 85

CHAPTER SIX: CONCLUSION AND RECOMMENDATIONS .................. 86 6.1 Conclusion .............................................................................................. 86

6.2 Recommendations .................................................................................. 88

REFERENCES ....................................................................................................... 90

APPENDIX 1 ........................................................................................................... 93 APPENDIX 2 ........................................................................................................... 94 APPENDIX 3 ........................................................................................................... 97

APPENDIX 4 ........................................................................................................... 100

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LIST OF TABLES

Table No. Page No.

‎2.1 Notations used for General Move Parameters 16

‎2.2 Controlled Move Parameters 20

‎2.3 Index Value for Crank in Controlled Move 21

‎2.4 Index Value for Machining Time 22

‎2.5 Index Value for Alignment in Controlled Move 23

‎2.6 Parameters in Tool Use Sequence 23

‎4.1 The time function mapping for the W/S-1 46

‎4.2 The time function mapping for the W/S-2 48

‎4.3 The time function mapping for the W/S-3 50

‎4.4 The time function mapping for the W/S-4 51

‎4.5 Work elements and times taken for workstation 1 52

‎4.6 Current activity time summary for rear window assembly 53

‎4.7 Takt Time calculation 54

‎4.8 Comparative scenario of W/S times 54

‎5.1 Activity times as estimated for the current workstation 1 58

‎5.2 Activity times as estimated for the current Assembly operation in

workstation 2 61

‎5.3 Activity times as estimated for the current Assembly operation in

workstation 3 63

‎5.4 Activity times as estimated for the current Assembly operations at

workstation 4 65

‎5.5 Summary of Standard Times for the four different workstations. 67

‎5.6 Proposed changes for Rear Window Assembly Line 70

‎5.7 Activity task times as estimated for the proposed workstation 1 74

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‎5.8 Activity task times as estimated for the proposed Workstation 2 76

‎5.9 Activity task times as estimated for the proposed workstation 3 77

‎5.10 Activity task times as estimated for the proposed fourth workstation 78

‎5.11 Takt Time calculation 80

‎5.12 Comparative scenario of W/S times 81

‎5.13 Economic evaluation of proposed changes 85

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LIST OF FIGURES

Figure No. Page No.

‎2.1 Evaluations of Work Measurement Methods 10

‎3.1 Flow chart of major activities of the research work 33

‎3.2 MOST Application process flow 35

‎4.1 Current layout of the undertaken assembly line 42

‎4.2 Five main assembly operations with on-line and offline tasks for rear

window assembly 44

‎4.3 Activity of fixing the channel rubber in frame (within workstation 1) 45

‎4.4 Fixing glass to frame in workstation 2 47

‎4.5 Applying silicon to frame corner for workstation 3 49

‎4.6 Preparation of frame for testing for workstation 4 51

‎4.7 Current line balance loss for rear window assembly 55

‎5.1 Activity task times in Minutes for workstation 1. 60

‎5.2 Activity Times in Minutes for Assembly Operations in workstation 2 62

‎5.3 Activity Times in Minutes for Assembly Operations of workstation 3 64

‎5.4 Activity Times in Minutes for Assembly Operations in workstation 4 65

‎5.5 Cycle times for the four workstations 68

‎5.6 Process flow chart with the online and offline assembly operations

operations 72

‎5.7 Proposed plan for process layout with four work stations 73

‎5.8 Activity times in minutes for Workstation 1 with proposed changes. 75

‎5.9 Elemental times in minutes for Workstation 2 with proposed changes 76

‎5.10 Activity times in minutes for workstation 3 with proposed changes 78

‎5.11 Activity times in minutes for workstation 4 with proposed changes 79

‎5.12 Comparative scenario for improvement 82

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‎5.13 Proposed Line Balance Loss Analyses 84

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LIST OF ABBREVIATION

ASSY

CDF

Assembly

Cost-related Design Features

HRS

LBE

LBL

MIN

Hours

Line Balance Loss

Line Balance Efficiency

Minutes

MODAPTS Modular Arrangement of Predetermined Time Standard

MOST Maynard Operation Sequence Technique

MTM Method Time Measurement

PCS

PMTS

Pieces

Predetermined Motion Time System

PTS Predetermined Time Standards

SOP Standard Operating Procedure

SWAG

TMU

WIP

W/S

Sophisticated Wild Ass Guess

Time Measurement Units

Work In Process

Work Station

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CHAPTER ONE

INTRODUCTION

1.1 GENERAL BACKGROUND

In today‟s world of advanced technology, business has become more diversified and

too competitive in securing its own market share. Moreover, with the introduction of

alternative products by competitors, it has become even much more difficult to keep

track with consumers‟ behavior as they make choices in a fragile manner. Thus,

measures have to be taken in order to sustain in the competitiveness of a business in

the market and at the same time try to achieve higher yield in profitability based on

enhancement of productivity in different spheres of operational activities. Among the

various phases of activities involved in the whole supply chain of a product, the level

of optimal resources in assembly or fabrication process largely influences the overall

productivity. Optimum utilization of manpower and other resources can be a great

challenge. Failure to meet customer demand is sometimes carefully measured in terms

of manpower required to carry out a particular task, leading to surplus and sometimes

deficit in achieving the production target. This situation indirectly affects the

profitability of a business because more wages would be required to pay but in return

there will not be any proportional gains.

To be more accurate in justifying the requirement of manpower for a task to be

performed, it is essential to systematically analyze the time required for completion of

all of its elements. It is often necessary to eliminate or reduce the duration of non-

value added part of the task elements to optimize a work system.

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This approach may need an organization rebalance its production system

through time study or work measurement which could allow to save the valuable time,

to reduce cost and eventually to become competitive in the market. Moreover,

modification of a task by incorporating a tool and rebalancing the work load may also

lead to reduce the production cycle time. Thus, simultaneous balancing within an

undertaken assembly line by readjusting the cycle time and rebalancing the workloads

among different work stations can result in higher production rate to satisfy the

stipulated customer demand on time.

This project has been undertaken to investigate the scope of making possible

improvement in productivity of an assembly line. In this respect a rear window

assembly line as run by a local auto company for a particular model of car has been

chosen for this investigative study. According to the current operational procedure

practice and by using the existing facilities of machinery and manpower, the company

often fails to reach the daily requirement of 66 pieces as per customer demand. The

achievable average production rate is slightly lower than the dictated by the takt time.

At present, four employees are engaged in this production line to assemble the rear

window. Initiative is necessary to enhance the production rate by utilizing the existing

resources without sacrificing the quality of the product or by incorporating any major

additional resources in the assembly.

1.2 PRODUCTIVITY AND LINE BALANCING

There are various methods that can be applied for productivity improvement.

Assembly line balancing is one of such approaches. A simple process design criterion

is to balance the assembly line so that each workstation takes approximately the same

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amount of time. A balanced line often means better resource utilization and

consequently lowers production cost.

Line balancing is a classical problem for both the Operations Management and

Research. To retrieve the balance in assembly line, first, the line designer or the

manufacturing engineer should construct a process flow showing all work elements

and their precedence relations. Then, after defining the cycle time, it is necessary to

group work elements into a number of workstations such that (i) the precedence

relations are preserved, i.e., no work can be started unless all its preceding work

elements are completed, and (ii) the workstations time does not exceed the cycle time.

Value stream mapping is another approach through which non-value added activities

can be eliminated or reduced.

In fact, whatever method is adopted, it is essential to measure the work being

performed in each workstation of the assembly line. Thus, work measurement

techniques are necessary to precisely determine the task time of various operation in

the assembly process. For current situation the highest operation time at a workstation

is 9.5 minutes. But the target should be 7.8 minutes, based on customer requirement

and available working hours per day. Since the accomplishment of time study during

the real working time is likely to the production perturbation, stoppage of the process

and valuable time wasting, the Predetermined Measurement Time Standards (PMTS)

are now-a-days widely adopted. Maynard Operation Sequence Technique (MOST) is

one of such systems through which estimation of operation time can be done quiet

precisely.

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1.3 BRIEF DESCRIPTION OF MOST

As mentioned earlier, Maynard Operation Sequence Technique (MOST) is a form of

Predetermined Measurement Time Standards (PMTS). In MOST analysis

considerable efforts are made to simplify the work measurement method of the tasks

involved. In this respect a variety of higher-level Method Time Measurement (MTM)

data systems have been developed and which are now widely adopted in practice. This

attitude also leads us to examine the whole concept later to be known as MOST. For

overwhelming majority of work, however, there is a common dominator from which

work can be studied.

This common dominator is the displacement of object. All basic units of work

are (or should be) organized for the purpose of accomplishing some useful results by

simply moving the objects. Movements of objects follow a certain number of

consistently repeating patterns, such as reach, grasp, move, and position the objects.

These patterns are identified and arranged as a sequence of events followed in moving

an object. The process when the objects are picked up and moved freely through the

space is known as general move, and when the objects are moved maintaining contact

with another surface is called the controlled move. For each type of move, a different

sequence of events occurs as a result of the application of the two separate activity

sequence models.

General Move Sequence and Controlled Move Sequence are the two basic

sequences. For use of common hand tools there exists an additional sequence that is a

combination of these two basic sequences are Tool Use Sequence. Sequences have a

firm structure of parameters that represent single sub-activities.

Maynard operation Sequence Technique (MOST) acts as a family of tools.

Depending on the type of activities (building of ships, electronic assembly, etc),

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MOST can be used to conduct work measurement economically. Moreover, MOST

can guarantee the overall accuracy the time standardization. It dramatically decreases

applicator deviations through pre-printed sequence models. During the procedure of

analysis, the applicator‟s attention is focused on each sequence model parameter as

the calculation sheet is filled out and thereby it solves problems with documentation.

For instance, for a more detailed system, it requires about eight to twenty times more

pages of documentation. Thus, the MOST System is designed to assist an industrial

engineer to become more productive on the job of productivity enhancement. It is

based on concept keywords that represent type of grasping, movement and positioning

in sequence. It enables greater speed, carries out standard calculations, sets and

maintains complete labor time standards, and then updates data and standards.

Because of its simpler structure, the MOST is found to be much faster

compared to other work measurement techniques. Predetermined motion time systems

are traditionally based on assigning selected data from tables. The values are then

added together to arrive at the time for performing the complete operation.

1.4 PROBLEM STATEMENT

As mentioned earlier, with the current fierce competition in business, a company,

irrespective of what its products are, is driven to find the best way to ensure proper

utilization of the available resources and to improve work practices if there were any

scopes. A common and obvious option is to examine the current working methods

with a view to reducing or eliminating any idle and/or down time prevailing in the

operations.

The problems and challenges the company under study is facing are not

different from this kind of situation and are attributable to lack in capacity planning to

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execute the activities required for rear window assembly and their distribution among

the various workstations. Due to the inadequate focus in method analysis and

implementation of the standard time for the tasks to be carried out by the operators,

the non-value added activities in the operations such as manual screwing, extra

walking distances by the operators in shop floor, imbalance in the work load among

the various workstations are quite prevalent in the production system. The usage of

work measurement techniques is helpful for setting up time standards. However,

timing by direct observation and rating can sometimes lead to inconsistency and it

becomes impossible to benchmark correctly the time standards with those of the

competitors. To overcome this problem, implementation of MOST technique could be

an appropriate approach in streamlining the activities involved in rear window

assembly to lead to a balanced production line.

1.5 AIMS AND OBJECTIVES

This project work, by application of the MOST technique in a Rear Window assembly

line, aims at accomplishing an in-depth study with the following objectives:

1. To develop the time-function mapping on the basis of observing the

assembly operations currently performed in various workstations

recording the elemental times of the tasks.

2. To investigate and identify the bottlenecks and the non-value added

activities in the process of the assembly line.

3. To critically analyze the process by applying the MOST for work and time

standards and determine the scope rebalancing the workload and

readjusting the cycle time

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4. To balance the assembly line with the proposed modification and assess

enhancement of productivity and make suggestions for educating the

operators through standard operation procedures.

1.6 SCOPE OF WORK

The project has been initiated as an attempt to develop a working procedure to

enhance productivity of the rear window assembly which includes the following

activities:

1. To determine standard time using Maynard Operation Sequence

Technique for all the processes.

2. To collect appropriate data on production achievement history

3. To conduct the line balance analysis

4. To propose ideas on improvement of jigs and tools and process

rebalancing.

5. To suggest to re-arrange the production line and manpower segregation

6. To undertake a line trial and review of results.

7. To standardize the operation procedure.

1.7 SIGNIFICANCE OF THE STUDY

Accomplishment of this project has multiple impacts with respect to operational

improvement of a local industry, development of indigenous capability, gain of

knowledge and experience in applying MOST technique. Development of proper

work methods and standards, improved material handling and process workflow are

expected to guarantee better utilization of the available resources and render a

competitive edge for the manufacturer. Dissemination and replicating of this

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experience and knowledge in enhancing productivity to similar industries will

eventually improve the overall economy of the country.

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CHAPTER TWO

LITERATURE REVIEW

2.1 INTRODUCTION

In this chapter, the history, the salient features and the concurrent research activities

on work and time measurement techniques, as well as the production line balancing

concepts are briefly discussed with an underlined aim of enhancing the assembly line

balancing productivity chosen for the thesis.

2.2 WORK AND TIME MEASUREMENT TECHNIQUES

Inside most of the manufacturing industries, the owner can expand their market share

and increase the profitability through the incorporation of productivity improvement.

The term productivity improvement refers to the increase in output per work-hour. To

do so, most of the production shop floor managers are often found to be interested in

adopting the work and time measurement techniques, work design etc., which are also

considered as a tool of production planning. (Niebel & Freivalds, 1999). In his book,

Zandin defined the work measurement as (Zandin, 2003), it is the way of measuring

the time required by an experienced and/or well trained operator to perform a job in a

specific working method at a such speed that he can maintain consistently during his

working periods and without undue fatigue. Generally, these methods are used to

eliminate wastes, reduce operational costs and increase productivity by setting up the

standard time of accomplishing the tasks (Cross, 2008).

Apart from these, the work measurement techniques are also found to be

helpful in determining and rebalancing the work load within the workstations of the

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assembly line, defining the number of required operators for each of the workstations

etc. This as a result, helps to give up a proper production scheduling and capacity

planning (Almal & Agarwal, 2008). In the work of Mundel, the work measurement

techniques are found to be helpful for improving the work flow, delivering the high

quality products, upgrading the work schedule, allocating material and human

resources efficiently, enhancing the planning and capabilities including more reliable

budget and forecast (Mundel,1996). Additionally, to dig out and illustrates the in-

depth knowledge about the work measurement methods, the process of its evaluation

is shown in Figure 2.1 and some of them are briefly discussed in following sub

sections:

Figure ‎2.1 Evaluations of Work Measurement Methods

2.2.1 Predetermined Motion Time System (PMTS)

The Predetermined Motion Time systems are widely used in the field of work

measurement to estimate the time needed by qualified workers to perform a particular