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Productivity Improvement using Work Study Techniques at Assembly Work Station

Authors:
  • KLE Technological University (Earlier BVB College of Engg and Tech)-Hubballi, Karnataka, India

Abstract

This work is intended to study the cycle time and existing method of different work stations and suggesting improved method for the same so as to reduce the cycle time and to improve productivity at Vaibhav Vidyut Company Private Limited, Hubli. During the plant visit and discussions made with the proprietor and also according to the operation process chart put up in the early study, it was found that the inefficient time associated with the assembly area is more. Hence the assembly section was selected for work study. The importance of this work is directly related to the reduction of the inefficient time and increasing the productivity. The new approach of studying the operations by Video work study techniques is the first of its kind in Hubli. The advantages of this project lies in the improvement of the productivity by reducing the cycle time, smooth flow of components for assembly, reducing the worker fatigue, suggesting new methods and installing it.
... Here the method, i.e. how the work is executed, is investigated. Thereafter, the recorded data are analysed utilising the questioning technique (Kulkarni, 2014) in order to develop an improved method of working. This is called the proposed method. ...
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Purpose The purpose of this article is to demonstrate that basic interventions using method study investigations can improve productivity in the workplace. Continuous improvement of operational processes allows an organisation to develop its capabilities to keep it ahead of its competitors. Design/methodology/approach A mixed-methods approach was used as the research design of the study. It involved an intensive method study investigation at a tap manufacturer to improve productivity. Structured searches using keywords were carried to identify important contributors to research articles in the areas of work-study, method study and productivity. Findings The empirical results indicate the essential need for method study investigations to improve productivity in organisations. It can be concluded that the systematic implementation of this methodology will ensure that productivity is enhanced in organisations. Research limitations/implications The research is restricted to a single manufacturing organisation. Literature on method study was found to be limited. Practical implications This research is intended to support organisations by providing a methodology to address areas of inefficiency and also to assist with subsequent turnaround strategies to ensure organisational effectiveness and sustainability. Originality/value The essential contribution that this article makes is that it provides organisations with a universally accepted, user-friendly technique to improve organisational effectiveness and productivity with minimal capital outlay.
... A general term for method study and work measurement which are used in the analysis of human work in all its circumstances, and which leads to the exploration of all factors which influence the efficiency and economy of the situation being reviewed, in order to effect improvement [1]. The effect of Work study has been addressed by a number of researchers: Darshan et al. [3] used video work study technique to reduce the cycle time and to suggest a new improved method at assembly work station of valve industry by using the work pro software. Murshida Khatun came up with comparison between the productivity and efficiency before and after applying work study techniques [4]. ...
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The work is carried out to determine the cycle time to produce rolling shutter and propose a better method to reduce the cycle time of the same using work study techniques and also recommend the ways to reduce fatigue level of worker using Ergonomics approach at metal section industry. As the manufacturing process does not have efficient work procedure and workers are exaggerated by unwanted fatigue, so the industry is not able to improve productivity. Thus, the purpose of this work is to suggest improvement areas to improve its productivity and efficiency by analyzing the problems associated with it. Identified problems were solved by video work study technique. An improvement in industry was achieved by minimizing the cycle time, changing the sequence of operation and reducing the workers fatigue. Work pro software is used for analyzing the data and to develop the proposed method. Keywords: Method study, Time study, Standard time, Video work study and Ergonomics.
... The advantage of productivity improvement using work study techniques at assembly work stations is achieved by reducing cycle time by providing smooth flow of components for assembly. This helps in reducing the worker fatigue and suggesting new methods for smoother work flow [7]. ...
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The lean manufacturing technology is most effective and efficient manufacturing concept which is used to improve the productivity with high quality. Based on lean manufacturing concept, the project is carried out in LCV assembly shop at one of the reputed automobile companies located in North Karnataka-India. Work standardization study is carried out and motion study is made by using Yamazumi sheet, Standardized work combination table (SWCT) and Standardized work sheet (SWS). Based on data collection number of line stoppages per day in assembly stations are identified. Among those stations critical station is being identified and using lean tools like kaizen and 5s techniques the improvements are made in those critical stations to reduce cycle time and number of line stoppages per day. The Ergonomics study and analysis is carried out as a part of this case study project to know how kaizen improvement reduces Work-related Musculoskeletal Disorders (WMSDs). After improvements in critical station. Non value adding activities are reduced and therefore 4% of cycle time is reduced and number of line stoppages per day is reduced by 33% in LCV assembly shop.
Chapter
One of the factors affecting the productivity of any manufacturing firm is the Cycle time. Lesser the cycle time required, the more production is obtained. Motion and time study techniques are used as productivity improvement techniques in many manufacturing firms. This case study was conducted in a manufacturing firm, situated at Satara, western India, which is engaged in the manufacturing of machines used for construction work. In this study, an attempt was made to reduce the assembly time of crusher machine, using time and motion study. After conducting this study, assembly time was reduced by 9 m, i.e., 10.71% reduction in cycle time was achieved. Work measurement also helped in proper planning of various tasks and scheduling, in order to reduce the indirect costs like electricity bill and rent, etc.
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In order to survive in this perpetually growing market, it's essential for a firm to specialize in continuously improving productivity. All organizations have joined the world economic competition to capture the world market to stay profitable and competitive. Productivity is a crucial factor in the production performance of a firm. Productivity growth is essential to the firm as a result of which it will meet its obligations to employees, shareholders, and governments (taxes and regulation), and still stay competitive or maybe improve its aggressiveness within the market place. This paper aims to consolidate knowledge regarding the important techniques and methods utilized within the current market scenario to increase productivity throughout a firm. The various techniques mentioned are, Time Study, Motion study, Line Balancing, Work Study, Kanban and 5S. This paper additionally aims to consolidate data on the various necessary techniques that are accustomed to attain an improved level of productivity. The various aspects of every technique and their impact on the performance of a firm are discussed thoroughly.
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