SAQIB ALI WAJID

Operations Coordinator (Assembling Unit # 4)

Work Study
The subject of work study covers the systematic investigation of human activities necessary to
perform a given task economically. It involves the study of factors, with effect the efficiency of
human activities. It is a management tool for improving the existing method and to establish
time standard for various jobs. Work study is classified into two areas.
v  Method study
v  Work Measurement
Method Study
It is the systematic recording and critical examination of existing and proposed way of doing
work as a means of developing and applying easier and more effective method.
Work Measurement
It involves the application of the time study technique designed to establish the time for
qualified worker to carry out specified job at a defined level of performance.
Objectives of Work Study
v  Find out the most economical way of doing work
v  To improve the workplace layout
v  Standardizing the methods, material, tools and equipment
v  Accurately determine the time required by a qualified and experienced worker working
at normal pace to do the work at a defined level of performance
v  Assuming in the training of the workers on new method
Product Layout
This type of layout is for the continuous production of specified product as in MEDICAL DEVICES
Pvt. Ltd. (Unit # 4).The process equipment and work force is arranged in the sequence of operation
required for the specified product. Material handling is minimum with low in-process inventory.
Line Balancing
The product layout design requires special emphasis on line balancing. The operation time of
each stage is nearly equal. In a case where the operation time of a stage is much higher than
other, line balancing may be achieved by creating multiple stations for this specific long
operation. Product layout with large number of operations is provided with intermediate buffer
storages to improve the line performance.

PER DAY CAPACITY CALCULATION USING WORK MEASUREMENT & ASSEMBLY LINES B
UNIT #4
Item: GLD, EVD, CALLISTO, LUNALITE-D, SU blades
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr 15 min = 26100 sec

Sr. # Process name Worker name Qty Normal time (sec) per unit time (sec)
 1 Deburing Sajida 10 114 11.4
Deburing Yasmeen 10 119 11.9
Deburing Samra bhutta 10 191 19.1
Deburing Samra irfan 10 91 9.1
Deburing Rubina sehar 10 194 19.4
Deburing ABC 10 136 13.6
Deburing ABC 10 115 11.5
Deburing ABC 10 109 10.9

2 Sharpness checking Noreen 10 19 1.9

Sharpness checking Shamsa 10 24 2.4

3 Cleaning of blade Sania 10 70 7

Cleaning of blade Aniza 10 87 8.7
Cleaning of blade Rizwana 10 65 6.5

4 Double ball plunger Nasreen 10 75 7.5

Double ball plunger Atia 10 55 5.5

5 Acrylic tube fitting Razia 10 57 5.7

Acrylic tube fitting Musarat 10 46 4.6

6 Fitting of mounting Aziza 10 50 5

Fitting of mounting Rashida 10 44 4.4

7 Hammering Sadia 10 58 5.8

Hammering Yasmeen 10 62 6.2

8 Q.C ABC 10 24 2.4

Q.C ABC 10 29 2.9

Monitoring results
60000

50000

40000

Column
30000 Column
Column
20000 Column
Column
10000

0
Deburing Sharpness Cleaning of Double ball Acrylic tube Fitting of Hammering Q.C
checking blade plunger fitting mounting
 Column
10000

0
Deburing Sharpness Cleaning of Double ball Acrylic tube Fitting of Hammering Q.C
checking blade plunger fitting mounting

Total Workers = 21 (including superwiser)

For rework = 2
Balanced Assembly Line of Blades
Sr.# Process name Unbalanced worker Capacity Worker required Per Day Capacity
1 Deburing 8 16643 6 13932
2 Sharpness checking 2 24611 1 13736
3 Cleaning of blade 3 10743 3 13554
4 Double ball plunger 2 8225 3 14237
5 Acrylic tube fitting 2 10251 2 14108
6 Fitting of mounting 2 11151 2 14537
7 Hammering 2 8709 3 14920
8 Q.C 2 19875 1 13736
23 21

Production planning
Each organization is set up for a specific output capacity of goods or services or both. The plant
and equipment capabilities and capacities provide a potential to produce the required output.
The effective utilization of plant and equipment resources along-with manpower, material and
capital resources is necessary for the achievement of economic and performance goal of the
organization.
Three alternate strategies are available to prepare the production plan.
Vary Production Plan
Vary production has a direct relation to monthly requirement. In this plan, inventory carrying
cost is zero. However, the set up cost and labour hiring costs are very high. Moreover, the
administrative problems of hiring and lay-off of labour are complex and usually do not permit
this practice to be adopted.
Level Production Plan
In this plan, the production is planned at a uniform production rate throughout the year. The
production rate or level is determined by drawing a straight line through the start and end
points of the demand curve. In this plan, there is inventory carrying cost but most of the
complexities can be overcome.

For Company Blades

Company unit #4 production capacity= 13000 blades/day
Total demand= 1394355 blades
Total working days= 302
Rate of production/day= 1394355/302= 4617 blades

Month JAN FEB MAR APR MAY JUN JUL AUG SEP
Demand 34380 47250 113880 181226 84450 167050 82710 187120 190600
Days 27 24 26 26 25 26 24 25 22
Prod. 124659 108288 117312 117312 112800 117312 108288 112800 99264
P-D 90279 61038 3432 -63914 28350 -49738 25578 -74320 -91336
Is 41735 132014 193052 196484 132570 160920 111182 136760 62440
Ie 132014 193052 196484 132570 160920 111182 136760 62440 -28896
I avg 86874.5 162533 194768 164527 146745 136051 123971 99600 16772

Multi Level Production Plan

In this system, two or three levels of production are set. The production rate is lowest in low
demand period. This gives advantage of low inventories and inventory holding cost. The
maintenance of machines and availing of annual leave entitlement of labour is planned during
the period of low production rate. The high production levels are scheduled to conform to the
high demand period. Usually the multi-level production plans are most economical.

Tempo Printing
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr 15 min = 26100 sec
Total Workers = 9 (including superwiser + 2 Loader + 6 on machine worker)

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Tempo printing Hafiza 10 37 3.7
Alia
Aliza
2 Tempo printing Laila 10 34 3.4
Razia
Rehana

Item: EUROPA-E Black Preloaded type Handles

Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr 15 min = 26100 sec

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Deburring ABC 10 96 9.6
Deburring ABC 10 106 10.6
Deburring ABC 10 129 12.9
Deburring ABC 10 109 10.9

2 Open strip part A Uzma B 10 45 4.5

3 Fitt strip of part A Uzma B 10 65 6.5
4 Fitt spring of part B Saima 10 275 27.5
Fitt spring of part B Rehana 10 278 27.8

5 Spring in housing Samina 10 270 27

6 Checking cells Uzma 10 20 2
7 Filling cells Samina 10 103 10.3
 8 Fitting pin Uzma 10 56 5.6
9 Tapeing A & B Sadia 10 211 21.1
10 Welding+Untaped Sumbal+Afia 10 129 12.9
11 Lot number Humaira 10 30 3
12 Sleave checking Uzma B 10 29 2.9
13 Sleave fitting Humaira 10 59 5.9
14 Huck pin fitting Naila 10 73 7.3
15 Huck pin press Anum 10 55 5.5
16 Checking handles Khalida 10 51 5.1
Checking handles Shabnum 10 59 5.9

17 Gum on cap Uzma 10 15 1.5

18 Fitting cape Khalida+Shabnum 10 36 3.6

Total Workers = 12 (including superwiser)

Balanced Assembly Line of Black Preloaded type Handle Before Line Balancing
Sr.# Process nmae Balanced Workers Balanced Capacity
Fit strip in cap
1 Open + Fitt strip of part A 1 2I75
2 Strip & spring fitt in part B 3 2514 Outer ring fitt
3 Fit spring in battery housing 3 2300 Huck pin fitting
4 Checking + Filling cells 1 2121 Sleave checking
5 Fitt pin + wound tape 2 2006 Welding+Untaped
6 Welding + unwound tape 2 2023 Fitting pin
7 Lot no. + Check sleave + Fitt 1 2211
Nake wire
8 Huck pin fitt + Press fitt 1 2039
Fitt strip of part A
9 Checking handles + Fitt cap 2 2372
16 Deburring
0 2000
Item: Black C type Handles
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr 15 min = 26100 sec

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Deburring ABC 10 96 9.6
Deburring ABC 10 106 10.6
Deburring ABC 10 129 12.9
Deburring ABC 10 109 10.9

2 Open strip part A Uzma B 10 55 5.5

3 Fitt strip of part A Uzma B 10 65 6.5
4 Fitt spring of part B Saima 10 219 21.9
Fitt spring of part B Rehana 10 223 22.3

5 Nake wire Samina 10 340 34

Nake wire Uzma B 10 335 33.5
 6 Alfi Uzma 10 115 11.5
7 Fitting pin Samina 10 56 5.6
8 Tapeing A & B Sadia 10 211 21.1
9 Welding+Untaped Sumbal+Afia 10 129 12.9
10 Lot number Humaira 10 30 3
11 Sleave checking Uzma 10 29 2.9
12 Sleave fitting Humaira 10 59 5.9
13 Huck pin fitting Naila 10 73 7.3
14 Huck pin press Anum 10 55 5.5
15 Outer ring fitt Khalida 10 57 5.7
16 Outer ring press fitt Shabnum 10 80 8
17 Soldering 10
18 Fit strip in cap Uzma 10 49 4.9
19 Heating press Anum 10 50 5
20 Checking handles Khalida 10 258 25.8
Checking handles Shabnum 10 274 27.4
Checking handles ABC 10 316 31.6

Total Workers = 12 (including superwiser)

Balanced Assembly Line of Black C type Handle
Sr.# Process nmae Balanced Workers Balanced Capacity
1 Open + Fitt strip of part A 1 2I75
2 Strip fitting in part B 2 2360
3 Nake wire (strip B) 3 2322
4 Alfi 1 2269
5 Fitt pin + wound tape 2 2006
6 Welding + unwound tape 2 2023
7 Lot no. + Check sleave + Fitt 1 2211
8 Huck pin fitt + Press fitt 1 2039
9 Outer ring fitt + Press fitt 1 1905
10 Soldering
11 Fitt strip in cap + Press 1 2610
12 Fitt battries + Check handles 2 1970
17
Item: Green Preloaded type Handles
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr 15 min = 26100 sec

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Deburring ABC 10 96 9.6
Deburring ABC 10 106 10.6
Deburring ABC 10 129 12.9
Deburring ABC 10 109 10.9

2 Open strip part A ABC 10 45 4.5

 3 Fitt strip of part A ABC 10 65 6.5
4 Fill LED in housing ABC 10 75 7.5
Fill LED in housing ABC 10 59 5.9

5 Filling cells ABC 10 66 6.6

Filling cells ABC 10 65 6.5

6 Fitt housing ABC 10 98 9.8

Fitt housing ABC 10 103 10.3

7 Fitt A & B + tape ABC 10 124 12.4

Fitt A & B + tape ABC 10 135 13.5
Fitt A & B + tape ABC 10 120 12

8 Welding+Untaped ABC+ABC 10 129 12.9

9 Lot number ABC 10 30 3
10 Sleave checking ABC 10 29 2.9
11 Sleave fitting ABC 10 59 5.9
12 Huck pin fitting ABC 10 73 7.3
13 Huck pin press ABC 10 55 5.5
14 Checking handles ABC 10 51 5.1
Checking handles ABC 10 59 5.9

15 Gum on cap ABC 10 17 1.7

16 Fitting cape ABC+ABC 10 36 3.6

Total Workers = 12 (including superwiser) Before Line Balancing

Balanced Assembly Line of Green Preloaded type Handle Fitting cape
Sr.# Process nmae Balanced Workers Balanced Capacity Checking handles
1 Open + Fitt strip of part A 2 4350
2 Fill LED in housing 1 4423 Huck pin fitting
3 Filling cells 1 4015 Sleave checking
4 Fitt housing 2 5326
Welding+Untaped
5 Fitt A & B + tape 2 4208
6 Welding + unwound tape 4 4046 Fitt housing
7 Lot no. + Check sleave 1 4078 Fill LED in housing
8 Huck sleave & pin fitt + Press 2 4314
9 Checking handles + Fitt cap 4 4744 Open strip part A
19 0 5000

Item: Green C type Handles

Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr 15 min = 26100 sec

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Deburring ABC 10 96 9.6
 Deburring ABC 10 106 10.6
Deburring ABC 10 129 12.9
Deburring ABC 10 109 10.9

2 Open strip part A ABC 10 45 4.5

3 Fitt strip of part A ABC 10 75 7.5
4 Bending LED wire ABC 10 39 3.9
5 Fitt LED + Part A + ABC 10 168 16.8
Tape A & B ABC 10 178 17.8
ABC 10 160 16
ABC 10 189 18.9
ABC 10 334 33.4
ABC 10 242 24.2
ABC 10 195 19.5

6 Welding +Untaped ABC+ABC 10 129 12.9

7 Lot number ABC 10 30 3
8 Sleave checking+ ABC+ABC+ABC 10 121 12.1
Sleave fitting + 10 118 11.8
Huck pin fitting 10 125 12.5

9 Huck pin press ABC 10 55 5.5

10 Outer ring fitt ABC 10 57 5.7
11 Outer ring press fitt ABC 10 80 8
12 Soldering 10
13 Fit strip in cap ABC 10 49 4.9
14 Heating press ABC 10 51 5.1
15 Checking handles ABC 10 349 34.9
Checking handles ABC 10 272 27.2
Checking handles ABC 10 258 25.8

Total Workers = 12 (including superwiser)

Balanced Assembly Line of Green C type Handle
Sr.# Process nmae Balanced Workers Balanced Capacity
1 Open + Fitt strip of part A 1 2193
2 Fitt LED + Tape Part A & B 2 2346
3 Welding + unwound tape 2 2023
4 Lot no. + Fitt sleave & pin 1 2269
5 Fitt pin + wound tape 2 2006
6 Lot no. + Check sleave 1 2211
7 Huck pin & sleave fitt + Press 2 2039
8 Outer ring fitt + Press fitt 1 1905
9 Soldering
10 Fitt strip in cap + Press 1 2610
11 Fitt battries + Check handles 2 1970
 15

UNIT #4 (I.F)
Item: Europa S Mac. blades
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec

Sr. # Process name Worker name Qty Normal time (sec) per unit time (sec)
1 Deburing Zishan 10 129 12.9
Deburing Waqar 10 135 13.5

2 Bending of tube Nadeem 10 65 6.5

3 Earth wire fitt Zaheer 10 67 6.7
Earth wire fitt Usman 10 63 6.3

4 Fitting of tube Abdul Rauf 10 78 7.8

5 Earth wire 2nd fitt Umair 10 68 6.8
6 Bulb assumbly Arif 10 140 14
7 Fitt E.W & Pin Waheed 10 75 7.5
8 Cut extra wire Waqar 10 55 5.5
9 Double ball plung Afzal 10 71 7.1
Babar 10 55 5.5
Nabeel 10 62 6.2

10 Cleaning of blades Waheed 10 54 5.4

11 Lot number Furqan 10 24 2.4

Total Workers = 16 (including superwiser)

Balanced Assembly Line of Europa S Mac. Blades
Sr.# Process name Worker required Per Day Capacity
1 Deburing 2 3819
2 Bending of tube 1 3876
3 Earth wire fitt 1 3761
4 Fitting of tube 1 3230
5 Earth wire 2nd fitt 1 3705
6 Bulb assumbly 2 3600
7 Fitt E.W & Pin 1 3360
8 Cut extra wire 1 4581
9 Double ball plung 1 3549
10 Cleaning of blades 1 4666
11 Lot no + bulb ass. 1 10500
13
Item: DPIT blades
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec

Sr. # Process name Worker name Qty Normal time (sec) per unit time (sec)
1 Removal of flashes Afzal 10 90 9
Removal of flashes Waqar 10 95 9.5

2 Single plunge Adnan 10 45 4.5

3 Ball spring plunge Babar 10 75 7.5
Ball spring plunge Nadeem 10 70 7

4 Cleaning of blades Nabeel 10 50 5

Cleaning of blades Waheed 10 54 5.4

5 Acrylic light fitting Zishan 10 25 2.5

6 Fitting of mounting Umair 10 50 5
Fitting of mounting Furqan 10 65 6.5

7 Hammerinr +QC Abdul rauf 10 34 3.4

8 Lot number Zaheer 10 24 2.4
Monitoring results
25000

20000

15000
Column H
Column G
10000 Column F
Column E
Column D
5000

0
Removal of Single Ball spring Cleaning of Acrylic light Fitting of Hammerinr Lot number
flashes plunge plunge blades fitting mounting +QC
 Column G
10000 Column F
Column E
Column D
5000

0
Removal of Single Ball spring Cleaning of Acrylic light Fitting of Hammerinr Lot number
flashes plunge plunge blades fitting mounting +QC

Total Workers = 16 (including superwiser)

Balanced Assembly Line of DPIT Blades
Sr.# Process name Unbalanced worker Capacity Worker required Per Day Capacity
1 Removal of flashes 2 5452 3 10410
2 Single plunge 1 5600 2 11200
3 Ball spring plunge 2 6960 3 11371
4 Cleaning of blades 2 11088 2 11088
5 Acrylic light fitting 1 10080 1 10080
6 Fitting of mounting 2 9871 2 10535
7 Hammerinr +QC 1 8400 1 8400
8 Lot number 1 11454 1 11454
12 15

Hot Stamping
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 3

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Lot no. stamping ABC+ABC 10 29 2.9
Lot no. stamping ABC+ABC 10 27 2.7

White Room
Cleaning
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 15 ( including superwiser)
Table # 1
Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Checking ABC 10 37 3.7
2 Cleaning ABC 10 115 11.5
Cleaning ABC 10 121 12.1
Cleaning ABC 10 107 10.7
Cleaning ABC 10 114 11.4
Cleaning ABC 10 135 13.5
 3 Tray fill ABC 10 36 3.6

Total Workers = 7 (including superwiser)

Balanced Assembly Line of Cleaning Table # 1
Sr.# Process nmae Unbalanced worker Capacity Worker required
1 Checking + M.Handling 1 6810 1
2 Cleaning 5 10704 4
3 Tray filling 1 7000 1
7 6

Table # 2
Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Checking ABC 10 36 3.6
2 Cleaning ABC 10 125 12.5
Cleaning ABC 10 137 13.7
Cleaning ABC 10 109 10.9
Cleaning ABC 10 126 12.6
Cleaning ABC 10 139 13.9

3 Tray fill ABC 10 23 3.7

Total Workers = 7 (including superwiser)

Balanced Assembly Line of Cleaning Table # 2
Sr.# Process nmae Unbalanced worker Capacity Worker required
1 Checking + M.Handling 1 7000 1
2 Cleaning 5 9978 4
3 Tray filling 1 6810 1
7 6

Label on Pouches
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 3 ( including superwiser)

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Stick labels ABC 10 73 7.3
Stick labels ABC 10 41 4.1
Stick labels ABC 10 24 2.4

Pouch Packing
Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 8
 Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Checking ABC 10 21 2.1
Checking ABC 10 23 2.3

2 Pouch packing ABC 10 27 2.7

Pouch packing ABC 10 23 2.3

3 Sealing ABC+ABC 10 18 1.8

Sealing ABC+ABC 10 16 1.6

Label on Pouches of DPIT

Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 3 ( including superwiser)

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Stick labels ABC+ABC 10 82 8.2
Stick labels ABC+ABC 10 51 5.1
Stick labels ABC+ABC 10 66 6.6

Pouch Packing for DPIT

Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 8

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Checking ABC 10 21 2.1
Checking ABC 10 23 2.3

2 Inner packing ABC 10 42 4.2

Inner packing ABC 10 57 5.7

3 Inner Sealing ABC 10 72 7.2

Inner Sealing ABC 10 61 6.1

4 Outer packing ABC 10 46 4.6

Outer packing ABC 10 52 5.2
Outer packing ABC 10 61 6.1

5 Outer Sealing ABC 10 47 4.7

Outer Sealing ABC 10 31 3.1

6 Checking ABC 10 24 2.4

 Checking ABC 10 23 2.3

Box Packing ( 20 pcs )

Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 10( excluding superwiser)

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Checking ABC 10 13 1.3
2 Box formation ABC 10 94 9.4
3 Packing in box ABC 10 51 5.1
Packing in box ABC 10 29 2.9

4 Tape + Weight ABC 10 74 7.4

Box Packing ( 10 pcs )

Total time= 8.5 hr = 30600 sec
Calculation time= 7 hr = 25200 sec
Total Workers = 10( excluding superwiser)

Sr. # Process name Worker name Qty Efficient time (sec) per unit time (sec)
1 Checking ABC 10 13 1.3
2 Box formation ABC 10 94 9.4
3 Packing in box ABC 10 18 1.8
Packing in box ABC 10 23 2.3

4 Tape + Weight ABC 10 74 7.4

5 Shrink Wraping ABC 10 58 5.8
r working

f operation

& ASSEMBLY LINES BALANCING

Normal capacity Efficient time (sec) per unit time (sec) Efficient capacity
 2289 110 11 2372 To avoid bottle necking only 6 persons
2193 107 10.7 2439
1366 141 14.1 1851 Lack of skills so Proper training req
2868 85 8.5 3070
1345 164 16.4 1591 Lack of skills so Proper training req
1919 131 13.1 1992
2269 100 10 2610
2394 104 10.4 2509
16643 18434
13736 14 1.4 18642 In case of MAC 3 & 4 only 1 person
10875 21 2.1 12428 Not right man to the right job here
24611 31070 Material handling layout problem
3728 62 6.2 4209
3000 83 8.3 3144 Lack of skills can be performed 10 j
4015 55 5.5 4745 Process not making sense here
10743 12098
3480 48 4.8 5437 One more person is required here to b
4745 45 4.5 5800
8225 11237
4578 42 4.2 6214 Lack of skills so Proper training require
5673 39 3.9 6692 Can be done 10 units job within 35 sec
10251 12906
5220 36 3.6 7250
5931 35 3.5 7457
11151 14707
4500 46 4.6 5673 Applying force through hammer not s
4209 47 4.7 5553 Lack of skills so Proper training req
8709 11226
10875 18 1.8 14500 one person is enough for balanced lin
9000 21 2.1 12428
19875 26928

Column Y
Column X
Column W
Column V
Column U

Q.C
 Column U

Q.C

Before Line Balancing After Line Balancing

Per Day Capacity Q.C Q.C
13932 Hammering Hammering
13736 Fitting of mounting Fitting of mounting
Acrylic tube fitting Column G Acrylic tube fitting
13554
Column F Double ball plunger
14237 Double ball plunger
Column E
Cleaning of blade Cleaning of blade
14108 Column D
Sharpness checking Sharpness checking
14537 Column C
Deburing Deburing
14920 Process name Process name
13736

For Company Handles

Company unit #4 production capacity= 900 blades/day
Total demand= 273941 blades
Total working days= 302
Rate of production/day= 273941/302= 907 blades

OCT NOV DEC Month JAN FEB MAR APR MAY

71919 109430 124340 1394355 Demand 6230 8160 15480 9630 6940
27 25 25 302 Days 27 24 26 26 25
 121824 112800 112800 Prod. 24489 21768 23582 23582 22675
49905 3370 -11540 P-D 18259 13608 8102 13952 15735
0 49905 53275 Is 0 18259 31867 39969 53921
49905 53275 41735 Ie 18259 31867 39969 53921 69656
24952.5 51590 47505 1255889 I avg 18259 25063 35918 46945 61788

Efficient capacity
7054 Loading layout problem

7676

14730

Efficient capacity
2718 For balanced line 2 persons are enough for removal of flashes
2462
2023
2394
9597
5800
4015
949
938
1887
966
13050
2533 Repition of worker is here
 4660 Repition of worker is here
1236
2023 In welding instead of using two fitting blocks (129 sec) use 1 block (75 sec).
8700
9000 Repition is here
4423
3575
4745
5117
4423
9540
17400 Repition of worker is here
7250

Before Line Balancing After Line Balancing

Fit strip in cap Checking handles + Fitt cap
Outer ring fitt Huck pin fitt + Press fitt
Lot no. + Check sleave + Fitt
Huck pin fitting
Welding + unwound tape
Sleave checking
Column J Fitt pin + wound tape
Welding+Untaped Column I Checking + Filling cells
Fitting pin Column H Fit spring in battery housing
Nake wire Strip & spring fitt in part B
Fitt strip of part A Open + Fitt strip of part A
Deburring Process nmae
0 2000 4000 6000 8000 10000 0 1000 2000 3000

Efficient capacity
2718
2462
2023
2394
9597
4745
4015
1191
1170
2361
767
779 Repition of worker is here
1546
 2269
4660 Repition is here
1236 Buffer storage is required before welding
2023 In welding instead of using two fitting blocks (129 sec) use 1 block (75 sec)
8700
9000
4423
3575
4745
4578
3262

5326 Repition of worker is here

5220
1011
952
825
2788

Efficient capacity
2718
2462
2023
2394
9597
5800
 4015
3480 For balanced line 1 persons are enough
4423
7903
3954 For balanced line 1 persons are enough
4015
7969
2663
2533
5196
2104 For balanced line 2 persons are enough
1933
2175
6212
2023 Both welding machines should work in this case for balanced line
8700
9000
4423 Single person on both sleave & pin fitting (12.1 sec) save the time instead of separate (15.7 sec) working
3575
4745
5117
4423
9540
15352
7250

Before Line Balancing After Line Balancing

Fitting cape Checking handles + Fitt cap
hecking handles Huck sleave & pin fitt + Press
Lot no. + Check sleave
Huck pin fitting
Welding + unwound tape
Sleave checking Col
Column F Fitt A & B + tape Col
elding+Untaped Column E Col
Fitt housing
Column D Col
Fitt housing Filling cells
Fill LED in housing
LED in housing
Open + Fitt strip of part A
pen strip part A
0 5000 10000 15000 20000

Efficient capacity
2718
2462
2023
2394
9597
5800 1 person is enough for both open & fitt strip
3480
6692
1553 For balanced line 2 persons are enough
1466
1631
1380
781
1078
1338
9227
2023 Welding machine is out of order at this time
8700
2157 This method is effective in time saving instead of separate working on sleave & pin fitting
2211 Material handling problem is there
2088
6456
4745
4578
3262

5326
5117
747
959
1011
2717
Normal capacity
1953
1866
3819
3876
3761
4000
7761
3230
3705
1800
3360
4581
3549
4581
4064
12194
4666
10500
 Normal capacity Efficient time (sec) per unit time (sec) Efficient capacity
2800 70 7 3600
2652 80 8 3150
5452 6750
5600 45 4.5 5600
3360 65 6.5 3876
3600 68 6.8 3705
6960 7581
5040 44 4.4 5727
4666 47 4.7 5361
9706 11088
10080 25 2.5 10080
5040 45 4.5 5600
3876 59 5.9 4271
8916 9871
7411 30 3 8400
10500 22 2.2 11454

Column H
Column G
Column F
Column E
Column D

er
 Column G
Column F
Column E
Column D

er

Before Line Balancing After Line Balancing

Lot number Lot number
Per Day Capacity Hammerinr +QC Hammerinr +QC
10410 Fitting of mounting Fitting of mounting
11200 Acrylic light fitting Acrylic light fitting
11371 Column F
Cleaning of blades Cleaning of blades
11088 Column E
Ball spring plunge Column D Ball spring plunge
10080 Single plunge Single plunge
10535 Removal of flashes Removal of flashes
8400
0 00 00 00 00 00 00 0
11454 00
20 40 60 80 10
0
12
0
20 40

Efficient capacity
8689
9333
18022

Efficient capacity
6810 1 person should be for checking with material handling
2191 4 persons are enough here
2082
2355
2210
1866
 10704
7000

Worker required
6810
7133
7000

Efficient capacity
7000 1 person should be for checking with material handling
2016 4 persons are enough here
1839
2311
2000
1812
9978
6810

Worker required
7000
7962
6810

Efficient capacity
3452
6146
10500 So much Efficient
20098
Efficient capacity
12000
10956
22956
9333
10956
20289
14000 Handling should be perform these persons
15750 Layout problems
29750

Efficient capacity
3073 10 Person should work to give balance demand in pouch packing
4941
3818
11832

Efficient capacity
12000
10956
22956
6000
4421
10421
3500
4131
7631
5478
4846
4131
14455
5361
8129
13490
10500
 10956
21456

Efficient capacity
19384
2680
4941 There should be 1 more person at this process
8689
13630
3405

Efficient capacity
19384
2680
14000
10956
24956
3405
34344
bottle necking only 6 persons are required here instead of 8

kills so Proper training required

kills so Proper training required

f MAC 3 & 4 only 1 person is enough to balance the line

man to the right job here
handling layout problem

kills can be performed 10 jobs in 55 sec. so Proper training required

ot making sense here

person is required here to balance the assumbly line

ills so Proper training required

ne 10 units job within 35 sec

orce through hammer not straight

kills so Proper training required

n is enough for balanced line other may use for material handling
ne Balancing
Q.C
ammering
mounting
ube fitting Column G
Column F
ll plunger
Column E
g of blade
Column D
s checking
Column C
Deburing
cess name

JUN JUL AUG SEP OCT NOV DEC

61940 29440 46710 4087 24850 29454 31020 273941
26 24 25 22 27 25 25 302
 23582 21768 22675 19954 24489 22675 22675
-38358 -7672 -24035 15867 -361 -6779 -8345
69656 31298 23626 -409 15458 15097 8318
31298 23626 -409 15458 15097 8318 -27
50477 27462 11608 7524 15277 11707 4145 316173
 Column H
Column G
Column F
Column E
Column D
Column C

1000 2000 3000

separate (15.7 sec) working

Column G
Column F
Column E
Column D
e & pin fitting
 After Line Balancing
Lot number
Hammerinr +QC
Fitting of mounting
Acrylic light fitting
Column F
Cleaning of blades
Column E
Ball spring plunge Column D
Single plunge
Removal of flashes

0 00 00 00 00 00 00
20 40 60 80 10
0
12
0
25000

20000 Process name

Deburing
15000 Sharpness checking
Cleaning of blade
Double ball plunger
10000
Acrylic tube fitting
Fitting of mounting
5000 Hammering
Q.C
0
1 2 3 4 5 6 7 8 9

Deburring 9597
Open strip part A 4745
Fitt strip of part A 4015
Fitt spring of part B 2361
Nake wire 1546
Alfi 2269
Fitting pin 4660
Tapeing A & B 1236
Welding+Untaped 2023
Lot number 8700
Sleave checking 9000
Sleave fitting 4423
Huck pin fitting 3575
Huck pin press 4745
Outer ring fitt 4578
Outer ring press fitt 3262
 Fit strip in cap 5326
Heating press 5220

Fit strip in cap

Outer ring fitt

Huck pin fitting

Sleave checking
Column J
Welding+Untaped Column I
Column H
Fitting pin

Nake wire
Fitt strip of part A

Deburring
0 2000 4000 6000 8000 10000

Process name Unbalanced worker Unbalanced capacity

Deburing 8 16643
Sharpness checking 2 24611
Cleaning of blade 3 10743
Double ball plunger 2 8225
Acrylic tube fitting 2 10251
Fitting of mounting 2 11151
Hammering 2 8709
Q.C 2 19875

Q.C
Process name Worker required Per Day Capacity Hammering
Deburing 6 13932
Fitting of mounting
Sharpness checking 1 13736
Cleaning of blade 3 13554 Acrylic tube fitting
Double ball plunger 3 14237 Double ball plunger
Acrylic tube fitting 2 14108
Cleaning of blade
Fitting of mounting 2 14537
Hammering 3 14920 Sharpness checking
Q.C 1 13736 Deburing
Processofname
Cleaning blades
Double ball plung0 00 00 00 00
20 40 60 80 10
Deburing 4880 Cut extra wire
Bending of tube 5478 Fitt E.W & Pin
Earth wire fitt 9723
Bulb assumbly
Earth wire 2nd fitt
Fitting of tube
 Double ball plung
Cut extra wire
Fitt E.W & Pin
Bulb assumbly
Fitting of tube 3111
Earth wire 2nd fitt 4200 Earth wire 2nd fitt
Bulb assumbly 1800 Fitting of tube
Fitt E.W & Pin 3360 Earth wire fitt
Cut extra wire 4581
Bending of tube
Double ball plung 12194
Cleaning of blades 4666 Deburing

0 2000 4000 6000 8

Cleaning of blades
Deburing 5051
Double ball plung
Bending of tube 6810
Earth wire fitt 13631 Cut extra wire
Fitting of tube 3189 Fitt E.W & Pin
Earth wire 2nd fitt 5142 Bulb assumbly
Bulb assumbly 1938
Earth wire 2nd fitt
Fitt E.W & Pin 3405
Cut extra wire 5142 Fitting of tube
Double ball plung 12852 Earth wire fitt
Cleaning of blades 5361 Bending of tube
Deburing

0 2000 4000 6000

Cleaning of blades
Deburing 5015
Bending of tube 5478 Double ball plung
Earth wire fitt 5142 Cut extra wire
Fitting of tube 5911 Fitt E.W & Pin
Earth wire 2nd fitt 5142
Bulb assumbly
Bulb assumbly 5400
Earth wire 2nd fitt
Fitt E.W & Pin 5950
Cut extra wire 5142 Fitting of tube
Double ball plung 7098 Earth wire fitt
Cleaning of blades 5361 Bending of tube
Deburing

0 1000 2000 3000

Open + Fitt strip of part A 4350 Checking handles + Fitt cap

Fill LED in housing 4423
Filling cells 4015 Huck sleave & pin fitt + Press
Fitt housing 5326 Lot no. + Check sleave

Welding + unwound tape

Fitt A & B + tape
 Checking handles + Fitt cap

Huck sleave & pin fitt + Press

Lot no. + Check sleave
Fitt A & B + tape 4208
Welding + unwound tape
Welding + unwound tape 4046
Lot no. + Check sleave 4078 Fitt A & B + tape
Huck sleave & pin fitt + Press 4314 Fitt housing
Checking handles + Fitt cap 4744
Filling cells

Fill LED in housing

Open + Fitt strip of part A

0 1000 2000 30

Open strip part A 5800

Fitt strip of part A 4015
Fill LED in housing 7903 Fitting cape
Gum on cap
Filling cells 7969 Checking handles
Fitt housing 5196 Huck pin press
Fitt A & B + tape 6212 Huck pin fitting
Sleave fitting
Welding+Untaped 2023 Sleave checking
Lot number 8700 Lot number
Sleave checking 9000 Welding+Untaped
Fitt A & B + tape
Sleave fitting 4423 Fitt housing
Huck pin fitting 3575 Filling cells
Huck pin press 4745 Fill LED in housing
Checking handles 9540 Fitt strip of part A
Open strip part A
Gum on cap 15352
Fitting cape 7250 0 00 00 00 00
20 40 60 80 10
0

Lot number 11454

Removal of flashes 5452
Single plunge 5600 Hammerinr +QC
Ball spring plunge 6960
Cleaning of blades 11088 Fitting of mounting
Acrylic light fitting 10080 Acrylic light fitting
Fitting of mounting 9871
Hammerinr +QC 8400 Cleaning of blades

Ball spring plunge

Single plunge

Removal of flashes

Lot number

0 2000 4000 6000 8000 1000

 Removal of flashes

Lot number

0 2000 4000 6000 8000 1000

Lot number 10500 11454

Removal of flashes 5452 6750
Single plunge 5600 5600
Ball spring plunge 6960 7581
Cleaning of blades 9706 11088
Acrylic light fitting 10080 10080
Fitting of mounting 8916 9871
Hammerinr +QC 7411 8400

Hammerinr +QC
Lot number 11454
Removal of flashes 10410 Fitting of mounting
Single plunge 11200
Ball spring plunge 11371 Acrylic light fitting
Cleaning of blades 11088 Cleaning of blades
Acrylic light fitting 10080
Fitting of mounting 10535 Ball spring plunge
Hammerinr +QC 8400 Single plunge

Removal of flashes

Lot number

0 2000 4000 6000 8000 10000 12000

 ocess name
buring
arpness checking
aning of blade
uble ball plunger
rylic tube fitting
tting of mounting
mmering
C
 Q.C

Hammering

Fitting of mounting
Acrylic tube fitting Column G Deburing
Column F Sharpness checking
Double ball plunger
Column E Cleaning of blade
Cleaning of blade Column D60000
Double ball plunger
Column C
Sharpness checking 50000 Acrylic tube fitting
Fitting of mounting
Deburing 40000 Hammering
Process name Q.C
30000
0 5000 10000 15000 20000 25000 20000

10000
Q.C
0
ing
ting
tting
Column G
ger Column F
ade Column E
Column D
ing Column C
ing
me
lades
plung0 00 00 00 00 0 0 0 0
20 40 60 80 00 00 00 00
a wire 10 12 14 16

& Pin
umbly Column H
nd fitt Column G
Column F
tube
plung
a wire
& Pin
umbly Column H
nd fitt Column G
Column F
tube
re fitt
tube
uring

0 2000 4000 6000 8000 10000 12000 14000

f blades
ll plung
tra wire
W & Pin
sumbly Column H
2nd fitt Column G
Column F
of tube
wire fitt
of tube
eburing

0 2000 4000 6000 8000 10000 12000 14000

of blades 30000 Deburing 4480

ball plung Bending of tube 5478
25000
extra wire Earth wire fitt 9723
20000 Fitting of tube 3111
E.W & Pin
15000 Earth wire 2nd fitt 4200
assumbly Column G
Bulb assumbly 1800 Column W
re 2nd fitt Column F
10000 Column V
Column E
Fitt E.W & Pin 3360
ng of tube Column U
5000 Cut extra wire 4581
Column T
h wire fitt Double ball plung 12194 Column S
0
ng of tube
Cleaning of blades 4666
Lot number 10500
Deburing

0 1000 2000 3000 4000 5000 6000 7000 8000

ndles + Fitt cap

pin fitt + Press

+ Check sleave

nwound tape
Column G
tt A & B + tape Column F
Column E
ndles + Fitt cap

pin fitt + Press

+ Check sleave

nwound tape
Column G
tt A & B + tape Column F
Column E
Fitt housing
Column D
Filling cells

LED in housing

strip of part A

0 1000 2000 3000 4000 5000 6000

g cape
on cap
andles
press
fitting
fitting
ecking
umber Column F
taped Column E
+ tape
Column D
ousing
g cells
ousing
part A
part A
0 00 00 00 00 00 00 00 00
20 40 60 80 10
0
12
0
14
0
16
0

Column F
Column E
Column D

000 4000 6000 8000 10000 12000

000 4000 6000 8000 10000 12000

Column D
Column C
Column B

6000 8000 10000 12000

 Deburing 16643 18434
Sharpness checking 24611 31070
Cleaning of blade 10743 12098
Double ball plunger 8225 11237
Acrylic tube fitting 10251 12906
Fitting of mounting 11151 14707
Hammering 8709 11226
Q.C 19875 26928
Column Y
Column X
Column W
Column V
Column U
 4480 5015
5478 6810
9723 13631
3111 3189
4200 5142
1800 Column W 1938
3360 Column V 3405
Column U
4581 5142
Column T
12194 Column S 12852
4666 5361
10500 11454
 Deburing 5051
Bending of tube 6810 Lot no + bulb ass.
Earth wire fitt 13631 Cleaning of blades
Fitting of tube 3189 Double ball plung
Earth wire 2nd fitt 5142 Cut extra wire
Bulb assumbly 1938 Fitt E.W & Pin
Fitt E.W & Pin 3405 Bulb assumbly
C
Cut extra wire 5142 C
Earth wire 2nd fitt C
Double ball plung 12852
Fitting of tube
Cleaning of blades 5361
Lot no + bulb ass. 5040 Earth wire fitt
Bending of tube
Lot no + bulb ass.
Deburing
Cleaning of blades
Double ball plung 0 2000 4000 6000 8000 10000 12000 14000

Deburing Cut extra wire

5015
Bending of tube Fitt E.W & Pin 5478
Earth wire fitt 5142 Column F
Bulb assumbly
Column E
Fitting of tube Earth wire 2nd fitt
5911
Column D
Earth wire 2nd fitt Fitting of tube
5142
Bulb assumbly 5400
Earth wire fitt
Fitt E.W & Pin 5950
Bending of tube
Cut extra wire 5142
Double ball plung Deburing
7098
Cleaning of blades 53610 1000 2000 3000 4000 5000 6000 7000 8000
Lot no + bulb ass. 5040

Removal of flashes 5452 Lot number

Single plunge 5600
Hammerinr +QC
Ball spring plunge 6960
Cleaning of blades 11088 Fitting of mounting
Acrylic light fitting 10080
Acrylic light fitting
Fitting of mounting 9871
Hammerinr +QC 8400 Cleaning of blades
Lot number 11454
Ball spring plunge

Single plunge

Removal of flashes

0 2000 4000 6000 8000 10000 1200

Removal of flashes 10410

Single plunge 11200 Lot number

Hammerinr +QC

Fitting of mounting
 Lot number
Ball spring plunge 11371
Cleaning of blades 11088 Hammerinr +QC
Acrylic light fitting 10080 Fitting of mounting
Fitting of mounting 10535
Hammerinr +QC 8400 Acrylic light fitting
Lot number 11454
Cleaning of blades

Ball spring plunge

Single plunge
25000
Removal of flashes

20000 0 2000 4000 6000 8000

15000

10000
Removal of flashes 5452 6750 Column H
Single plunge 5600 5600 Column G
5000plunge Column F
Ball spring 6960 7581
Column E
Cleaning of blades 9706 11088 Column D
0
Acrylic light fitting 10080 10080
Fitting of mounting 8916 9871
Hammerinr +QC 7411 8400
Lot number 10500 11454
 Column F
Column E
Column D

8000 10000 12000 14000

Column F
Column E
Column D

8000

Column F
Column E
Column D

00 6000 8000 10000 12000

 Column F
Column E
Column D

2000 4000 6000 8000 10000 12000