Project report

SESSION: 2K20 5th SEMESTER

Group members:

M ahsaan sadiq (20-ie-03)

Muhammad waqas (20-ie-12)

Arslan Ashraf (20-ie-13)

Muhammad hassaan (20-ie-14)

Subject:
Work study and methods engineering

Submitted To:
Dr. Zahid Rasheed

DEPARTMENT OF INDUSTRIAL ENGINEERINg

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 Table Of Contents
1. Abstract: .............................................................................................................................................. 4
2. Introduction: ....................................................................................................................................... 4
3. Methodology: ....................................................................................................................................... 5
3.1. Plant Layout: ............................................................................................................................... 5
4. Work study implementation: ............................................................................................................. 6
4.1. Analysis of existing plant layout: ............................................................................................... 6
4.2. Proposed plant layout: ................................................................................................................ 7
5. Comparison of existing method and proposed method ............................................................... 9
6. Conclusions:....................................................................................................................................... 10
7. References:......................................................................................................................................... 10

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 List of tables
Table 1. Flow process chart of Existing method ........................................................................ 6
Table 2..Flow process chart of Proposed method ...................................................................... 8
Table 3. Summary of flow process chart (Present and proposed) ............................................ 9

List of figures

Figure 1. Existing plant layout ........................................................... 5

Figure 2. Proposed plant layout ................................................................................................... 7

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apply work and time study techniques in
a manufacturing unit for enhancing
productivity
1. Abstract:
The work is carried to determine total cycle time to manufacture one gate valve
assembly in Rehman Engineering works. Improvement in productivity can be
achieved through more efficient use of capital investments, human resource,
technological innovation, and developments. The goal was to improve the productivity
through more efficient use of capital and human resource. The results obtained from
this research work indicated that in proposed method there was reduction in total cycle
time of 73 minutes and the total distance travelled by 130meters, which lead to
increase in productivity at the assembly line of Rehman Engineering works.

2. Introduction:
Productivity improvement can be attained through different ways: that is, through more
effective use of human resources, through technological innovations and developments, and
finally through capital investments. Work study is defined as a complete set of techniques
through which work can be simplified, standardized and measured. Work study may require
almost no or least capital investment. Productivity can be raised to a reasonable extend with
use of work study. Raghunath G. Kulkarni et al. aimed at the study was to maximize
production rate through detailed analysis of existing plant layout to meet the increasing
customer demand. Simulation study is carried out during several orientation visits to the plant
and getting familiar with the system components. Among existing simulation software’s such
as Arena 10.0, Promodel, Process model etc, Arena 10.0 was used to run real time simulation
and construct the system model [1]. Ravikumar Kamble and Vinayak Kulkarnipaper explains
the study about productivity improvement at assembly work station using work study[2].
Hadiusing the concept of shortest route, they built model for the established single model
assembly line balancing problem[3]. M Duran T. etal, in many situations the worker or
machine will develop quickly because of continuous repetition of like activities. As a result,
manufacturing lead time of the product shortens [4]. Khalid, S. and Salehhave studied the
manufacturing process of the automobile industry, during the study the bottleneck
process was identified with operation process chart and analysis was done with help of simulation
software called Arenaand they have obtained the solution to increase manufacturing capacity[5].

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 3. Methodology:

In order to improve the productivity in Rehman Engineering works, initially plant visit was made,
and discussions made with proprietor and observations made during the visit, the ineffective time
related with the manufacturing and assembly plant layout was found to be more. The existing methods
involved in gate valve body manufacturing and assembly workstation were studied and finding
improved methods using work study techniques to decrease lead time and get better productivity.
Bottle necks were identified at various stages of the existing layout. Flow process chart was drawn
through several orientation visits to the plant and getting familiar with the different work elements.
Flow process chart was drawn for both existing and proposed system. With the work study, results
of both existing as well as proposed method were compared which results in reduction in total cycle
time to manufacture and assemble one gate assembly.

3.1. Plant Layout:

The manufacturing process of gate valve manufacturing at industry has 7 sections in the plant. It is the
process layout where in similar machines are placed at a place with similar operations. The flow of
materials is concurrent. Using the concept of method study the flow process chart was drawn for existing
layout and proposed layout. The plant under the study consists of 7 workstations and is as follows: lathe,
drilling, boring, welding, storage, assembly, and quality check. The part to be manufactured will move
from lathe workstation to drilling section then to the boring workstation followed by welding workstation
and finally to storage. Each part at the plant is sent through quality check.

Figure 1. Existing plant layout

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 4. Work study implementation:
4.1. Analysis of existing plant layout:
In existing study of plant layout the sequence of operations followed are: lathe-drilling-boring- welding-
storage-assembly-quality check. There are 6 departments in the plant. The drilling and boring department
are dependent on lathe department while the assembly department depends on drilling, boring and
welding. It was found that when layout sequence is change to lathe-boring-welding- drilling-storage-
assembly-quality check. Data collection includes the distance travelled and time required for each
operation. The flow process charts collect and classify the complete information necessary for the
analysis and improvement of plant operations as a whole or phase wise. This sequence of operations
were followed to manufacture and assemble one gate valve assembly, the total cycle time taken was
7.5hours. The distance travelled by component in existing plant layout was 400meters. The fig 2 explains
about existing layout of
Table 1. Flow process chart of Existing method
Step Activity Time Distance Operation Transport Inspection Delay Storage Value
# Description (s) (m) Category
1 Turning operation 120 VA
2 Inspection 3 NVA
3 Movement 20 100 NVA
4 Jigs and fixtures 10 VA
5 Drilling operation 100 VA
6 Movement 10 50 NVA
7 Boring operation 20 VA
8 Movement 5 20 NVA
Welding
9 operation 10 VA
10 Movement 10 30 NVA
11 Storage 10 NVA
12 Movement 25 160 NVA
13 Bonnet assembly 10 VA
Hand wheel
14 attachment 10 VA
Gasket
15 attachment 10 VA
Gate valve
16 assembly 10 VA
17 Testing 20 VA
18 Movement 10 40 NVA
19 Storage 5 VA

Count 10 6 1 2

Time Per
Process 325 min 107 min 3 min 15 min
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 Total
Total VAs 11 8
NVas
325 NVAs 125
VAs Time
min Time min
Distance Lead 7.5
400m
Travelled TIme hrs

4.2. Proposed plant layout:

In proposed study of plant layout the sequence of operations followed are: lathe-boring-welding-
drilling-storage-assembly-quality check. Data collection includes the distance travelled and time
required for each operation. The flow process charts collect and classify the complete information
necessary for the analysis and improvement of plant operations as a whole or phase wise. As
outcome of analysis, operations may be eliminated, combined or rearranged. Workstations, storage
space area, and inspections may be relocated to decrease the travel distance and thereby save the
labour time.

Figure 2. Proposed plant layout

This sequence of operations were followed to manufacture and assemble one gate valve
assembly, the total cycle time taken was 6.28hours. The movement of component in existing plant
layout was 270meters.

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 Table 2. Flow process chart of Proposed method
Step Activity Time Distance Operation Transport` Inspection Delay Storage Value
# Description (m) (m) category
1 Turning operation 120 VA
2 Movement 5 30 NVA
3 Boring operation 20 VA
4 Movement 4 20 NVA
5 Welding operation 20 VA
6 Movement 10 100 NVA
7 Jigs and fixtures 3 VA
8 Drilling operation 100 VA
9 Movement 20 90 NVA
10 Bonnet assembly 10 VA
Hand wheel
11 attachement VA
12 Gasket attachment 10 VA
13 Gate valve assembly 10 VA
14 Testing 20 VA
15 Movement 5 NVA
16 Storage 5 NVA
VA

Count 10 5 0 1
Time Per
Process 333 min 39 min 0 5 min

Total VAs 10 Total NVas 6

333 44
VAs Time min NVAs Time min
Distance 270 7
Travelled min Lead Time hrs

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 Table 3. Summary of flow process chart (Present and proposed)
Work elements Present method Proposed method
Operations 10 10
Inspections 3 0
Transportation 6 5
Delays - -
Storage 2 1
Value added time 325 333
Non Value-added time 125 44
Distance travelled 400 270

Comparison of Work elements of existing and

Proposed Layouts

500 458
400 377
400
325 333
300 270

200
125
100 44
11 10 8 6
0
Total VAs VAs Time Distance Total NVas NVAs Time Lead TIme
Travelled(m)
Before After

5. Comparison of existing method and proposed method

The main goal of study was to minimize the total cycle time and total distance travelled. In
the present method the total cycle time taken was 7.5hours and total distance travelled was
400meters. In the proposed method, the total cycle time taken was reduced to 6.28hours and
total distance travelled was reduced to 270metres. The main reason for this improvement in
reduction in total cycle time and total distance travelled was the number reductions in
inspections, transportations and storages. The value and non-value added activities were
recognized and respective times were also noted down. The reduction non-value added
activities and non-value added times will reduce total cycle and finally, improve productivity
of valve manufacturing industry. The total cycle time taken in existing plant layout to
manufacture one gate valve assembly is 458 minutes and the total cycle time taken in
proposed plant layout to manufacture one gate valve assembly is 377 minutes. The savings
in total cycle time was 81minutes.

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 6. Conclusion:

The productivity improvement was achieved using the principles of work study and concepts of
method study in Rahman Engineering Works with the same amount of resources as well as
human labors. It was done during the existing layout analysis, existing sequence of operations
followed. The total time taken to manufacture one gate valve assembly is 450minutes.
During the proposed layout analysis existing sequence of operations followed, the total time taken
to manufacture one gate valve assembly is 377 minutes. The manufacturing time or SAM was
reduced by 81 minutes followed by the reduction of lead time by half hour.

7. References:

1. Kulkarni RG, Kulkarni VN, Gaitonde VN. Productivity improvement in assembly

workstation of motor winding unit. Materials Today: Proceedings. 2018 Jan 1;5(11):23518-
25.

2. Kamble R, Kulkarni V. Productivity improvement at assembly station using work study

techniques. International Journal of Research in Engineering and Technology (IJRET)
eISSN. 2014 Sep:2319-1163.

3. Gökçen H, Ağpak K, Gencer C, Kizilkaya E. A shortest route formulation of simple U-

type assembly line balancing problem.Applied Mathematical Modelling. 2005 Apr
1;29(4):373-80.

4. Toksarı MD, İşleyen SK, Güner E, Baykoç ÖF. Simple and U-type assembly line balancing
problems with a learning effect. Applied Mathematical Modelling. 2008 Dec
1;32(12):2954-61.

5. Al-Saleh KS. Productivity improvement of a motor vehicle inspection station using motion
and time study techniques.Journal of King Saud University-Engineering Sciences.
2011 Jan 1;23(1):33-41.

6. Savsar M, Al-Jawini A. Simulation analysis of just-in-time production systems.

International Journal of Production Economics. 1995 Nov 1;42(1):67-78.

7. Lan S, Wang X, Ma L. Optimization of assembly line based on work study. InIndustrial

Engineering and Engineering Management, 2009. IE&EM'09. 16th International
Conference on 2009 Oct 21 (pp. 813-816). IEEE.

8. Chauhan M , Kulkarni VN 2018 An experimental study on productivity improvement using

workstudy and ergonomics, International journal of darshan institute on engineering
research & emerging technologies 7, 1.

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