LAB 3

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMW 3353 MANUFACTURING MANAGEMENT

LAB SHEET 3

WORK SYSTEM DESIGN

Learning Outcome LO3 Conduct experiments or laboratory tasks related to topics discussed
(LO):
in IE.
Program Outcome: PO5 Ability to select and apply appropriate techniques, resources and
modern engineering tools, with an understanding of their limitations.
Synopsis: This experiment enriches students’ knowledge on job design and work
measurement using time study technique. Students are exposed to the concept
of job design/work method and work measurement using time study technique
through plastic cloth peg assembly activity. The experiment is conducted in the
Industrial Engineering / Quality Control Laboratory.
Related Lecture’s 1. Work system design
Topic:
Prepared by: TS DR KAMRAN LATIF Date: 1 September 2020

Approved by Dr Ridhwan Jumaidin Date

LM/SLM/HOD

QMS : REVISION RECORDS

Date
Revisio Approved by
Description (DD/MM/YY Prepared by :
n No LM/SLM/HOD:
)
Contents reviewed after 5
years. Change material
01 4/9/2018 DR. ROHANA Dr Ridhwan
from cloth pegs to toy
assembly.
 1.0 THEORY
i. Work design / Work Method
ii. Work Measurement
iii. Time Study
2.0 EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS
i. Plastic cloth-peg
ii. Metal pins
iii. Stopwatch
iv. Plastic storage (as needed)

3.0 PROCEDURES/ METHODOLOGY

WORK MEASUREMENT – TIME STUDY
i. Select from group member one or two operator(s) to perform the cloth peg assembly activity.
ii. The other group members will act as the time keeper and the data recorder.
iii. Ask the operator(s) to perform the cloth peg assembly and record the time to assemble 10
cloth pegs. Repeat this step 10 times with the same operator (10 cloth pegs per observation
x 10 observations).
***Note : The operators should practice a few times to do the task before the actual
work measurement can be done.
iv. Use 90% for Operator 1 and 110% for Operator 2 Rating Performance (RP) performing the
plastic cloth peg assembly.
v. Use 10% Allowance Factor (AF) for each operator doing the task.
vi. Determine the Standard Time for the cloth peg asssembly. Use the Time Study Sheet
provided to record your work measurement data.
vii. Explore the work method approach in order to improve the cloth peg assembly Standard
Time. Use the Time Study Sheet provided to record your data on the improved work
method.
viii. Establish a work instruction / work standards for the cloth peg assembly process.

TIME STUDY SHEET

Date / Time : Observer : Product : Page : /

Job Element/Task Operator 1 2 3 4 5 6 7 8 9 10 Avg R PR AF

Avg = Average R = Range PR = Performance Rating AF = Allowance Factor

4.0 RESULTS AND DISCUSSION

Present the calculation of Time Standard for plug adapter assembly based on the experiment
performed in the laboratory.

Answer:

Before System Design After System Design

Average Time

Normal Time

Standard Time
DISCUSSIONS
i. From your Standard Time data, calculate how many cloth pegs could be assemble within 8
working hours.

Answer:

Before System Design After System Design

Normal Time of Normal Time of
Worker A Worker A
Normal Time of Normal Time of
Worker B Worker B
Standard Time of Standard Time of
Worker A Worker A
Standard Time of Standard Time of
Worker B Worker B

ii. From your data, determine whether 20 observations/data is enough to calculate the
Standard Time with 5% of accuracy percentge and 95% of confidence level. If not, how
many observations/data are required in order to get a more accurate Standard Time?

Answer:

iii. Discuss a better approach to perform the job in order to improve the productivity of the cloth
peg assembly.

Answer:
In order to improve the productivity of the cloth peg assembly is to analyze the production
tasks and its integral motions. The next step is to record each motion, the physical effort it
takes, and the time it takes, also known as time and motion study. Then motions that are not
needed can be eliminated also known as non-value added activities and any process
improvement opportunity exists must be identified. In aspect of time in assembly and quality
wise , make sure to make the surrounding of work placed was cleaned and comfort to do
work assembly. In addition, the source of light also must be good to avoid limit vision ob
worker during assembly process . Lastly ,must be arrange according their type to make
easier for the worker to pickup the part for assembly for the assembly area.
iv. The performance rating of the worker will affect the standard time.

Answer:
a. What is performance rating?

Performance rating is the step in the work measurement in which the analyst
observes the worker's performance and records a value representing that
performance relative to the analyst's concept of standard performance.

b. What factors are needed to be considered in determining performance rating?

- Ability to effectively evaluate skills, knowledge and group work performance.

- Safety
- Allowance
- Planning and organizing
- Adaptability.

c. How to improve worker’s performance rating?

One of the best ways improve worker’s performance rating is to actually give them a
reason to do so. Recognizing your workers for a job well done will make them feel
appreciated and encourage them to continue increasing their productivity. Next, The
ways to improve worker’s performance rating is communicate effectively. Every
manager knows that communication is the key to a productive workforce. Then,
keep goals clear and focused. If a goal is not clearly defined and actually
achievable, employees will be less productive. So, try to make sure employees’
assignments are as clear and narrow as possible. Let them know exactly what you
expect of them, and tell them specifically what impact this assignment will have.

v. When calculating Standard Time, we need to add allowance factor for the worker doing the
job

Answer:

Yes.This is because allowances are considered and provided to compensate the

worker/operator for the production interruptions that may occur due to his personnel
legitimate needs or the factors beyond his controls. For example the delay may occur due to
operators personnel needs such as drinking water, taking tea, going to toilet etc.,
 unavoidable delays like waiting for tools, materials or equipment, maintenance of machine
and periodic inspection of parts/materials.The fundamental purpose of allowances is to add
enough time to the basic time of the production in order to enable the average worker to
meet the standard while performing at a normal pace. The determination of allowances is
probably the most controversial part of work study.

vi. Explain THREE (3) factors needed to be considered in determining the Allowance Factor.

Answer:

1) Environmental factors.
- While determining the relaxation allowance, certain factors like heat, humidity, vibration,
dust, light intensity, noise level etc. have to be taken into account. These are called the
environmental factors and these factors are of seasonal nature. These factors are more
significant for workers conducting the work under open air or where the environmental
factors affect the work such as work in a construction company or in shipyards.
2) Individual factors.
-A thin, alert and active worker requires a smaller allowance to recover from fatigue than an
inept, dull and obese worker. In the similar manner, every worker conducts his work
according to the Learning Curve which is unique for everyone.
3) Nature of work.
-Allowances calculated or determined for light or medium work are not acceptable for
operation involving very hard work and which is done under very difficult conditions. For
example, the work involving more eye movement, more physical work (by hands or by legs)
or more mental work needs greater allowances than that of light easy and work involving
very less physical work or movements. Some factors inherent to the job such as gloves or
masks to be worn while working, constant danger or risk regarding the surface finish or
quality of the work etc. varies from job to job. Thus, the determination of allowances
becomes more difficult and controversial.
 vii. Associate the importance of work measurement with work method in work system design to
determine the best standard time for the plastic cloth-peg assembly.

Answer:

- Work measurement is very important for promoting productivity of an organization. It enables

management to compare alternate methods and also to do initial staffing. Work
measurement provides basis for proper planning. Since it is concerned with the measurement of time
it is also called 'Time Study’.

5.0 CONCLUSION
i. Conclude your finding why work measurement is important in productivity measurement and
improvement.

Answer:

ii. Give your suggestions and ideas on how Work Method improvement for plastic cloth peg
assembly is important to improve the Standard Time.

Answer:
6.0 OTHERS

FORMULAS & TABLES

Using R factor to determine how many observations required on + 5% accuracy and 95% level of
confidence
• Factor R = Range / Average Observed Time
ASSESSMENT CRITERIA:

Your response to each task will be graded separately based on the checklist attached. To obtain
maximum marks, ensure that your response addresses each of the tasks in the question accordingly.

Assessment checklist for Lab Activity 2

Assessment tasks Mark allocation LO PO C/P/A level

Procedure (Justification of the work 15 LO3 PO5

P2 - Set
system design measure)

Outcome (Ability to show data in 20 LO3 PO5 P5 - Complex Overt

tables ) Response

Outcome (work system design 30 LO3 PO5 P5 - Complex Overt

Measurement) Response

25 LO3 PO5 P5 - Complex Overt

Outcome (Discussion) Response

Discipline (Ability to perform lab 10 LO3 PO5 P2 - Set

and safety regulations)

TOTAL 100

SPECIFIC INSTRUCTION

1. Answer in ENGLISH .
2. Must include list of references .
3. Submit your assignment ONCE only in a SINGLE file.
4. Submit your assignment ONLINE.
5. Submission date: Week 4
6. This lab report/activity accounts for 5% of the total marks for the course.
APPENDIX
 LAB 3
FAKULTI TEKNOLOGI KEJURUTERAAN
MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMW 3353 MANUFACTURING MANAGEMENT

LAB REPORT 3

WORK SYSTEM DESIGN

INSTRUCTOR’S NAME

STUDENT’S NAME MATRIX NO:

S1.
S2.

ASSESSEMENT RUBRICS
MARK GIVEN MARKS
ASSESSMENT TASK/ITEMS
ALLOCATION S1 S2
1. Procedure (Justification of the work 15
system design measure)
2. Outcome (Ability to show data in tables) 20
3. Outcome (work system design 30
Measurement)
4. Outcome (Discussion) 25
5. Discipline (Ability to perform lab and 10
safety regulations)
TOTAL MARKS 100

Approved By: ………………………………………………..…..

(Instructor’s Signature & Stamp)

Date: …………………………………………….........