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Lab Report EWS 1B

The document summarizes a time and motion study conducted to analyze the assembly process of a truck. Time studies were performed on 4 assemblers performing different elements of the assembly. Basic times were calculated for each element and an overall standard time was determined. A flow process chart mapped the assembly steps. Key findings included the basic and standard times for each element. The conclusion recommended improvements to reduce unnecessary steps and improve productivity.

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Mojery Mohau
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© © All Rights Reserved
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Download as DOCX, PDF, TXT or read online on Scribd
50 views

Lab Report EWS 1B

The document summarizes a time and motion study conducted to analyze the assembly process of a truck. Time studies were performed on 4 assemblers performing different elements of the assembly. Basic times were calculated for each element and an overall standard time was determined. A flow process chart mapped the assembly steps. Key findings included the basic and standard times for each element. The conclusion recommended improvements to reduce unnecessary steps and improve productivity.

Uploaded by

Mojery Mohau
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Department of Mechanical and Industrial Engineering

Technology
BEngTech (Industrial Engineering)
Engineering Work Study B1 [EWSMIB1]
Time and method study
Group No:
Surname and initials Student number

Due date:
1. AIM
The experiment's goal is to discover the time it takes to finish step in the assembly of a truck,
as well as the performance and productivity of each member, to reduce unnecessary steps.

2. LITERATURE REVIEW

The PDCA (Plan-Do-Check-Act) cycle/Deming cycle is a widely used process improvement


framework in various industries. It was developed by Walter A. Shewhart in the 1920s. The
PDCA cycle involves a systematic approach to continuous improvement.
Here's a brief literature review on the PDCA cycle:
Historical Development:

The PDCA cycle was first implemented to improve manufacturing processes and has its
origins were statistical quality control. Shewhart initially addressed it in connection to
statistical process control charts.
Deming, an established figure in the field of quality management, placed emphasis on the
PDCA cycle's contribution to management and organizational process enhancement.
Plan (P):
Organizations investigate issues, set goals, and make decisions regarding improvement
throughout the "Plan" phase. Defining goals, strategies, and action plans are part of this
phase.
Literature often highlights the value of precise planning, which includes establishing
measurable objectives and identifying resource needs.
Do (D):

The "Do" phase involves carrying out the planned revisions. It is the phase where
recommended improvements are implemented.
Research on this stage frequently highlights the importance of efficient project
management, tracking development, and recording modifications made.
(C) Check:

Organizations evaluate results and compare them to the goals set during the planning phase
during the "Check" phase. The gathering and analysis of data is important at this point.
Several tools and approaches for data analysis, including as statistical techniques and key
performance indicators (KPIs), are covered in the literature.
Act (A):

The "Act" phase focuses on executing corrective measures according to the "Check" phase's
findings. This may entail modifying the strategy, streamlining procedures, and achieving
critical advancements.
Researchers often stress how important it is to use the data gathered during the "Check"
phase to guide ongoing improvement initiatives.

PLANNING
-Organise all of our elements and place them next to the nuts and bolts needed to assemble
each element.
-Check if all elements are available.
-Plan on which elements are we going to assemble first by looking on with parts will most
elements be attached to.
-We plan on who will do what by assessing on who has the most experience in this type of
work.
-Plan on how long you must spend on assembling each element.
List of Elements Equipment (Tools) Fastener Time (seconds)
Fastening the floor - Small Spanner - Socket screws 20s Each member
member side -Allen key -Nuts (M6)
members (2 times). -Small washer

Join the wheel and -Allen key -Socket screws 14s Each
the wheel holders (4 -Nuts
times)
Time to position the -None -None 12s
wheels to be fastened

Fasten the wheel -Big Spanner -Medium washer 15s Each


holder to both the -Machine screws
floor panel and floor -Nut (M8)
side members.
(4 times)
Fastening the front -Small Spanner -Small Washer 17s
bumper to the floor -Nut (M6)
panel. -Socket screw
Fastening the rear -Small Spanner -Small washer 17s
bumper to the floor -Nut (M6)
panel. -Socket screw
Fastening the seat to -Big Spanner -Bolts 19s
the floor panel. -Medium washer
-Nut (M8)
Fastening the bracket -Small Spanner -Small washer 9s Each
to the doors (2 times) -Allen key -Nut (M6)
-Socket screw
Fastening the door to -Small Spanner -Small washer 20s
the floor side -Allen key -Nut (M6)
member. -Socket screw
Fastening the roof to -Hands -Nut (M6) 20s
the brackets on the -Allen key -Small washer
doors. -Socket screw

Fastening the -Small Spanner -Nut (M6) 17s


windscreen to the -Allen Key -Small washer
roof brackets. -Socket screw
Fastening the bolts -Small Spanner -Nut(M6) 12s each
and nuts to the gaps -Small washer
on the back of the -Socket screw
truck.(6 times)
Inspect to truck, -None -None 20s
make sure are the
parts are installed
correctly
3. TIME STUDIES

3.1. TIME STUDY SHEET


R= rating, WR= Watch reading, ST=Subtracted time BT=Basic time (Normal time)
Element 1
Assembler: Brian Magagula Timer: Moeti Mojeri
Element description R WR ST BT
Fastening the floor member 50 52.8s 52.8s 26.4s
side members (2 times).
Fasten the wheel holder to 50 129.6s 76.8s 38.4s
both the floor panel and
floor side members.
(4 times)
Time to position the 100 141.6s 12s 12s
wheels to be fastened.
Fasten the wheel holder to 75 220s 78.4s 58.9s
both the floor panel and
floor side members.
(4 times)
TOTALS 220s 135.7s
Element 2
Assembler: Moeti Mojeri Timer: Brian Magagula
Element description R WR ST BT
Fastening the front 125 240.1s 20.1s 25.13s
bumper to the floor panel.
Fastening the rear bumper 125 261.5s 21.4s 26.75s
to the floor panel.
Fastening the seat to the 75 283.5s 22s 16.5s
floor panel.

TOTALS 63.5s 68.38s


Element 3
Assembler: Simphiwe Mokori Timer: Aleck Maphanga
Element description R WR ST BT

Right Door Panel to Floor 75 296.2s 12.7s 9.53s


Panel
Left Door Panel to Floor 75 310.1s 13.9s 10.43
Panel
Fasten the roof brackets to 75 325.7s 15.6s 11.7s
the door
Fasten the roof panel to the 75 342.9s 17.2s 12.9s
roof brackets.
TOTALS 59.4s 44.56s
Element 4
Assembler: Aleck Maphanga Timer: Simphiwe Mokori
Element description R WR ST BT
Fasten the wind shield to the 50 362.4s 19.5s 9.75s
roof brackets
Fastening the bolts and 75 407.4s 45s 33,75s
nuts to the gaps on the
back of the truck.
(6 times)
Inspect to truck, make 150 427.4s 20s 30s
sure are the parts are
installed correctly

TOTALS 50 84.5s 73.5s

3.2. CALCULATION

RBT (1) =∑BT/n

= (26.4 + 38.4 + 12 + 58.9)/4 = 33.93

 RBT (2) =∑ BT /n
= (25.13 + 26.75 + 16.5)/3 = 22.79

 RBT (3) =∑ BT /n
= (9.53+ 10.43 + 11.7 + 12.9)/4 = 11.14

RBT (4) = ∑ BT /n

= (9.75+ 33.75+30)/3 = 24.5

 WC (1) =RBT (1) +(RBT (1) *ALLOWANCE%)


=33.93 +( 33.93 * 5%) = 35.63

 WC (2) =RBT (2) +(RBT (2) *ALLOWANCE%)


=22.79 +( 22.79 * 5%) = 23.93
 WC (3) =RBT (3) +(RBT (3) *ALLOWANCE%)
=11.14 +( 11.14 * 5%) = 11.70

 WC (4) = RBT+ (RBT (4) *ALLOWANCE%)


=24.5 +(24.5 * 5%) = 25.73

TWC = WC (1) +WC (2) +WC (3) +WC (4) = (35.63 +23.93 + 11.70 +25.73) = 96.99
STD =TWC+ (TWC*CONTIGENCY ALLOWANC)
= 96.99 + (96.99 * 10%) = 106.69

3.3. TIME STUDY SUMMARY SHEET


BT= Basic time
F= Frequency
Obs. = Number of observations

Element number Element description BT F Obs.


4. METHOD STUDY: FLOW PROCESS CHART
Description symbols remarks

Separate each element


Place all similar elements
together.
Delegate on who does what
Join the side panels to the floor
side members.
Attach wheels to wheel holders
Join the wheel holders to the floor
panel as well as the floor side
members.
Attach the rear bumper to the
floor panel at one end
Attach the front bumper to the
floor panel at the other side
Attach the seat to the floor panel
Attach the bracket to the roof and
wind screen.
Attach the doors to the floor side
members.
Rench the sides of the brackets
that possess the roof and
windscreen to the doors.
Rench the remaining bolts and
nuts into the holes in the back of
the truck
Check if all bolts and nuts are
tight.
Store the truck in the submission
area
5. FINDINGS/RESULTS

6. CONCLUSION AND RECOMMENDATION

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