Process improvement in manufacturing industry using time study and work measurement analysis

Mohd Zain, Nurulwahida (2021) Process improvement in manufacturing industry using time study and work measurement analysis. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Time study analysis and work measurement method is defined as a scientific analysis approach meant to find the optimum way to do a regular task and measure the time spent by an average worker in a set workplace to accomplish a particular task. The primary goal of this project was to enhance productivity at the biscuit company by implementing time study analysis and work measurement methods. Due to the lengthy production process, the industry was unable to meet the high demand for long rusk biscuits from customers. The objective of the study is to conduct time analysis and work measurement method in the manufacturing line. The approach of direct observation and video recording was used to identify the present process flow of the long rusk biscuit. This study only focuses at the first seven processes in the manufacture of long rusk biscuits, out of a total of 17. For detailed study, each main process was divided into several work elements. The observation was carried out on the seven key processes, taking into consideration the cycle time and motion of each job done by the worker, and the standard time was established by taking allowances and performance rating into account. A cause-and-effect diagram was used to examine seven problems in the present production process. Four of the seven critical issues were analyzed utilizing 5 whys techniques, and each problem was given a countermeasure. Another aim of the research is to provide a process flow alternative to reduce manufacturing time. The process flow that leads in a prolonged production line has been determined; there is one main process and three work elements that cause effort required to produce the long rusk biscuit. There are four solutions that have been proposed to improve the production time, which is adoption of 5S techniques for Process 1, adoption of new Standard Operating Procedure (SOP) for Process 2, and adoption of new equipment for process 4 and 7. The proposed alternatives are capable of creating a well-organized workstation, making the work method easier to execute, and optimizing the labor action to perform the specific task.

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