Productivity improvement in UMW manufacturing industry using time study and work measurement analysis

Zulkarnain, Muhammad Izz Taufiq (2024) Productivity improvement in UMW manufacturing industry using time study and work measurement analysis. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Work measurement techniques and time study analysis are scientific methodologies meant to determine the best way to execute routine chores and calculate the time taken by an average worker to finish particular activities. This research sought to apply these techniques to improve output in UF (ultrafiltration) membrane manufacture. A long manufacturing procedure made the sector unable to satisfy great demand. With an eye on processes 1 through 6, the study aimed to do time analysis and work measurement on the UF membrane production line. The current process flow was found by direct observation and video capture. Every key procedure was split into multiple work components for close examination. Six main processes were observed under consideration of the cycle time and motion of every job carried out by employees. Accountable for allowances and performance evaluations, standard timings were developed. Seven current manufacturing process issues were investigated using a cause- and- effect diagram. Using the 5 Whys approach, three of these important concerns were examined and countermeasures for every one of them were suggested. The study sought to offer substitute process flows to cut production time as well. The study found three labor components and one primary mechanism causing delays in UF membrane output. The three main concerns identified were insufficient training, outdated machinery, and inefficient workflow. The impact from these issues resulted in frequent errors, machine downtime, and high cycle time per unit. Three solutions were proposed: implementation of Kobetsu Kaizen approaches for Process 4, implementation of Poka Yoke in Process 5, and adoption of new equipment for Process 6. These proposed solutions aim to maximize labor actions for specific tasks, simplify work techniques, and organize the workspace. Implementation of these solutions is expected to reduce errors, minimize downtime, and significantly reduce production time.

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