Redesign work system for productivity improvement : a case study

Leow, Mei Mei (2017) Redesign work system for productivity improvement : a case study. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This case study was concerning on identify, analyze and propose solution for the selected topics and industry that involved. This project was done at one of the balloon manufacturing company at Malacca, Malaysia. There are issues that having problem on the business which is the packaging department cannot reach their monthly target and delay the shipment to customer. This related to the packaging process of the balloon until the shipping process. This case study was focus on the packaging process and solving this problem by stopwatch time study and line balancing method. Stopwatch time study used to determine the packaging process flow and the standard time on each process. For line balancing method is used to reassign the workload among the operator, minimize idle time and balance bottlenecks on the packaging line. Due to the variety of the product in the balloon manufacturing company, this case study focus on two main type of product which name as product A and product B. Product A is single colour and Product B is mix colour in one packet. After the stopwatch time study, the product A standard time is 1669.88 sec/carton, while product B standard time is 2606.43 sec/carton. By using line balancing method the current packaging line efficiency is determined. Line efficiency for product A is 53% and product B is 64%. The current line efficient is not sufficient, the standard time is beyond the takt time. The product do not produce under the takt time, thus do not meet the customer demand. After reassign the workload among the operator, bottlenecks issues solve in the packaging line. Both product line efficiency increases to 89% for product A and 93% for product B. Based on the current packaging process, there are a few recommendation made in order to improve the efficiency of the packaging line.

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