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Introduction
The 20th century World’s globalization and development invited the citizens to
reside in urban areas favoring lifestyles in the vicinity of their work, schools and comfort;
in 2008, for the first time in history, more than half of humanity was living in urban areas.
Behind national development, the construction sector was the engine of growth, along
with of productivity that serves as one of the vital aspects of the construction industry.
in the Philippines, preferred the Concrete hollow block having as components sand and
cement. The concrete hollow block, compared to the brick is preferred because of its
durability, sound and fire resistance, rapid production, thermal insulation and for its low
cost. Statistically, CALABARZON region has been ranked 5th in the Philippines in terms
of number of constructions. In line with this, with the non-stop cities’ development and
the construction industry is in its growing phase, the demand for concrete hollow blocks
is also arising.
construction company that has a strong focus on business development and value.
They started with small projects to large Government projects which gave the company
the opportunity to introduce itself in construction industry, afterwards, the company also
decided to arise batching plant and produce their own CHB products. The company
various problem successively, were found in: workplace condition, work performance,
The production line of hollow block making process in Calamias has six workers who
Three concrete hollow blocks are produced within a process cycle. Finished goods have
an average weight of 8.5 kilograms each. The Architect stated that the company is
having difficulties in coping with increasing demand of hollow blocks to supply the
18000
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12000
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0
Jan' Feb' Mar' Apr' May' Jun' Jul' Aug' Sep' Oct' Nov' Dec' Jan' Feb'
18 18 18 18 18 18 18 18 18 18 18 18 19 19
Demand Output
from January 2018 to February 2019. It can be seen that the company’s demand is not
presented that the company was not able to meet the demand noticeably by month of
March 2018 up to February 2019. Considering other factors such as number of labor
and days of work, it still clearly show given the monthly demand, company is having
B. Process Flow
inches wide) used in small construction and the raising of small rooms like bathrooms.
On the other hand is equipment B that produces CHB 5 (Concrete Hollow Blocks 5
inches long and 3 inches wide) used in private and residential projects. Lastly is the
equipment C producing CHB 6 (Concrete Hollow Blocks 6 inches in length and 3 inches
molding, drying and stacking. In mixing, the raw materials are put together with the
proportions such as 2/3 palanas, 1/3 cement and undefinable quantity of water in the
mixer. Steel pallets are then put inside the equipment, they will serve as the blocks’
bases.
The process of producing Concrete Hollow Blocks consists of four basic
processes: Preparation, Oil Coating, Mixing, Molding, Drying and Stacking. The current
Supply Co.
The following are the process description on producing Concrete Hollow Blocks:
The process consists of preparing all the raw materials needed from the area
provided such as palanas, cement and water. Applying oil coating on the equipment
was included in the process to provide smooth service where the mixture will be placed.
Steel pallets are placed inside the equipment molder which will serve as the blocks’
bases.
Step 2: Mixing
Raw materials consists of two thirds of palanas, one third of cement and
The produced concrete mixture will be placed on the rectangular steel container
that lets the concrete mixture dispense gradually inside the equipment’s molder. The
operator will turn on the equipment that will give uniform vibration which sets the mixture
to the pallet. Simultaneously with the vibrating equipment, the operator will perform the
repetitive sliding motion of pushing and pulling of steel container to fully dispense the
Step 5: Drying
The compacted blocks are pushed upward from the molder and transported to
the material handling facility for drying process. It will take one to three days for the
Step 6: Stacking
After drying the concrete hollow blocks within one to three days, the hollow
Among the 6 Ms Method and Measurement resulted to be the root causes behind
the problem. In measurement, is presented the absence of standard time: the observers
recorded ten different records, once compared, high standard deviation was found, this
1/3 of cement and unquantifiable water; during the process itself, the operators
unattentively tend to add the components regardless the standard measures causing
then, wastage of material. Third, lack of equilibrium of tasks: tasks are not equally
divided among the operators, forcing at times severe duties to some operators, while
work, as the operators’ qualifications were not taken in consideration: sometimes drivers
were used in the assembling of CHB, their fatigue factors not taken in consideration and
lack of ergonomically design equipment; unity of direction because no specific order nor
plan were assigned to the operators: they didn’t have target output to encourage or
pressure the operators, tasks not well observed and initiative because based on the
interview with the supervisors, it was observed they had good ideas to improve the
C.Research Objectives
(CHB) Making Process in R.Y. Saligvera Builders Construction and Supply Corporation.
Source: https://www.visual-paradigm.com
engineering’s (BPR) flow on how to improve business process effectively. The process
management capability of BPR can help a business design, plan and asses the process
though process map. Business Process Re-engineering will able the company to
Business Process Re-engineering initial step is the mapping and analyzing of the
current process. In analyzing the existing process, Motion and Time Study, Work
Measurement and Value Stream Mapping (VSM) are used. The steps included in
method study are select the work, record the data by presenting charts, diagrams and
models to examine the data and develop a more economical way. Work measurement
used by breaking down the jobs into elements measuring the quantity of work involved
in the methods by direct observation and using time study synthesis. With the methods
inefficiencies will be identified. After that is to redesign new process to visualize desired
business process and solve the problems identified, also with the use of VSM.
Redesigned new process may import the current process map to make changes or start
from scratch. The utilization of Value Stream Mapping (VSM) will be of consideration.
Value stream mapping is a lean management tool that helps visualize the steps needed
to take from product creation to delivering it to the end-customer. The VSM allows the
Analysis with the use of different Industrial Engineering tools such as Flow process
chart, Gang chart, Yamazumi chart etc. Things that will be identified include areas of
changes, gaps to be studied and solutions to address the gaps. Identifying project
works comes next to classify the set of work packages and structure the work leading to
the right person to complete the work and setting of completion date for the particular
work. Lastly is the performance assessment wherein KPI for performance measurement
will be identified and conducted on an on-going basis. Assessing the improved working
E. RELATED LITERATURE
A country's growth engine is the construction industry, along with productivity that
serves as one of the building industry's essential aspects. The construction industry
serves as one of the most important and significant sector that supports a country's
creating jobs for the masses, and creating a link between the economy and other
industries (Dixit et al., 2018). Therefore, improving the building productivity is of critical
companies and nations to increase profitability, reduce costs, create and maintain
In line with the industry are the sectors including construction services and
construction manufacturing of masonry units. One type of building construction that can
masonry units specifically the precast material, cement concrete hollow block. Cement
concrete hollow blocks (CHB) are modern building materials and are used as such in all
buildings such as residential, commercial and industrial buildings. The CHB varies in
different sizes and shapes and were widely used in developing countries, including the
Philippines, for masonry work. With the growing phase of modern construction, demand
the cement concrete hollow blocks, raw materials including sand, cement, fine gravel
and water were used. The process of producing CHB consists of four basic processes
construction industry, several problems were encountered thus recognizing the industry
poor working environment, lack of man power, low productivity and so on.
set of inputs in proper quality and quantity into a specified set of outputs thus achieving
an industry's goals.
According to Palop 2016, the term "productivity" has different meanings for
"productivity" will have a wide variety of meanings. Some will define it as the rate of
productivity generally as the average direct labor hours required to install a unit of
material. It is said that perfect productivity can be achieved with a 40-hour work week,
with people taking all the holidays and vacation days as planned, all of the engineering
drawings would be 100% complete and no delays of any kind during construction;
everyone would work safely; everything would fit perfectly the first time; the weather
would be 70 degrees F; and there would be no litigation at the end of the project. The
study can be associated with manufacturing in construction industry specifically
production of precast materials were working condition, processes and standards are of
On the other hand, Moktadir et al., 2017 defined productivity as the ratio between
wealth output and resource input used during the production process. Moreover,
productivity index.
Output
Productivity =
Input
productivity can be used to measure the extent to which a specific output from a given
input can be extracted. Moreover, increasing productivity is one of the key issues to
boost more profit from the same resource types. Improving productivity helps satisfy
customers and reduce the time and costs involved in developing, producing and
delivering products. Moktadir et al., also added that productivity includes an effective
prices, and process inventory and time delivery levels. Productivity is regarded as a
turnout and reducing set-up time. Productivity can also be achieved by increasing the
such as 5S, Motion Study, Work Measurement, VSM, TPM, Kanban, Kaizen and others.
The tools are applicable in any industry including manufacturing in construction industry.
quality and service this approach focuses on business process optimization (Boonsiri,
2016).
approach is Agunshinta et al., (2015). The research shows that existing business forms
in a clinical research center situated in Bekasi are still run physically. It requires a great
and obtainment units. These wasteful procedures are broke down here. Be that as it
may, the utilization of data innovation must be offset with the availability of existing
assets to work. Without supporting assets, particularly HR accessible, data innovation is
nothing. The Business Reengineering Process strategy used to fathom the current
reenacts the current business forms and the proposed business forms, plays out an
investigation of reproduction results, and looks for corporate open doors utilizing data
innovation. This Business Process Reengineering (BPR) investigate helped the clinical
productivity and adequacy of existing procedures that will at last diminish cost and time.
Results demonstrated that business forms increment with data innovation use and limit
Moreover Chin-Tsai' et al., (2011) also uses the Business process Re-
endure, ventures must almost certainly alter their unique business forms.” BChin-Tsai’
for undertakings to upgrade their inward and outer correspondence and capacity. In the
study conducted, investigation proposes a BPR model for provider choice in hardware
Taiwan. The BPR model furnishes chiefs with another perspective about business
forms. In this original copy, the BPR model for buy furnishes chiefs with another
perspective. In the buying office, undertakings dependably put a great deal of exertion
into sparing expenses and avoiding misuse. A way to deal with putting orders
objectively spares working hours for representatives as well as keeps away from
maltreatment in buying conduct. The BPR model gave in this examination should
consolidate the ERP idea and data innovation for augmenting its comfort and
helpfulness. The BPR model offers another thought for procedure improvement; the
ERP idea coordinates purchasers (request) and providers (supply); the IT device
assumes the job of accelerating this reengineering activity. It is evident in the research
that the approach benefits the company by systematic method given by Business
Process Re-engineering.
the different lean tools to be executed. Work Study, Work Measurement, Methods Study
and Value Stream Mapping are the common tools used in improving a process in a
manufacturing industry. These tools play a significant role in providing innovative ways
means of a consistent system of the work done in an industry, in order to attain the best
possible use of the men, machines, materials, available in the building at present.
Tapiwa et. al, (2013) also defined work study as the specific examination of the
techniques for doing exercises in order to improve the persuasive utilization of assets
and to set-up benchmarks of execution for the exercises being completed. It is one of
the most useful assets that administration can use to improve efficiency. The
implementation lists of each work think about procedure should yield improved
worker resolve, decreased turnover and non-attendance. The term ‘work study’
embraces method study and work measurement. Method study, being the systematic
maintenance policy to guide the engineering section on how they operate contributed to
most of the challenges being experienced. The reason for a maintenance structure is to
limit or lessen the span of breakdowns in this way expanding plant accessibility. A
In addition, work study can be divided into method study and work measurement
human working methods by considering all factors that affect the working efficiency and
conditions. After the job of interest has been selected, time study can be examined by
recording all information about the job, breaking the job down into elements, examining
those elements and determining the sample size, recording the time to perform each
element using a stop-watch, assessing the speed of working, converting the observed
time to basic time, determining the allowances, and determining the standard time.
In the study that Moktadir and co-researchers have conducted year 2017 in the
industry's profit earning largely depends on improving productivity. The study proves
how the production process and operations gap can be found. Increased productivity
was achieved by implementing work study and method study and establishing new
effective processes for specific operations. The study illustrates in particular the
products. Line balancing is the key point in increasing productivity for specific products.
The study also shows the improvement in productivity by reducing work content and
balancing line. A combination of lean and work study technique could be used to carry
out further research. Time study has been taken by stop watch and determined the
basic time for all operation sequences and the capacity of each workstation per day has
been calculated.
In earlier the work content per piece was 80.04 minutes. After line balancing and
critical analysis the work content was 71.03 minutes. So, that the work content reduced
to 9.01 minutes after line balancing and critical method work. In this proposed line the
standard output at 100% efficiency was 656 pieces bag per day. Input of this proposed
line was 582 pieces bag per day. The proposed method helps to increase productivity to
12.71% with reduction of work content and line balancing applying method study and
work measurement.
A Case Study of Vision Lens Factory (Pisuchpen., et al.,2014) states that improved the
bottleneck process in a lamp assembly line using the basic concepts of work study,
ECLS, and line balancing. The result shows the improvement for both product and
operator. The reduction in production time resulted in better productivity. Khalid and
Saleh (2011) studied the manufacturing process in the automobile industry both before
and after the improvement had been made, by using an operation process chart. The
bottleneck of the process was selected to study and improve to increase manufacturing
capacity.
Also, there are many components that impact the productivity of an assembling
line. The most broadly handled issue is the means by which to improve effectiveness
and efficiency. Motion and time study about system is one of the productivity
improvement strategies utilized in many assembling organizations. Motion and time
ideal approach to execute the redundant undertaking and to quantify the time spent by a
normal laborer to finish a given task in a fixed work environment. The points of these
frameworks are to make items at creation rates in the briefest time, in the most
profitable way, economically and with the quality required. The points of the examination
production system in little and medium industry. The goals are to re-structure the format
conducted by Cury and Saraiva (2018) utilizes the Motion and Time study. The study is
all about the application of motion and time study in the production line of organic
lenses in Manaus Industrial Hub. Researchers stated that the time and motion study
Work Study can result to Work Standardization which is one of the tools that can
of the most powerful but least used lean tools. By documenting the current best
practice, standardized work forms the baseline for kaizen or continuous improvement. It
reduces the variations of the process and improves the quality of products and
processes. In this contribution is described 5S method, which is used in organizations to
eliminate, respectively elimination of waste in the workplace through five steps. Mĺkva et
al., (2016)
guiding them to operate uniformly and follow instructions in order not to make errors.
situations of choice because employees decide the extent to which they adhere and
execute said standardization. The standard data acquired will be applicable in one of
Another lean manufacturing tool is the Value Steam Mapping (VSM). Singh et. al,
(2015) states that “Value Stream Mapping is the visualization and work processes are
streamlined using Lean Manufacturing tools and techniques”. VSM helps in the
processes to identify, demonstrate and decrease waste. Waste is any activity not
adding value to the final product.VSM can serve as a lean manufacturing blue print.
by Yuvamitra et al., (2017) states that “In today’s competitive market, in order to
value stream mapping. Value stream mapping is used to visualize the current process
for easier understanding and problem identification. Throughout this case study, Lean
concepts have been applied to the rope manufacturing process. The goal was to
decrease the overall time required for the company to get the customer’s order.” In the
study, lean concepts were applied by changing the setup sheets for all departments, the
processing time will be reduced by an estimated 68%. Reducing the process time will
also affect the waiting time for each order. This case study applied Lean changes to the
information flow system, as well as the material flow system, to reduce the total time
required from the time an order is received to the time the rope is shipped to the
customer.
assembling was likewise considered and it demonstrates that the floor format can make
the entire procedure progressively proficient. 6.5 minutes can be spared in material
taking care of by changing the assembling floor setup to make the material stream
progressively sorted out. This is an absolute investment funds of 33% for material
dealing with time. This contextual analysis likewise demonstrates that having a security
supply of material will also decrease the hanging tight time for the procedure by
evaluated 88%. Executing changes in both the data stream framework and the material
stream framework will spare an expected 75% for the assembling time of the rope. At
the end of the day, the proposed changes will reduce the time it takes to produce the
rope and ship the request from 36 days to 9 all out days.
Another case study is the Value stream mapping in glide manufacturing of Insti-
Tools in Zimbabwe. The case study was performed by Dzanya et. al, 2015. According to
the study, the Glides are basically plastic components manufactured for supporting
beds and sofas (legs). Due to globalization and rapid advances in manufacturing
is the tool for that. Value Stream Mapping (VSM) is a tool for Lean Manufacturing which
is used in mapping and identifying all specific actions required to remove the non-value
activities in manufacturing process. This paper aims to eliminate and improve the quality
in the production of Glides by applying Value Stream Mapping. The current state map
(CSM) was designed, analyzed and suggestions were then given to improve the
operational process whereas the future state map (FSM) was drawn for lean
implementation.
In line with the study of glides, lean production means continuous improvement.
Value Stream Mapping (VSM) have been established to be a useful tool to eliminate
some waste in a cycle and find that there are more waste for you to eliminate in next
cycle. The CSM helped to identify the areas of potential improvement while the FSM
suggest ways to reduce waste and increase throughput. As a result of this study entitle
the lead time was reduced by 60.88%, there was no reduction in WIP, Processing time
Guzel et. al, (2018) case study of textile industry utilizing Value Stream Mapping
implemented increase productivity and effectiveness by removing 64% of lead time with
the use developing a value stream map for a textile producer to find the resource of the
wastes, non-value added steps and look for the appropriate solution for these. Lean
techniques such as 5s, takt time, JIT were applied in this company and the results were
shared with managers of the company. Production Lead Time (PLT) downed from 14.5
deriving and defining target conditions in the value stream of packing also uses VSM.
The authors planned logistic processes, the Operation Sequences of Forklifts of the
processes and transport sequences and applied them as a result, productivity increased
by 36%. The study operated also helped the company to attach itself to continuous
improvement.
With the proper execution of lean manufacturing following the Business Re-
organizations can gain after implementing such tool are ensuring better product quality,
reducing equipment breakdown, reducing total costs, utilizing resources properly, line
improving employees ' working attitude. Most organizations that was able to achieve the
result of improvement to minimize any equipment breakdown, lessen idle time, utilized
resources properly and provides a systematic flow resulting to a higher productivity such
The study will provide information and available data that could help reduce non
value adding, lessen idle time and improve the productivity to increase the production
capacity of the workers of the Concrete Hollow Block Making process of RY Saligvera
Builders and Construction Supply Company. The results of the study will benefit the
following:
The findings of the study will contribute to the benefits of the society as
productivity pays a great role in everyone’s life. The study revolving around the
innovation will belong to a step nearer to the goal of achievement full and productive
employment, and decent work, for all women and men by 2030. Promoting sustainable
industries, and investing in scientific research and innovation, are all important ways to
The research will set standards, their tasks and responsibilities toward the goal
operators’ tasks will be allocated, avoiding too much stress, evaluating their physical
conditions and limiting their tasks accordingly. Job allocation will avoid confusion
between the operators and through their collaboration, the target goal then will be more
reachable. this study would enable the laborers to improve their methods of working
This study will benefit the company to increase the productivity of Concrete
Hollow Block Making Process in RY Saligvera Builders and Construction Supply Co.
Since the demand of the CHB in construction firm is not stable and the company is
lacking to meet the target output, the productivity improvement will have a great impact
to the company. Company workers would also benefit, through the accomplishment of
the goals of the company, the workers could have more motivation and incentives in the
future.
This study will be helpful to the researchers to have more knowledge and
experience in managing and dealing with different problems of the company and how it
can be solved. The study will also help the researchers to be more familiar with different
Industrial Engineering tools and use it in a real-world situation. Also, the researchers will
everything that they do. This study will also enhance the knowledge such as logical and
intellectual skills of the researchers that they can apply in the future. As the researcher’s
experiences broaden through this study, the overall personality of the researchers
would be enhanced.
conducting their research. For future ideas, this research can serve as a basis for
further improvement of the study giving various ideas that would enhance their
knowledge. The theories, concepts, frameworks, recording and tools used for analyzing
The study will focus on eliminating idle time to improve productivity incurred by
the workers on the line. The study will include the process on producing cement
Concrete Hollow Block; tools will be evaluated to suggest ways on how to improve the
performance of the workers under the line which produces Model Size number six (#6)
Other product of cement Concrete Hollow Block including Model Sizes numbers
four (#4) and five (#5) will not be covered on this study. The proposed improvement
would only cover the five workers on the production line of CHB #6. The study will not
comprise other factors that cause inefficient production such as, poor organization
operational definition:
Cycle Time. The amount of time from the moment the operation started of making
Idle time. The ineffective or unproductive time of the workers and machines in
Palanas. Mixed sand and fine gravels that are used as one of the raw materials in
Productivity. The measure on production efficiency of how the target outputs of cement
Concrete Hollow Blocks (CHB) being met in Saligvera Builders Construction and Suppy
Company.
Production. The process of making Concrete Hollow Blocks (CHB) wherein the raw
materials used is mixed to become as finished goods that is then delivered to the
customers.
Time Study. The method which involves direct observation and the measurement of the
operators’ work using a stopwatch to determine the time required for the completion of
elements for each worker in making cement Concrete Hollow Blocks (CHB).
Flow Process Chart. The tool used to study the process in detail to identify the areas
Gang Process Chart. The tool used to illustrate the relationship of the manual work
performed by the workers and the equipment involved in making cement Concrete
Value Stream Mapping. The tool used for lean manufacturing to analyze and improve
the flow of information or materials required to produce cement Concrete Hollow Blocks
(CHB).
Yamazumi Chart. The stacked bar chart used to show the balance of cycle time
workloads between the five operators of the Model Size #6 production line of cement