WORK STUDY

WORK SAMPLING
GERALD KWINJO H1111185F I.M.E

A DETAILED WORK STUDY DONE ON THE 7th OF NOVEMBER 2011, AT OLINDA MANUFACTURING WITH THE MAIN AIM OF MEASURERING THE WORKING TIME AND PERFOMANCE INDEX OF A WORKER ON MANUAL TASK AND DEDUCING A TIME STANDARD FOR THE TASK AND ALSO MAKE IMPROVEMENTS WERE NECESSARY.

CONTENTS 1. 2. 3. 4. 5. 6. INTRODUCTION2 METHODOLOGY3 STOP WACTH TIME STUDY...4 RECOMANTATIONS6 CONCLUTION..7 REFRENCES.7

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COMPANY BACKGROUND OLINDA MANUFACTURING is a manufacturing company that was founded by OLIVER INDALA a successful technoprenoure in 1998 in the Light Industrial area, Granite side Harare starting with only but just a few machines. The company then relocated to 128 Dartford Road, Willovale in 1999. In that very year they managed to procure new machinery plastic & metal moulds press machines and ventured into the manufacture of products that suited the hard economic environment the country was in for the past years. The company mainly targeted the local market that is around the Glen View shopping complex, Siaso in Mbare, Bowlyn Furniture. DST and other local companies and they also do jobs on requests for other companies and individuals with a goal to be one day the major supplier of hardware to furniture manufacturing companies in Zimbabwe and beyond. COMPANY STRUCTURE MACHINE SHOP This section comprises of plastic moulding machine ,zinc molding machines used to do jobbing .This section we also find eccentric press machines used mainly in the production of hinges. Most of the products produced by Olinda Manufacturing are kitchen wear such as Sink let hinges ,Butt hinges ,Piano hinges ,Backing hinges ,Panel hinges ,Panel locks ,Keys ,All window frame components ,Cabinet handles ,Saddles ,S- tubes ,Wire pegs ,Plastic pressing ,Tool making TOOL SHOP This is the section were tools and dies are custom made to suite the requirements of a customers and also introduce new and innovative designs. This section includes the lathe machines, drills just to mention just but a few Due to financial constrains that led to the companys standards to degrade the company is now embarking on projects to recapitalize itself so that it can reestablish itself in the manufacturing fraternity and start running major projects . It is because of these major developments that gave rise to the need of a work study so as to establish standards of work that help in increasing efficiency of workers and hence boosting productivity. The main purpose for conducting a work study is to measure the activities and delays of workers (motion study) and measure working time and
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performance index of a person on a manual task and to establish time standard for a manual task, developing and maintaining a standard that both reduces costs and the time taken to complete a task thereby maintaining the standards and even improving the system further more hence the goals of our survey

METHODOLOGY In the machine shop we concentrated with the manufacture of cabinet hinges .the Company mainly bases on both jobbing and batching and hence this causes a lot of stoppages in order to reset the machines so that they can produce another component .Below is the process chart for the cabinet hinge production: Raw material arrival to stores Materials moved to work station 1 Await processing Step 1,2&3 simultaneously done
(that is ,the punching of two holes First degree bending and cutting)

Wait collection Moved to station 2 Wait next task Culling done Wait collection To assembly Assembly done Inspection of hinges Stores

After looking at the whole process we zeroed on to the culling process, where we had a worker who was being aided by a SIX TONNE ECCENTRIC PRESS machine that was triggered by a release using Page | 3

his foot after aligning his element. The worker had his unfinished hinges on a small table fixed to the machine. The table is fixed between his legs where he is seated on a small stool. When he loads his table he picks one element with his left hand, fixes it to a slot on the machine, steps on the leaver using his right foot to instantly release the press that pushes the hinge down a curvy slot and hence causing it to curl. He then strikes an ejection pin using a soft hammer to eject the element into a collecting bin.

STOPWATCH TIME STUDY

PROCESS CHART

1 PIKING UP ELEMENT

2 INSERTING INTO SLOT ON MACHINE 3 PRESSING LEAVER ,SIMULTANEOUSLY RELEASING PRESS 4 EJECT COMMPONENT USING SOFT HAMMER

Production of one element in this process took a very short space of time so i timed for the production of ten elements and calculated the average time. TIME FOR 10 ELEMENTS (s) 47.27 47.00 52.63 42.65 54.47 43.13 42.07 44.05 54.82 total TIME FOR ONE ELEMENT(s) 4.72 4.70 5.26 4.27 5.45 4.13 4.21 4.41 5.48 42.63 Page | 4 Total time for one element=42.63 Average time= 42.63/10 =4.26 seconds

WORKERS RATING Looking at the environmental working conditions in the factory. There were high temperatures due to the molding machines, a lot of noise was coming from the eccentric press machines including the one the worker was using, there was also poor ventilation and hence the worker was working in an average environment (rating 0.00) according to B.S.I scale The worker proved to possess a lot of skill and effort in his work and proved to be consistent in his work despite the fact that he was being observed and I awarded him the following ratings: SKILL EFFORT CONDITION GOOD EXELLANT AVARAGE +0.06 C1 +0.08 B2 +0.00 +0.03 A2 +0.17 = observation time (1+rating) =4.26(1.17) =4.98seconds Determination of standard time Allowances for personal time, fatigue & delays .PF&D Allowance (DOD-5010.15-1-M, Basic Volume, App II) The worker was doing a recitative job for the whole day the worker becomes bored at the end of the day and his sitting posture would end up giving him back pains. And also because of the noise the worker becomes irritated and hence by inspection the worker was given the following allowances. Since the company did not have a quite forma and very strict system the workers take their time to do their personal activities like smoking relaxing and the materials he want to use might be delayed on another work station Allowance for; personal time = [30 min/ (8h*60)]*100% = [30/480*100%] =6.25% Allowances for fatigue = [(15/480)*100%] Page | 5 .

CONSISTANCY EXELLANT TOTAL RATING Basic time

=3.13% Allowance for delays = [(10/480)*100%] =2.08% Standard time =Basic time (1+Apfd) =4.98(1.115) =5.551seconds The standard time of the worker is 5.55seconds RECOMANDATIONS Within any industry it is vital to consider ergonomics and safety of workers to prevent health problems on workers that are as a result of malpractices. When a company is ergonomic and considers the safety of workers enjoys the benefits of employees with a boosted morale and selfmotivated and this reduces the allowances for fatigue and delays and hence this boosts the productivity of the company. This also in the long run reduces the number of worker absentees and the amount of money the company pays for medication of workers who develop help problems at the work place. OBSERVATIONS Poor ventilation COMMENTS There is poor air circulation within the factory with the main door being the only opening, only 50% of windows opened RECOMANDATIONS Ventilation facility to be installed, at list 4m2 of floor space is allowed for each to maintain air movement by cross or through ventilation (Factories and Works (General) Regulation, RGN 262 of 1976, section 4) We recommend that workers should rotate all the times. Factories and Works (Registration and Control of Factories) RGN of 1976, section Management should introduce chairs that are ergonomic and reduce strain on worker Workers should be constantly reminded of the importance of their health and safety in a workplace and

Repetitive Work

Workers are exposed to same type of jobs (e.g. on press machines) which is Ergonomically hazards. Workers were sitting on makeshift stools that are ergonomic hazards Workers were working with noisy and heavy machines but were no wearing ear muffs and safety shoes.

Poo r furniture

Protective clothing

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The assumption that has been used in this report is the worker elements are external since our main objectives were to rate the worker and calculate his standard time and not that of the machine. CONCLUSION Work Study is the systematic examination of the methods of carrying out activities such as to improve the effective use of resources and to set up standards of performance for the activities carried out. This involves carrying out a time study like the stop watch time study which involves taking the observed time, and with it calculate a basic time using the equation Basic time = observation time (1+rating), were the worker has been rated according to his skill, effort, working condition, and his consistency on the job. After calculations the basic time was 4.98 seconds. A standard time is then calculated using the equation, Standard time =Basic time (1+Apfd). Where Apfd is the allowance given for personal time, fatigue, and delays is the time allowed to a worker to compensate for attending to personal needs, for fatigue, and for delays occurring due to conditions beyond an associates control. The standard time was found to be 5.55seconds. Work study also involves motion study where the motions carried out by a worker when executing a task are breached down analyses and all useless moves are eliminated to make sure our workers save energy by doing economic moves and from our study the workers were skilled and so due to experience they were doing efficient moves. We also looked at ergonomics in the work place and noted that improvement needs to be done on the stools the workers were sitting on replacing the old makeshift stools with modern ergonomic chairs that have arm rests and are comfortable to sit on for long hours hence in the long run promoting the health of workers and reducing the amount of money the company pays for the health of the workers. It has also been recommended that the management carry out meetings with workers every day in the morning to remind workers the importance of safety in industry and encourage them to wear safety clothing each day no matter how heavy or boring they are to wear.

REFRANCES 1. Factories and Works (General) Regulation, RGN 263 of 1976 2. (Registration and Control of Factories) SI 68 of 1990 3. Factories and Works (Machinery) Regulation, RGN 262 of 1976, 4. Brian Ladao is an Industrial Engineer/Consultant, mailto: bladao@envistacorp.com. 5. Meyers, F. E., and J. R. Stewart. Time and Motion Study: For Lean Manufacturing. 3rd ed. Upper Saddle River, NJ: Prentice Hall, 2001. 6. Rutter, R. Work Sampling: As a Win/Win Management Tool. Industrial Engineering, February 1994, pp. 3031

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