INCREASING THE DAILY QUOTA OF H.S. CRAFT MFG. CORP.CHAPTER I
PROBLEM AND ITS BACKGROUND
IntroductionChristmas lights are strands of electric lights used
to decorate homes, public/commercial buildings and Christmas trees
particularly during Christmas season heightening the Yuletide
excitement are amongst the most recognized form of Christmas
lighting. Christmas lights come in a dazzling array of
configurations and colors. The tradition of stringing electric
lights may have started as a Christmas thing. This custom goes back
to the use of candles to light up the Christmas tree in every homes
way back during the 18th Century. It was occasionally decorated
with candles, which at the time was a comparatively expensive light
source. Candles for the tree were glued with melted wax to a tree
branch or attached by pins. This kind of lighting in which candles
were used until technology marks the beginning of a new Christmas
light display. By the time 1880 rolled around, early electric
Christmas lights were introduced with electrification.Incandescent
lights are the ones that started it all. Even though they're well
over a hundred years old now, the technology largely remains the
same. The shapes and sizes of the bulbs, on the other hand, have
been in constant flux. Now we're left with major types of
incandescent Christmas light bulbs. The Mini/Fairy Light is the big
kahuna. If you haven't seen one of these by now, then you've
probably never seen Christmas lights. Traditionally, the set is
wired in series, hence the age old problem where if one bulb goes
out, the rest won't light. But it's not hard to find sets that are
wired in parallel nowadays.LED lights have been growing in
popularity for the past few years. Regardless of what you think of
their light output, there's no denying that they're much more
energy efficient than incandescent bulbs, and give off less heat.
LED lamps have a lifespan and electrical efficiency that is several
times better than incandescent lamps, and significantly better than
most fluorescent lamps.
Company Profile
The company H.S. Craft Mfg. Corp. was founded by George Tsai, a
Taiwanese business man. During late 1980s the first branch was in
RMT Industrial Complex, Tunasan Muntinlipa which only produces
Christmas lights to be exported in US markets. After one year, the
company added a new production line for tree top and icicle.After
eight years, many changes were made and the company was moved in
Silang Cavite with a bigger production space and more automatic
machines. More improvements were made as the business continues to
be known in the market. As the IT (Information Technology) era
came, the H.S. Craft was also into call center which cater orders
from individuals from the US. More customers/orders came and more
workers were given opportunity.As years passed by, H.S. Craft
continue to enhance its product and improves its production by
increasing and improving their machines and workers.As H.S. Craft
Mfg. Corp. continues its workmanship and service in producing
Christmas lights, it will make sure that it will continue to
brighten our Christmas season.
Background of the Study
The common tool used by Industrial Engineers to gather detailed
information on process is time and motion study. This study is the
scientific study of the conservation of human resources in the
search for the most efficient method of doing a task. A fascination
with the word efficiency began in the late 19th and early 20th
centuries when it was considered one of the most important
concepts. Time study began in the 1880s as a means of wage-rate
setting by Frederick W. Taylor, who is regarded as the father of
scientific management. It consists of a wide variety of procedures
for determining the amount of time required, under certain standard
conditions of measurement, for tasks involving some human activity.
Motion study was developed by Frank B. Gilbreth and Lillian M.
Gilbreth and consists of a wide variety of procedures for the
description, systematic analysis, and means of improving work
methods.
The concept of time study is connected to motion study. In time
studies, the observer must have basis for the categories which they
record in time data. Activities are broken down into categories
such as transport, operation, inspection, delay, and storage. Those
divisions are the foundation for motion study. Motion studies are
typically characterized by very detailed human motion into the most
basic movements.
The Christmas lights produced by H.S. Craft Mfg. Corp. were made
by machine operated by trained personnel and man power for the
manual works. H.S. Craft Mfg. Corp. is into planning, designing,
and producing Christmas lights to be exported abroad and delivered
to different companies like GE Holidays and Target
Supermarkets.
According to the interview with the Production Head, the H.S.
Craft Mfg. Corp. can produce 8.4M Christmas lights during their
Production month (September March). With these data, the
researchers found out that they can produce 58,333 set of Christmas
lights a day and they can increase their daily quota to achieve
more finished product with the same production time.
Statement of the Problem
This study sought to determine the increase in production by
increasing their daily quota by 11% in the same consumable
production time without affecting the H.S. Craft Mfg. Corp.
standard in the quality of their product.
General ProblemThe daily quota of the production is low
Specific ProblemThe wide range of distances of production area
The researchers used Time and Motion Study in H.S. Craft Mfg. Corp.
to monitor the production of Christmas lights. The company needs to
be monitored in order to control the cycle time and labor power.
This study suited in H.S. Craft Mfg. Corp. because 90 percent of
the production in this company is manual basis and the best tool to
measure the work is time and motion study because it includes the
rating factor and allowances. It can also be used as a tool for
productivity improvement and increase efficiency. Since time and
motion study is important for the company, it has to be done
precisely with the element of allowance, rating factor and head
count to produce a standard time which can be used as reference to
conclude the whole performance of production.
ObjectivesGeneral:To increase daily quota by 11% to produce more
productsTo use time and motion study to improve the layout of the
production area to eliminate excess distance to be travelled
Specific: To find suitable rating factor and allowance using a
stopwatch for the time and motion study that is suitable for the
manual product at H.S. Craft.To be able to have record of time,
establish standard time and perform motion study, this can be used
as a reference by the company.
Significance of the Study
To the company This study can help the workers finish their work
in less time and less energy exerted. This study will also be
beneficial for the workers because this will aim to propose
alternative production layout. It is also beneficial for the
company because they will reach high daily quota and will be able
to produce more products with the same production time. It will
also provide simplification, increased productivity, increased
profit and increase earning.
To the students This study will enhance their skills in using
time and motion study. This will also enhance their skills in
analyzing problems in manufacturing companies and be able to meet
and socialize with other people in the same field. This can also be
a guide for future researchers especially those concerned in
operation and time management.
To the readers This can serve as a reference and can help the
readers to be knowledgeable about time and motion study.
Scope and Delimitations of the Study
The researchers conducted company visit last January 31, 2015
and gathered time and motion study data. The following days were
used to research about the company itself and other sources like
lectures from Methods Engineering course, internet, and
articles.The study was conducted at H.S. Craft Mfg. Corp. located
at #1 Maguyam Road Bo. Biga, Silang Cavite. This study is focused
on production of Christmas lights. It also focused on the process,
time management and motion of workers. The age, gender, and
lifestyle of workers in the company are not tackled. The study
conducted a time study by observing the worker and giving rating
factors and allowances to produce standard time. This study is
taken using a stopwatch time study technique. This study does not
include the process of transport and the number of workers who
transports the product.
CHAPTER IICONCEPTUAL FRAMEWORK
The basis for conceptualizing the production rate of H.S. Craft
Mfg. Corp. is to provide an alternative facility layout that can
keep the distance not too far away from each element by using time
and motion study and to increase their daily quota by 11% to
maximize work time.
Related Literature and Studies
Productivity Improvement by Method StudyThere are a number of
approaches to improving productivity: the best-known currently is
probably Lean (more later) but such approaches go back many years
to the days of the early productivity .Essentially because of the
nature of the productivity ratio all are concerned with making
better use of existing resources or reducing the resources needed
to produce current outputs.This introduction to productivity
improvement methodologies will focus on just one of them (others
will follow but all of them are some form of variation of the same
underlying approach.Many people (and especially people of a certain
age) will immediately think of time and motion when asked to
describe a productivity methodology. This refers to the early days
of work study when the aim (as it often still is today) is to
reduce thetimetaken by, and the motion involved in, work. This is
reflected by the fact that work study was made up of 2
complementary techniques: method study and work measurement. Work
measurement as the name suggests involves measuring how long work
takes as the basis of understanding how time can be reduced and as
the basis of comparing different ways (methods) of carrying out the
work.However, the improvement methodology of work study was method
study and an understanding of method study gives a real insight
into how all productivity improvement methodologies
work.Source:http://www.evancarmichael.com/Productivity/3310/Productivity-Improvement-via-Method-study.html
Time and Motion Studies about Slow ProductionIn practice the
slower people would fail to meet targets set and the faster more
able operators would slow down to only produce the target causing
an actual reduction in output. Where incentive schemes were
introduced for exceeding targets the operators would often take
short cuts such as failing to do quality checks to try to gain
bonus leading to higher levels of rejects at the customer. For
example the activity timing for lean manufacturing, with lean we
try to simplify the activity timing as much as possible, we also
try to identify the individual work elements and identify them as
either adding value or as being non-value adding and wasteful steps
to be eliminated or reduced. Lean manufacturing tools are team
tools, by this I mean they should not be used by an expert who
comes to town to implement their changes on the workplace; they are
for the use of the people involved in the workplace to help them
create and agree their own improvements by identifying each work
element as being either value adding or non-value adding we have an
opportunity for the teams to either totally eliminate the non-value
adding steps or to reduce them making their processes more
efficient and also easier and safer for themselves. They can also
create additional improvements by considering the work method study
itself and comparing between shifts and individuals to find the
most efficient way. These methods can be used within your kaizen
teams to ensure continual improvement of
processes.Source:http://leanman.hubpages.com/hub/Work-Study-Method-Study-and-Activity-Timing
Time studies Taylor argued that even the most basic, mindless
tasks could be planned in a way that dramatically would increase
productivity, and that scientific management of the work was more
effective than the "initiative and incentive" method of motivating
workers. The initiative and incentive method offered an incentive
to increase productivity but placed the responsibility on the
worker to figure out how to do it. To scientifically determine the
optimal way to perform a job, Taylor performed experiments that he
called time studies, (also known as time and motion studies). These
studies were characterized by the use of a stopwatch to time a
worker's sequence of motions, with the goal of determining the one
best way to perform a job. The following are examples of some of
the time-and-motion studies that were performed by Taylor and
others in the era of scientific management.Pig IronIf workers were
moving 12 1/2 tons of pig iron per day and they could be
incentivized to try to move 47 1/2 tons per day, left to their own
wits they probably would become exhausted after a few hours and
fail to reach their goal. However, by first conducting experiments
to determine the amount of resting that was necessary, the worker's
manager could determine the optimal timing of lifting and resting
so that the worker could move the 47 1/2 tons per day without
tiring. Not all workers were physically capable of moving 47 1/2
tons per day; perhaps only 1/8 of the pig iron handlers were
capable of doing so. While these 1/8 were not extraordinary people
who were highly prized by society, their physical capabilities were
well-suited to moving pig iron. This example suggests that workers
should be selected according to how well they are suited for a
particular job.The Science of ShovelingIn another study of the
"science of shoveling", Taylor ran time studies to determine that
the optimal weight that a worker should lift in a shovel was 21
pounds. Since there is a wide range of densities of materials, the
shovel should be sized so that it would hold 21 pounds of the
substance being shoveled. The firm provided the workers with
optimal shovels. The result was a three to four fold increase in
productivity and workers were rewarded with pay increases. Prior to
scientific management, workers used their own shovels and rarely
had the optimal one for the job.BricklayingOthers performed
experiments that focused on specific motions, such as Gilbreth's
bricklaying experiments that resulted in a dramatic decrease in the
number of motions required to lay bricks. The husband and wife
Gilbreth team used motion picture technology to study the motions
of the workers in some of their
experiments.Source:http://www.netmba.com/mgmt/scientific/
Case Study Application of Time Study Model in Aluminum
CompanyThis paper presents a case study in the development and
application of a time study model in a hollowware aluminum
manufacturing plant. The organization engages in the production of
three product lines: kettles, frying pans, and cooking pots of
diverse categories. The motivation for this study was the need to
intervene in frequent crises that normally arose between the
employee-association and the management of the company regarding
questions of productivity. The three products have similar
production processes. Hence, the method of breaking down the
processes into jobs and tasks was adopted and analyzed through the
use of differential calculus. This method was applied to the
manufacturing processes with the kettle production system drawn as
an example. The kettle production process consists of several major
activities including stamping and oiling, press forming, trimming,
spinning, degreasing, polishing, labelling, wiping and wrapping,
spout holing and bumping, inspection, riveting, and packing. By
understanding and applying the model, managers can logically trace
the effects of time wastages on the production output of systems
and their effects. The studys most important finding is that the
time of producing a unit of product is directly proportional to the
number of production stages involved and the time spent at each
stage. This can be represented by some structural equations, which
are characteristics of the system being studied. The limitations of
the study lie in the variability of the major components of the
system. The model does not incorporate some variables which may
influence decisions made based on the computation of time for which
the model may be
used.Source:http://www.google.com.ph/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8&ved=0CB4QFjAA&url=http%3A%2F%2Fakamaiuniversity.us%2FPJST7_2_153.pdf&ei=o-juVJOII5DmoAS_nYKIDw&usg=AFQjCNH90oaf6wACetVaAEFodBJtnPAMXw&bvm=bv.86956481,d.cGUTime
and Motion Studies What are they and Can They Help You?Time and
Motion studies are an appropriate solution when theefficiencyof a
drug, medical device, or intervention is the outcome of interest.
In the current environment of more stringent evidence requirements
by regulators and payers alike, real-worldevidencethat complements
traditional efficacy and safety data is warranted to ensure
successful market access and product uptake.Per theU.S. Department
of Health & Human Services, a time and motion study is an
observation method used to determine the timing and duration of
tasks or procedures. These non-interventional studies collect
observational data to quantify the impact of a medical intervention
on the dynamics of health care professional involvement within a
process, as well as the resources consumed in terms of time and
consumables. For example, in a time and motion study, observers may
follow clinicians and record how long specific tasks, such as
completing a prescription or listening to a patient describe her
symptoms, take to complete. Researchers and practice managers may
use that data to evaluate whether and to what extent health
information technology applications, including computerized
provider order entry, electronic prescribing, and electronic health
records, could increase efficiency and allow clinicians more time
for other tasks.UBC experts perform time and motion studies in
order to demonstrate value for new pharmaceutical products in late
stage development. For example, when collecting time and motion
data for intravenous (IV) and subcutaneous (SC) processes, value
messages for a switch from IV to SC administration could be
expressed as staff time saved or infusion chair time freed up for
either an individual patient or for a center population. Time
savings can be monetized to reflect the opportunity cost of freeing
up personnel and/or facility time. Such derived evidence can serve
as crucial inputs for activity-based costing exercises or to inform
healthcare management decisions. These studies and the evidence
they collect can also inform health economic analyses that include
budget impact models.Time and motion methodology is a robust study
design solution forlate phase researchwhen efficiency is a key
attribute of a products value
proposition.Source:http://www.ubc.com/blog/time-and-motion-studies-what-are-they-and-can-they-help-you
Time and Motion Studies of Lagoon There is a widely held view
that work systemscan be improved upon through time and
motionstudies. This also applies to play systems as the
StrawbridgePointers demonstrated last week whenseven skippers told
their loved ones theyd be backin five minutes and then proceeded to
enjoy themotions of a gently pitching deck on Eastern Covefor the
rest of the daytime taken to record the weather forecast washardly
worth the motion however, as the predictedstiff northerlies and
fresh souwesters evaporated,leaving a fluky noreaster to send the
fleet overthe bay in a kindly fashion. Weather forecasters spend a
lot of time for littlemotion it seems. Angels Wings, complete with
a newly patchedhull, wasted no time in getting canvas aloft withthe
Jar Cat setting a brisk pace on the reach toBaud inBeach. Rubicon
offers a most kindly motion when atsea, the commodore and the
Churchills sippingfrom fine china with pinkies raised and
steppingback in time as they dunked Glens cookies. Protagonists of
time and motion studies emphasizethat they encourage a fair days
work.This was obviously misconstrued aboard IbisII as a long days
play, as former electronics mogul,B. Uren and his crew-for-hire
enjoyed a terrificrun from Shoal Bay to join the fleet. The zest on
40 is ideal for long stretches ofleisure afloat but will be hard at
work in the NewYear as she tries to wrest the Ballast Head Cupfrom
the mainland invaders. Time and motion was stuck in fast-forward
onGolden Odyssey this last week as Tim Williamshas dismantled,
rebuilt, re-bolted and re-positionedhis ageing Yammer, all in
record time forhim to host the Thompsons on the gaffer,
Runssmoothly too, no shifters or pliers clattering aboutin the
bilge. No time wasted by Andy Wood on Sapphire,either. He and
Russell Colman skimmed about thebay, sailing rings around some
lethargic craft. Sapphires profile looking very chic with
astrategically placed dodger keeping the lads in theshade. Never
slaves to the stopwatch, Nick and Prueand Greg had the beautiful
Dauntless trailingalong following a belated start. Shed barely
cleared the beacon before beingalmost run down by an Orange
Roughie-led stampedeof hungry sailors, intent on lunch aboard
LaHoya, moored at the head of Pelican Lagoon. The fleet dodged
moorings and boats beforerafting up in glorious sunshine alongside
GlenWingates Petersen 44 - time slowed to a waltzand motion was
restricted to short elbow movementsor taking a nap.The underlying
principles of time and motionstudies were exhibited later in the
afternoon whenthe commodore allowed his boat inker to proceeddown
the boat ramp in extremely rapid time topick up Dauntless for her
annual bottom scrub. Time stood still for most onlookers and
scaredthe motions out of Nick. No shortage of candidates for the
porthole thisweek, but Tim W finally awarded the esteemedboard to
Andy Wood for being the only one to dothings right. Or so he
said.Source:http://www.theislanderonline.com.au/story/2758428/time-and-motion-studies-at-lagoon/
Research ParadigmPROCESSOUTPUTINPUT
A solution to the companys problem which is to lessen the
distance to travelled and to increase their quota to producemore
products which can lead to a higher sales and income Progress of
our study
Proposed Flow process chart Proposed flow charts Proposing new
facility layout Proposing cost and effect diagram Knowledges that
accumulate from the company are: Lectures Articles Observing Asking
question Listening Record time(using stopwatch), motion and the
area of the company
Knowledges that we accumulate form the company
Definition of terms Definition of Terms
Methods Study - Subjecting each part of a given piece ofworkto
closeanalysisto eliminate every unnecessaryelementoroperation, as
ameansof approaching the quickest and best method of performing the
work. It also includes formulation
ofincentiveschemes,andimprovementandstandardizationofequipment,methods,operatortraining,working
conditions, etc. Also calledmethodsengineering.Productivity - An
economic measure of output per unit of inputElement A division of
work that can be measured with stopwatch equipment and that has
readily identified terminal point or break points Delay - a
situation in which something happens later than it shouldFatigue -
is a subjective feeling of tiredness which is distinct
fromweakness, and has a gradual onset.Flow process chart
-inindustrial engineeringis a graphical andsymbolic
representationof theprocessingactivities performed on the work
piece.Process is an instance of a computer program that is being
executed. It contains the program code and its current
activity.Motion Study - Method for establishing employee
productivityProcess layout - is a design for the floor plan of a
plant which aims to improve efficiency by arranging equipment
according to its function.Technician - is a worker in a field
oftechnologywho is proficient in the relevant skills and
techniques, with a relatively practical understanding of the
theoretical principles.Quotas - is simply a legal quantity
restriction placed on a good imported that is imposed by the
domestic government.
Pig iron - is the intermediate product of smeltingironore with a
high-carbon fuel such as coke, usually with limestone as a flux
Shoveling - is a tool for digging, lifting, and moving bulk
materials, such as soil, coal, gravel, snow, sand, or ore.
Brick iron is abrickhaving a sprinkling of dark spots caused by
the presence of ironsalts.
Sector An area of an economy, a part of an economy that includes
certain kinds of jobs Management - in business and organizations is
the function that coordinates the efforts of people to accomplish
goals and objectives using available resources efficiently and
effectively.
CHAPTER IIIMETHODOLOGY
Research Design
The method we used to define the nature of the workplace is via
descriptive research. It is the type of research that is mainly
concern in describing the condition and the degree in detail of the
present situation. It exists on the time of the study and to
explore the cause of the particular phenomenon. It aims to obtain
an accurate profile of the people, events, or situation around the
workplace. Pertaining to this research type, it is very essential
that the researcher has a broad understanding in performing time
and motion study.
The first hand data from the company that is formulated,
rationalizes and has sound conclusions is very approached
descriptive and quick in the practical way and requires financial
aspects. It has a great advantage for the researcher as well as to
the instructor so that the procedures is plainly stated and
illustrated. This method is either considered qualitative or
quantitative data, giving us greater options in determining how the
HS Craft Mfg. Corp. can increase their quota every day.
Under descriptive research, it explores the causes of why in
some areas they need to exceed the number of quota of produced
Christmas lights in their monthly allocation in the production
line. The accomplices in this research study are the workers of HS
Craft Mfg. Corp. last January 2015.
The qualitative method will equip us, the readers to develop
knowledge through the data gathered from the company- by research
and interview. Analysis of statistical data, identification of the
problems, formation of the conclusion, presentation of solutions,
and recommendations comes afterwards to fulfill the qualitative
method throughout the study at HS Craft Mfg. Corp. provided
significant inputs for the researchers study. It focus in the data
such as background of the company and the observation per worker
which are their motions considering the time and distant places in
the process lay-out using stopwatch as a tool.
The researchers conducted several trial in every elements
corresponding to the employees and the workers line of actions
inside the company. We taught about their views regarding to their
kind of business they are in. Provided with the information from
them, the researchers decided to propose alternative and different
ways to improve what was to improve and continue the actions in
line to exceptional methods in creating Christmas lights. This will
help them to alleviate some of their workload and to increase the
number of production. All of this data were treated full
confidential and with extra care for thesis purposes only.Data
Gathering ProceduresGathered information regarding time and motion
study concerning the flow of production.Conducted time and motion
study at HS Craft. Mfg. Corp. Located at No.1, Maguyam Road Bo.
Biga,Silang, CaviteThe researchers gave the letter of approval for
conducting methods study to the HR Dept. of HS Craft Mfg. Corp.
Implemented the proposed alternative processes to HS Craft. Mfg.
Corp. for the betterment of the said company
Analyzed the computed statistical data and comes up with the
answer to the problem of HS Craft. Mfg. Corp.Create alternative
processes that help HS Craft. Mfg. Corp. to increase daily quotas
and to decrease inefficiency
Previously, the researchers wrote a letter to the Human Resource
Dept. of HS Craft. Mfg. Corp. stating, that if we can conduct
research study pertaining to time and motion study of their
production of Christmas lights. Another letter for the management
is informing them about the said line of actions. After the
approval, the researchers obtained the operation processes inside
the company and the breakdown of the tasks given to every sector of
production.
The researchers also conducted some interview with Ms. Gems
working schedules, time of arrival and departure in the workplace,
break time and time on performing their jobs correlated to the
things she had stated to us. Then we preceded with observations
which doing their jobs occur and started their recording time by
using the stopwatch. Then after the observing and recording,
analysis and adjusting the schedule would enhance workers problem
of fatigue. Processes were made by the researchers to minimized the
consumed and distance travelled by the workers.
Research Instruments
The data collected are gathered through interviews and company
files with Ms. Gemma Cruzs help and the workers of HS Craft Mfg.
Corp.Time and motion study were implemented by the researchers. It
means in conducting this research study, the researchers must
perform actual observations on the facilities and operations inside
the company. The researchers monitored the workers, the more trials
the more accurate precision in finding the statistical mean for
every method in the company.
Time and Motion Study Formula:
Sample size, n = Where: h = accuracy level desired as percent of
job statement, expressed as a decimal (Ex: 5%=0.05)z= number of
standard deviations required for the desired level of confidences =
standard deviation of the initial samplex = mean of the initial
sampleNote:
Allowance Factor = Non-work time / Total timeAverage Element
time = Element times / No. of cyclesNormal time = Average element
time x Performance ratingStandard time = Total normal time / 1-
Allowance factorWork Sampling Sample size
Where:p = estimated value of sample proportion (of time worker
is observed busy or idle)h = accuracy level desired in percent,
expressed as decimalNormal time = (Total time) (% of time working)
(Rating) / No. of units producedStandard time = Normal time / 1-
Allowance
Data Gathering Instrument
A stopwatch was used by the researchers for accurate and precise
time of motion of the workers while doing the procedures in making
the Christmas lights. The researchers also made a scheduling time
table, normal time including the break time of the workers.
Calculators was also used in computing the statistical way of
finding the standard time, deviations, allowance time, and other
computed numerical data. These particular instruments are tested
and proven that are reliable in dealing with time and motion study.
Delay occurs in the production area, the daily quota on operation
is low, and the wide range of distances of production area is
broad. This is the basic problems in the company that needed
improvement. By this method and with the proper gathering
instruments, we can sort the problem in no time.
Research Locale
The study was conducted to the workers of HS Craft Mfg. Corp. at
No. 1 Maguyam Road Bo. Biga, Silang, Cavite. This place was
selected for knowing the efficiency of the said study on
determining the daily quota of Christmas lights they produced. We
would guarantee after this methods study, we can raise the number
of quota by 10% and improve their working measures that they
produced here in the said company.CHAPTER IVPRESENTATION, ANALYSIS
AND DATA INTERPRETATIONElementsTrial 1Trial 2Trial 3Trial 4Trial
5Trial 6Trial 7Trial 8Trial 9Trial 10Mean
1Bulb wire assembly into
base/husk10.839.399.299.239.149.189.4310.0310.339.739.66
2Bulb wire assembly into lamp
holders0.54250.540.56030.63780.550.65020.55310.52120.62370.54250.5721
3Twisting2.312.212.292.252.182.122.192.152.142.302.21
4Plug
assembly0.77470.67870.9280.80570.680.690.88670.69310.68040.78140.7599
5Bulb pushing2.953.023.022.523.082.473.143.782.982.792.98
6Bundling/
packing8.688.626.216.197.197.316.416.387.158.267.24
7Light testing 11.041.061.011.051.041.061.091.011.021.041.04
8Light testing 2/ Final
packaging1.001.001.001.001.001.001.001.001.001.001.00
The following data gathered above are the process time (in
minutes) an element is being done. There are eight elements in
making a Christmas tree; Bulb wire assembly into base/husk, Bulb
wire assembly into lamp holders, Twisting, Plug assembly, Bulb
pushing, Bundling/ packing, Light testing 1, Light testing 2/Final
packaging. In every element, the researchers conducted ten trials.
The mean is the total gathered time over ten trials (in minutes).
These data are necessary to complete the needed computations.
Formula:Normal Time = Average Element time x Personal
RatingStandard Time = Normal Time (1 + Allowance
Factor)Where:Personal rating = 95%Allowance Factor = 11%Average
Element time = Mean per element
Computation:Element 1Normal Time = 9.66min x .95 =
9.18minStandard Time = 9.18min (1+.11) = 10.19min = 0.0102min/pcx
100pcs = 1.02min 1000pcsElement 2Normal Time = 0.5721min x .95 =
0.5435minStandard Time = 0.5435min (1+.11) = 0.6033minx 2pcs =
1.21min
Element 3Normal Time = 2.21min x .95 = 2.10minStandard Time =
2.10min (1+.11) = 2.33min
Element 4Normal Time = 0.7599min x .95 = 0.7219minStandard Time
= 0.7219min (1+.11) = 0.8013min
Element 5Normal Time = 2.98min x .95 = 2.83minStandard Time =
2.83min (1+.11) = 3.14min
Element 6Normal Time = 7.24min x .95 = 6.88minStandard Time =
6.88min (1+.11) = 7.64min
Element 7Normal Time = 1.04min x .95 = 0.988minStandard Time =
0.988min (1+.11) = 1.10min
Element 8Normal Time = 1.00min x .95 = 0.95minStandard Time =
0.95min (1+.11) = 1.05min Total Standard Time = 18.29min
The Christmas lights produce by the H.S. Craft has 100 light
bulbs per set. In getting the Standard Time of the element 1, since
theBulb wire assembly into base/husk produces 1000 pieces of bulbs
in its process time and the researchers are after the pieces done
per minute, the minutes gathered in element 1 will be divided by
1000 light bulbs and multiply by 100 light bulbs. For element 2,
since the Bulb wire assembly into lamp holders only produces 50
light bulbs with lamp holders per process time it will be multiply
by 2 to have its 100 light bulbs. The next elements are already
into 100 light bulbs so it will be computed as is.
Total set per minuteElementStandard time per
pieceWorkers/MachinesPieces per minute
1Bulb wire assembly into base/husk1.02min/pc20
machine20.4pcs/min
2Bulb wire assembly into lamp holders1.21min/pc16
machine19.31pcs/min
3Twisting2.33min/pc140 workers326.2pcs/min
4Plug assembly0.8013min/pc100 workers80.13pcs/min
5Bulb pushing3.14min/pc120 workers376.8pcs/min
6Bundling/ packing7.64min/pc120 workers916.8pcs/min
7Light testing 11.10min/pc120 workers132pcs/min
8Light testing 2/ Final packaging1.05min/pc120
workers126pcs/min
Total set per minute1997.64 set/min
The table shown above is the computation of set of Christmas
lights that can be produced in a minute. It can be determine by
getting the standard time of an element and multiplying it to the
numbers of workers or machine. The total set per minute is computed
by adding the pieces per minute of all elements.
8 hrs x 60 min = 480 min 1 hr480 min = 26.24 cycle18.29min
1997.64 set/min x 26.24 cycle = 52425.76 set
Formula:Percent can increase = Standard production of the
company Computed production of the company=58333.33 set52425.76
set= 1.11 or 111%
Therefore it can increase their production by 11%.
FISH BONE DIAGRAM
EXISTING FACILITY LAYOUT
PROPOSED FACILITY LAYOUT
EXISTING FLOWCHART1
Bulb wire assembly into base/husk2
Bulb wire assembly into lamp holder3
Twisting4
Plug Assembly1
Inspection5
Bulb Pushing2
Inspection6
7
Binding/Packaging8
Light testing 1
Light testing 2/Final packaging
PROPOSED FLOW CHART
Bulb wire assembly into base/husk1
2
Bulb wire assembly into lamp holder
3
Twisting
4
Plug Assembly
1
Inspection
6
Bundling/ Packaging7
Light Testing 1
8
Light Testing 2/ Final Packaging
EXISTING PROCESS FLOWCHART
Element DescriptionDistance (m)Time (min.)
1. Bulb wire assembly into base/husk
0 m
2. Bulb wire assembly into lampholder10 m
3. Twisting30 m
4. Plug Assembly130 m
5. Inspection0 m
6. Bulb Pushing140 m
7. Inspection0 m
8. Bundling/ Packaging150 m
9. Light testing 143 m
10. Light Testing 2/ Final Packaging10 m
PROPOSED PROCESS FLOWCHART
Element DescriptionDistance (m)Time (min.)
1. Bulb wire assembly into base/husk
0 m
2. Bulb wire assembly into lamp holder10 m
3. Twisting30 m
4. Plug Assembly130 m
5. Inspection0 m
6. Bundling/ Packaging150 m
7. Light testing 143 m
8. Light Testing 2/ Final Packaging10 m
CHAPTER VSUMMARY OF FINDINGS, CONCLUSION AND RECOMMENDATIONS
This chapter considered the most important data that are
digested and outcomes that are subsequently drawn. It tackles the
most important parts of the study. Suggestions and recommendations
are made in the light of the generated data from this research
project. The researchers also recommend some approaches that could
be used as basis in increasing the throughput of H.S. Craft Mfg.
Corp.
5.1 Summary of FindingsThis study aims to use Time and Motion
study in order to increase their daily quota. Plant visit and
observations was conducted for the research purposes. The main
research problem of this study is to identify what causes the low
daily production.The research revealed that by finding the standard
time of every element in the cycle of production, it is possible to
increase the daily quota of H.S. Craft Mfg. Corp. by 11%.
5.2 ConclusionSince the production of Christmas lights were
combination of Manual and Machine works. We conclude that condition
of workers affects and plays a big role in production. Workers may
not be physically and mentally prepared to perform their particular
jobs. Health, environment and extra-curricular activities such as
Chatting with their co-workers, Call of nature, and seldom sleeping
during work hours may cause a lot of delays. Fatigue due to
complicated processes in the production is also one of the major
reasons of delays. To minimize these delays, we recommend that the
supervisor conducts an hourly monitoring on areas that manual work
is present to fully supervise the production in order to avoid
unnecessary delays.
Machines also play a big role in the production. Electricity is
a main need in order for the machine to run and function well.
Machine malfunction is a part of the daily routine in the
production, to avoid this problems that will surely cause delays
that can be the reason of low set of daily quota since machine
works were present in the early part of the production, the company
provided an In-house technician in order to act fast and fix
whatever the problem causing the machine malfunction. Also,
frequent monitoring and check-up of the machine must be conducted
to monitor the conditions of machine, tools and equipment to keep
them in great shape to avoid delays. They should also increase the
number of the machines they have to reduce manual works and to make
the production faster.
Newly assigned workers may also take part in delays that might
be the reason of having a low quota. Lack of knowledge and
expertise in one area or procedure may bring confusion to workers
in performing such task. We, the researchers recommends that
workers must be trained well before placing them in a particular
workplace same with the supervisor in order for them to attend and
assist workers that are having a hard time during production.
5.3 Recommendations
The researchers proposed new production of Christmas Lights
procedures wherein the distance and time was reduced. We also
recommend the next batch of students who will conduct a research
study in HS Craft Mfg. Corp. to do the following: Measure the time
delay and allowances factor to enable them to complete the given
time and motion study. Include the process of transport and the
number of workers in this process Conduct the research study during
the whole production month of the company (September March) to make
the data more accurate.42