CHAPTER VI Imam Wildan

DESIGN OF INTEGRATED INDUSTRIAL SYSTEM 1 (MODULE 6)MICROMOTION STUDY

Group:IP-11Practical Date:May 25, 2015

Name:1. Imam MukhriPractical Day:Monday

2. Wildan AdiwenaPractical Hours:14.30-15.50

Class:IP CLASSSubmitted

Assistent:P - 96Yogyakarta, June 01, 2015

Assessment CriteriaAssistant

Report Format:

Contents:

TOTAL:(M Ihsan NST)

DESIGN OF INTEGRATED INDUSTRIAL SYSTEM 1 LABORATORYINDUSTRIAL ENGINEERING DEPARTMENTFACULTY OF INDUSTRIAL TECHNOLOGYISLAMIC UNIVERSITY OF INDONESIA2015CHAPTER VIMICROMOTION STUDY

6.1. Practicum Objectives1. To know the Micromotion Study method on the application of standard time with analyzing the working movement elements.2. Able to identify work elements and able to analyze the effective and ineffective work elements on certain job.3. Able to make improvements on movement elements which are not required or ineffective in order to perform facility or work station layout setting.4. Able to calculate the standard time by studying the movement elements with the help of movie recorder.

6.2. Practicum Tasks1. Observing and analyzing the movement of the working operations based on video record assembly.2. Calculate the standard time by using motion elements table.3. Determine the standard time of each element of the overall standard of work and working time in accordance with the SOP work operations.

6.3. Output6.3.1. DescriptionMicro motion Study is a technique that used to analyze in detail the worker movement (Wignjosoebroto, 1989). This technique was first developed by Gilbert in motion study techniques (Maynard, 1971). Activities are included in micro motion Study is a video recording and record the time (Barnes, 1980). In this practicum, we analyze in detail about the worker movement that assembly a sport car sedan. In this practicum we did the activity twice that did by the worker, the first activity show the initial layout of the work station and the second activity show the propose layout of the work station. After that we have to analyze about the differences in both initial and propose work station.In the given case study, can be seen that the operator at station, he assembly Tamiya 4WD. Tamiya have so many part and the parts is consists as below:Table 6.1. Layout ExplanationBOXJARAK (CM)JARAK (INCHI)DESKRIPSI

A64,525,4Body, Battery Belt, Body Lock

B6826,8Rear Rubber Tire, Rear Velg, Rear Axle, Gear

C52,320,6Chasis, Roller, Screwdriver, Screw

D68,226,9Battery

E5320.9Dynamo, Cover Dynamo, Home Dynamo, Large Plate & Small Plate, Axle

F35,614Front Tire Rubber, Front Velg, Front Axle, Gear 4WD

G59,523,4Front Plate, Switch, Front Cover

Table 6.2. Code for Objects used to Assemble Product

Name of Part or EquipmentCode

ScrewdriverC4

BodyA1

Battery BeltA2

Body LockA3

Rear TireB1

Rear VelgB2

Rear AxleB3

GearB4

ChassisC1

RollerC2

ScrewC3

BatteryD1

DynamoE1

Dynamo CoverE2

Home DynamoE3

Large & Small PlateE4

AxleE5

Front TireF1

Front VelgF2

Front AxleF3

Gear 4 WDF4

Front PlateG1

Switch G2

Front CoverG3

A. Initial LayoutAnalysis micro motion study activity used to analyze in detail the operators to do the work in relief so that it can get the standard for doing his job. The analysis micro motion study conducted in this research is the operator do assembles Tamiya car. Work done by one of the male with the work stands. The operator Tamiya location and distance of the layout of each layout to be seen on the figure below:

Figure 6.1 Initial layout

Figure 6.2 Initial Layout (operator to box)

From the video that we got from this practicum, we can identify the innefective and effective motion of work. Those are :Table 6.3 Table of Motion WorkMotion DescriptionMotion of workIdentification

Take chassis with right hand from the box CGrasp and transport EmptyEffective

Move chassis from right hand to left hand Grasp, transport loaded and HoldEffective

Reach roller and screw with right handGrasp and holdEffective

Put the roller and screw to assembly Grasp, hold and assemblyEffective

Put it into chassis with right hand and assembly with support left hand Grasp, Hold, and UseEffective

Take screwdriver with right hand from the box and use it to assembly the screw and roller to the chassis.

Hold, grasp, use, and assembly.Effective

Hold screw driver with right hand and hold chassis with left hand also grasp roller and screw with right hand

Grasp, Hold, Use and Assembly

Effective

Position screw driver and usePosition, use and AssemblyIneffective and Effective

Hold screw driver and take roller and screw with right hand.Grasp, Hold, Use and AssemblyEffective

Put it into chassis with right hand and assembly with support left handGrasp, Hold, Position and UseEffective and Ineffective

Hold screw driver and take roller and screw with right hand.Grasp, Hold, Use and AssemblyEffective

Put it into chassis with right hand and assembly with support left handGrasp, Hold, Position and UseEffective

Put screw driver in to the box by right hand and left hand hold the chassis with avoidable situation from operatorRelease load, pre-position, grasp, hold, and avoidable delayEffective and Ineffective

Take the rear tire and rear velg with right and left hand respectively from the box BTransport Empty, Grasp and HoldEffective

Assembly both of them.Hold, grasp and assemblyEffective

Hold wheel by left hand and grasp rear axle by right hand after that assembly both of themHold, grasp, positioning and assemblyEffective

Hold the Wheel by right hand and take chassis by left hand. Hold chassis by right hand and take rear gear by left hand then assembly both of themHold, grasp, transfer loaded, positioning, and assemblyEffective and ineffective

Take and hold chassis by left hand with right hand hold wheel then assembly but there is avoidable delay that forgot to assembly Gear 4WDHold, grasp, transfer empty, avoidable delay and assembly.Effective and Ineffective

Take the other rear wheel then assembly with the other side axle rear with little pressureHold, grasp, Transfer Empty, Position, and AssemblyEffective

Take dynamo from box E with right hand and left hand hold the chassisGrasp, hold and Transfer EmptyEffective

Assembly dynamo with chassis with little bit pressureGrasp, hold and Assemblyeffective

Take big plat by right hand and position it then assembly with dynamo Grasp, position, and assemblyEffective and ineffective

Hold chassis by left hand and take cover dynamo by right hand then assembly both of them.Hold, grasp, transfer loaded, position and assemblyEffective and ineffective

Put chassis by right handRelease loadEffective

Take front rubber tire with front velg from box F Grasp, Transfer Empty, and HoldEffective

Assembly both of them to become front wheelGrasp, hold, and Assembly

Take front axle with right hand from box F with left hand hold chassisGrasp, Hold, and Transfer EmptyEffective

Plan and search tirePlan and searchingEffective

Take tire and wheel by right hand then assembly Grasp, transfer loaded, and assemblyEffective

Put tire to the boxRelease loadEffective

Take tire by right hand and take wheel by left hand.Grasp, transfer loaded, and assemblyEffective

Hold tire by left hand and take axle by right handHold, grasp, transfer loaded, and assemblyEffective

Hold axle by right hand and take chassis by left handHold, grasp, transfer loaded, position, and assemblyEffective and ineffective

Hold chassis by right hand and take gear 4 WD by left hand.Hold, grasp, transfer loaded, and position.Effective and ineffective

Release gear 4 WDRelease loadIneffective

Take gear 4WD by left handGraspEffective

Assembly gear 4 WD with chassisPosition and assemblyEffective and ineffective

Hold chassis by right hand and take tire by left hand.Hold, grasp, transfer loaded, position and assemblyEffective and ineffective

Hold chassis by left hand and take front plat by right hand then assembly plat to chassis.Hold, grasp, transfer loaded, position, and assemblyEffective and ineffective

Hold chassis by left hand and take switch button by right hand.Hold, grasp, transfer loaded, and assemblyEffective

Hold chassis by left hand and take front cover by right hand.Hold, grasp, transfer loaded, position, and assemblyEffective and ineffective

Hold chassis by left hand and take battery by right hand.Hold, grasp, transfer loaded, and assemblyEffective

Hold chassis by left hand and take battery by right handHold, grasp, transfer loaded, position, and assemblyEffective and ineffective

Hold chassis by left hand and take battery cover by right handHold, grasp, transfer loaded, position, and assemblyEffective and ineffective

Hold chassis by left hand and take body by right handHold, grasp, transfer loaded, position, and assemblyEffective and ineffective

Hold chassis by left hand and take body locker by right handHold, grasp, transfer loaded, and assemblyEffective

Put Tamiya in to the groundRelease load Effective

B. Right Hand and Left Hand Map

Table 6.1 Mapping of left and right handWORK ELEMENT 1

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

13.1R20A20"Reach C1

2G1AGrasp C1

22.1M20C Move C1

Grasp C1G1A213.1R20A20"Reach C2

2G1AGrasp C2

22.1M20CMove C2

13.1R20A20"Reach C3

2G1AGrasp C3

22.1M20CMove C2, C3

Grasp C2G1A219.7P2SSEPosition C3

19.7P2SSEPosition C2, C3

13.1R20A20"Reach C4

2G1AGrasp C4

22.1M20CMove C4

19.7P2SSEPosition C4

32.4TS906'Turn C4 6 times 90

13.1R20A20"Reach C3

2G1A Grasp C3

22.1M20C Move C2

13.1R20A20"Reach C2

2G1AGrasp C2

22.1M20CMove C2

Turn C4 once 90 TS901'5.419.7P2SSEPosition C2, C3

Position C4P2SSE19.7

19.7P2SSEPosition C4

27TS905'Turn C4 5 times 90

13.1R20A20"Reach C2

2G1AGrasp C2

19.2M20AMove C2

Memegang BG1A213.1R20A20"Reach C3

2G1AGrasp C3

22.1M20CMove C3

19.7P2SSEPosition C3

2G1AGrasp C2, C3

19.7P2SSEPosition C2, C3

2RL1Release C3

13.1R20A20"Reach C3

2G1AGrasp C3

22.1M20CMove C3

19.7P2SSEPosition C3

19.7P2SSEPosition C3

27TS905'Turn C4 5 times

13.1R20AReach C2

2G1AGrasp C2

Grasp C2G1A213.1R20A20"Reach C3

2G1AGrasp C3

22.1M20CMove C3

19.7P2SSEPosition C3

Turn C1 once 90TS901'5.419.7P2SSEPosition C2 and C3

19.7P2SSEPosition C4

27TS905'Turn C4 5 times 90

2RL1Release C1

Standard Time = 26.64TMU740

Hours0.007

Minutes0.444

Seconds26.64

Work Element 2

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Reach B126"R26A15.815.8R26A26"Reach B2

Grasp B1G1A22G1AGrasp B2

Move B1M26C27.327.3M26CMove B2

Position B1 and B2P2SSE19.719.7P2SSEPosition B1 and B2

Reach B126"R26A15.815.8R26A26"Reach B2

Grasp B1G1A22G1AGrasp B2

Move B1M26C27.327.3M26CMove B2

Position B1 and B2P2SSE19.719.7P2SSEPosition B1 and B2

Standard Time = 4.6656TMU129.6

Hours0.0013

Minutes0.0778

Seconds4.6656

Work Element 3

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Grasp B1 and B2G1A215.8R26A26"Reach B3

2G1AGrasp B3

27.3M26CMove B3

19.7P2SSEPosition B3

20"R20A13.12G1AGrasp B1, B2, and B3

Grasp C1G1A2

Move C1M20C22.1

19.7P2SSEPosition B1,B2, and B3

10.5R14A14"Reach F4

2G1AGrasp F4

16.9M14CMove F4

19.7P2SSEPosition F4

Standard Time = 4.8816TMU135.6

Hour0.0014

Minutes0.0813

Seconds4.8816

Work Element 4

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Turn C1 once 180TS1801'9.415.8R26A26Reach B1 and B2

2G1AGrasp B1 and B2

27.3M26CMove B1 and B2

19.7P2SSEPosition B1 and B2

Grasp C1G1A213.1R20A20Reach E1

2G1AGrasp E1

22.1M20CMove E1

19.7P2SSEPosition E1

Standard Time = 4.3812TMU121.7

Hours0.0012

Minutes0.0730

Seconds4.3812

Work Element 5

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Grasp C1G1A213.1R20A20"Reach E5

2G1AGrasp E5

22.1M20CMove E5

19.7P2SSEPosition E5

Standard Time = 2.1204TMU56.9

Hours0.000589

Minutes0.03534

Seconds2.1204

Work Element 6

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

13.1R20A20"Reach E2

2G1AGrasp E2

22.1M20CMove E2

19.7P2SSEPosition E2

Release C1 RL12

Standard Time = 2.6532TMU56.9

Hours0.00056

Minutes0.03414

Seconds2.0484

Table 6.4

Work Element 7

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Reach F214"R14A10.510.5R14A14"Reach F1

Grasp F2G1A22G1AGrasp F1

Move F2M14C16.916.9M14CMove F1

Position F2P2SSE19.719.7P2SSEPosition F1

Reach F214"R14A10.510.5R14A14"Reach F1

Grasp F2G1A22G1AGrasp F1

Move F2M14C16.916.9M14CMove F1

Position F2P2SSE19.719.7P2SSEPosition F1

13.1R20A20"Reach C1

2G1AGrasp C1

22.1M20CMove C1

19.7P2SSEPosition C1

Grasp C1G1A210.5R14A14"Reach F1 and F2

2G1AGrasp F1 and F2

16.9M14CMove F1 and F2

Standard Time = 6.642TMU184.5

Hours0.0018

Minutes0.1107

Seconds6.642

Work Element 8

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

10.5R14A14"Reach F3

2G1AGrasp F3

16.9M14CMove F3

Grasp C1G1A219.7P2SSEPosition F1, F2, and F3

Standard Time = 1.9116TMU49.1

Hours0.0005

Minutes0.0294

Seconds1.7676

Work Element 9

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

10.5R14A14"Reach F4

2G1AGrasp F4

16.9M14CMove F4

19.7P2SSEPosition F4

10.5R14A14"Reach F1 and F2

2G1AGrasp F1 and F2

16.9M14CMove F1 and F2

19.7P2SSEPosition F1 and F2

Standard Time = 3.5352TMU98.2

Hours0.000982

Minutes0.05892

Seconds3.5352

Work Element 10

Left HandRight Hand

DescriptionDistance (Inch)CodeTMUTMUCodeDistance (Inch)Description

Grasp C1G1A213.1R20A20"Reach G1

2G1AGrasp G1

22.1M20CMove G1

19.7P2SSEPosition G1

Standard Time = 2.0484TMU56.9

Hours0.0006

Minutes0.0341

Seconds2.0484

Work Element 11

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Grasp C1G1A213.1R20A20"Reach G2

2G1AGrasp G2

22.1M20CMove G2

19.7P2SSEPosition G2

Standard Time = 2.0484TMU56.9

Hours0.0006

Minutes0.0341

Seconds2.0484

Work Element 12

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Grasp C1G1A213.1R20A20"Reach G3

2G1AGrasp G3

22.1M20CMove G3

19.7P2SSEPosition G3

Standard Time = 2.0484TMU56.9

Hours0.000589

Minutes0.03534

Seconds2.1204

Work Element 13

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Grasp C1G1A215.8R26A26"Reach D1

2G1AGrasp D1

27.3M26CMove G1

19.7P2SSEPosition G1

15.8R26A26"Reach G1

2G1AGrasp G1

27.3M26CMove G1

19.7P2SSEPosition G1

Standard Time = 4.6656TMU129.6

Hours0.0012

Minutes0.0777

Seconds4.6656

Work Element 14

Left HandRight Hand

DescriptionDistanceCodeTMUTMUCodeDistanceDescription

Grasp C1G1A215,2R25A25"Reach A2

2G1AGrasp A2

26.2M25CMove A2

19.7P2SSEPosition A2

Standard Time = 1.7244TMU47.9

Hours0.000479

Minutes0.02874

Seconds1.7244

Work Element 15

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Grasp C1G1A215,2R25A25"Reach A1

2G1AGrasp A1

26.2M25CMove A1

19.7P2SSEPosition A1

Standard Time = 1.7244TMU47.9

Hours0.0005

Minutes0.0287

Seconds1.7244

Work Element 16

Left HandRight Hand

DescriptionDistance (inch)CodeTMUTMUCodeDistance (inch)Description

Grasp C1G1A215,2R25A25"Menjangkau U (Body lock)

2G1AMemegang U (Body lock)

26.2M25CMembawa U (Body lock)

19.7P2SSEMengarahkan U (Body lock)

2RL1Melepas Rangkaian Tamiya

Standard Time = 1.7964TMU51.9

Hours0.0005

Minutes0.0299

Seconds1.7964

6.3.2. SOP Tamiya Assembly

From the calculated TMU that have done, there are 16 elements that become part of SOP with assembly time that get from analyze motion right and left hand

Table 6.5 SOP Assembly Tamiya

Work ElementDescriptionTime

1Assembly chassis and Roller26.64

2Assembly Rear Tire with Rear Velg4.6656

3Assembly Wheel with Rear Axle and Gear4.8816

4Assembly Dynamo on Dynamo Scuttle, Big Plat and Small Plat4.3812

5Assembly Gardan2.0484

6Assembly Dynamo and chassis2.0484

7Assembly Dynamo Cover6.642

8Assembly Front Tire with Front Velg1.7676

9Assembly Front Tire with Front Axle3.5352

10Assembly Gear 4WD2.0484

11Assembly Front Plat2.0484

12Assembly Switch2.0484

13Assembly Front Cover4.6656

14Assembly Battery Belt1.7244

15Assembly Body1.7244

16Assembly Body Lock1.7964

Standard Operation Procedure explain about the step that will be done in assembly Tamiya with operation and work station that using the standard time that have established.

6.3.3. ConclusionFrom the result left and right hand map we conclude that total standard time for assembly this Tamiya is 72.666 seconds. And there are some ineffective motion that operator has been done such as avoidable delay, position and etc.

.