Final Paper

College of EngineeringXavier University-Ateneo de Cagayan

IE 326Methods Engineering

SILK SCREEN PRINTING

SUBMITTED BY:LANUZA, MARK ANTHONY M.

BABATE, MARIVIC L.LUGMAY, ROSALYN G.

Bachelor of Science in Industrial Engineering – 4th Year level

SUBMITTED TO:Ms. Ma. Lourdes Abao

March 20, 2010

Background

Art Station is located at Yacapin-Corrales Street, Cagayan de Oro City and is owned and

managed by Mr. Owen G. Dadang. It is operating for 10 years already. Supplies used in their

operation are from Ace de Oro for the streamers and Goldcrest for their retailed paints. They use

brushes, paints, pencils, rulers, cutters and silkscreen as their primary equipments. Their usual

customers are Motormate and Emcor who orders both streamers and shirts. The costumers are

required to bring their own shirt or cloth because they only do the printing. Usually, their order

will be readily available three to four days after the order, especially if it is a multicolored

design. For a single colored print or a very simple design, it would only take a day for the

customer to get the order.

In the daily operation of Art Station, they only have 2 workers who works 12 hours a day

from 8am until 8pm. If they finish their work earlier they could go home early. They can get

avail an overtime pay also plus a Sunday day off. The salary that the workers get is by a

commission system. The worker gets 30% commission in every streamer and shirt orders. Their

standard streamer size costs 360Php.  This 2 workers that they have worked for the business for

the whole two years when Mr. Owen started managing and owning the business. They make

streamers and shirt printing as soon as they have orders. They use silk screen for printing and

have a special offer for their costumers in which in every 50 pieces of shirts, a customer can get a

10% discount. In every order they sometimes have a defective output, usually 1 at most. They

usually retouch it to correct the defect

Materials:

Tulco Screen

Pencil Ruler

Scotch Tape

Objectives:

This study aims to eliminate the inefficient actions and time during silk screen printing to

increase productivity travelled by micro motion study and to establish a standard method to do

the process.

Problem Statement:

We are much concerned on how to do silk screen printing in such a way that we can save

time and at the same time increase productivity during the process.

Scope and Limitation:

This study deals on the method analysis regarding the operation process of a small-scale

silk- screen printing business. We are only concerned on the manual operation.

Methodology:

1. Plan out the topic and decide on which business to possibly make a study.

2. Go to the target area and gather data by conducting interviews.

3. Formulate a flow process chart to know the time of each element.

4. Flow diagram to facilitate the operation layout.

5. Two hand process chart to study the micro motion to eliminate the unnecessary and to

combine the activities.

6. Do the time study to record the elemental analysis.

7. Go back to the chosen establishment for additional inputs.

8. Analyze the data gathered and propose a new method.

Analysis:

With a cycle time of 8.72 minutes for 19 shirts, we calculated 68 shirts for every 10-hour

working day. Also, we have calculated the effective time to be 4.01 minutes and 4.71 minutes

ineffective time. Mostly, the contributors to the long time duration are on the placing of the

screen and the design on top of the shirt before the actual printing.

We have decreased the cycle time from 8.72 minutes to 5.45 minutes with only 2.82

ineffective and 2.66 for the left hand effective times and 3.12 effective and 2.33 ineffective for

the right hand. This drop of cycle time was done basically by eliminating the distance from the

working table to the other work-related areas like the tool box area. Another source of time

decrease is the elimination of inspection by doing it simultaneously with the event right before it.

The decrease of ineffective activities was done by either reducing or eliminating

unnecessary or awkward hand and body movements like the standing of the operator while

applying the paint due to the inefficient or improper height and position or angle of the working

table.

Basically, much of the delays were caused by the distances travelled by the operator.

Upon distance decrease, time is also saved.

For the diagram, operations were done mostly on the working table. It was shown by

arrows that point to the working table refer to the flow diagram present. It was proposed that

since the travel time has consumed most of the cycle time, we have eliminated the transportation

by transferring the materials needed close to the working table. With this, we have reduced much

of our travel time.

Delay was eliminated by the use of blowers instead of the conventional air drying.

Transportation was reduced, together with inspection since it is already done simultaneously

with the activity preceding it.

For easier study, we have used the continuous timing. The operation was divided into

three element: Placing of the shirt on the table, placing the screen with the design on the top of

the shirt and the application of the paint. We have observed for the total 19 cycles. We used

continuous timing to present a complete record of the entire observation period for 19 cycles.

Also, we have recorded all the delays and foreign elements. Are elements are shorter so

continuous is much applicable.

We determined the normal time and observed time for each element of the cycle then we

computed for the rating by following formulas: NT= OT x (R/100). Our allowances is computed

by adding the variable allowances values of 2 from standing allowances, 2 from awkward

(bending) and 7 from very awkward (stretching). These numerical values were taken from the

ILO Recommended allowances Table 11.9 of the textbook Niebel’s Methods, standard and work

design. Standard time was then calculated by the formula ST=NT (1+ allowance)

We have studied the elemental time of the process and have reached to the sum of total

standard time of 7.992 minutes by adding all the three elements time.

Recommendation:

The working area should be rearranged in such a way that travel tie will be minimize.

Equipments should be within hand reach since there is still enough space near the working table.

And it should be 90% of the arm level to the working table. Awkward bending should be

eliminated to avoid muscle stress.

In the flow process chart, the materials should be readily available to prepare the design.

The operator should have skills or mastery in cutting the design to save the very long time spent

in the design cutting. Inspecting the t-shirt should also be avoid because it consumed so much

time to inspect the product whereas it can be done while putting the design or the screen on the

shirt. Also the working area should be situated near the tool box where all the materials needed

were placed to avoid the transportation motion.

Hot air blowers should be used to hasten the drying of the t-shirt, and to do it even

without sunlight especially during nights or rainy seasons.

Awkward position

Flow Process Chart

Location:Yacapin Street, CDO City Summary

Activity: Silk Screen Printing Event Present

Date:February 26,2010 Operation 11

Operator:Owen G. Dadang Analysts: Lugmay Rosalyn G. Transport 11

Method: Present Babate Marivic L. Delay 1

Type: Worker Lanuza Mark Anthony M. Inspection 5

Storage 4

Time(min) 33.35

Distance (ft) 72

Event Description Symbols Time (min) Distance (ft) Method Recommendation

Prepare the design ① 0.25 6

Bring the design on working table → 0.1 6

Ge`t the cutter from the tool box → 0.1

Cut the desired design ② 15

After cutting, set aside the cutter ▼ 0.05 6

Get the t-shirt from the tool box → 0.1 6

Go back to working table → 0.1

Place the t-shirt on top of the working table ③ 0.1Make sure that the shirt is properly oriented on top of the table □ 0.15

Place the cut design on top of the t-shirt ④ 0.1

Inspect if the design is situated properly □ 0.15 6

Get the screen and spreader from the tool box → 0.1 6

Bring the screen and spreader to the working table → 0.1Place the screen on top of the design at the top of the t-shirt ⑤ 0.1

Inspect if the screen is situated properly □ 0.15 6

Get the paint and spoon from the tool box → 0.1 6

Go back to working table → 0.1

Open the paint ⑥ 0.05

Get a spoonful of paint ⑦ 0.05

Transfer the paint from the spoon to the top of the screen ⑧ 0.1

Set aside the spoon and paint ▼ 0.05

Spread the paint using the spreader in one direction twice ⑨ 0.1

Slowly take away the screen from the shirt ⑩ 0.25

Set aside the screen ▼ 0.05 8

Bring the t-shirt to the drying area → 0.25

Check if the shirt is properly oriented towards the sunlight □ 0.05

Wait until dried D 15

Check if dried □ 0.05 8

Get the t-shirt from the drying area → 0.1 8

Go back to working table → 0.1

Fold the t-shirt ⑪ 0.25

Set aside ▼ 0.05

Flow Process Chart

Location:Yacapin Street, CDO City Summary

Activity: Silk Screen Printing Event Present Proposed % Difference

Date:March 5, 2010 Operation 11 12 8

Operator:Owen G. Dadang Analyst: Lugmay Rosalyn G. Transport 11 5 120

Method: Proposed Babate Marivic L. Delay 1 0

Type: Worker Lanuza Mark Anthony M. Inspection 5 4 25

Storage 4 4 0

Time(min) 33.35 17.15 81

Distance (ft) 72 0

Symbols Time (min)D (ft) Method Recommendation

Prepare the design ① 0.15Make sure all necessary materials are available

Bring the design and cutter on working table → 0.05 *

Toolbox should be situated near the working table

Cut the desired design ② 10Mastery in cutting the design should be prioritized

After cutting, set aside the cutter ▼ 0.05

Get the t-shirt from the tool box → 0.05 *Toolbox should be situated near the working table

Place the t-shirt on top of the working table ③ 0.1Make sure that the shirt is properly oriented on top of the table □ 0.05

This can be done placing the shirt on top of table

Place the cut design on top of the t-shirt ④ 0.1

Inspect if the design is situated properly □ 0.1This can be done while placing design on top of the shirt

Get the screen and spreader from the tool box → 0.05 *

Toolbox should be situated near the working table

Place the screen on top of the design at the top of the t-shirt ⑤ 0.1

Inspect if the screen is situated properly □ 0.05This can be done while placing screen on top of shirt

Get the paint and spoon from the tool box → 0.05 *Toolbox should be situated near the working table

Open the paint ⑥ 0.05

Get a spoonful of paint ⑦ 0.05Transfer the paint from the spoon to the top of the screen ⑧ 0.1

Set aside the spoon and paint ▼ 0.05Spread the paint using the spreader in one direction twice ⑨ 0.1

Slowly take away the screen from the shirt ⑩ 0.25

Set aside the screen ▼ 0.05

Bring the t-shirt to the drying area → 0.25 *Hot air blower can be used to hasten drying

Blow dry the printed shirts ⑪ 5

Check if dried □ 0.05

Fold the t-shirt ⑫ 0.25

Set aside ▼ 0.05

*Note:Distances are below 5 feet

Two-hand process chart

Operation: Silk Screen Printing Summary Left hand Right handOperator name: Owen G. Dadang Effective time 4.01 6.93Analysts: Babate Marivic Lanuza, Mark Anthony Lugmay, Rosalyn

Ineffective time 4.71 1.79

Cycle time = 8.72

Method: PresentLeft hand description Sym

bolT(min)

T(min)

Symbol

Right hand description

Get t-shirt RE,G 0.132.19 M,P,

RLPlace shirt on top of tablePlace shirt on top of table M,P,

RL2.06

Get the cut design RE,G 0.130.84 M,P,

RLPlace cut design on top of shirtPlace cut design on top of

shirtM,P,RL

0.71

Get the screen RE,G 0.13Place the screen on top of cut design and shirt

M,P,RL

2.10 1.98 M,P,RL

Place the screen on top of cut design and shirt

0.25 I Check if design, shirt and screen are properly oriented

Get the paint RE,G 0.130.42 G,U Open the paintOpen the paint H 0.29

Set aside the paint M,RL

0.29 0.29 RE,G Get the spoon

Hold the screen on top of the shirt

H 2.15

0.13 RE,G Get a spoonful of paint0.15 M Transfer the spoonful of paint

to the screen0.13 RE,G Get the spreader1.61 M,U Spread the pain all over the

screen area twice0.13 M,R

ESet aside the spreader

Take away the screen and design from the shirt

RE,G 0.25 0.25 RE,G Take away the screen and design from the shirt

Set aside the screen M,RL

0.05 0.05 M,RL

Set aside the screen

Pick up the printed shirt RE,G 0.05 0.05 RE,G Pick up the printed shirtBring to sun-drying area M,R

E0.25 0.25 M,R

EBring to sun-drying area

Two-hand process chart

Operation: Silk Screen Printing Summary Left hand Right handOperator name: Owen G. Dadang Effective time 2.66 3.12Analysts: Babate Marivic Lanuza, Mark Anthony Lugmay, Rosalyn

Ineffective time 2.82 2.33

Cycle time = 5.45

Method: ProposedLeft hand description Sym T T Sym Right hand descriptionGet t-shirt RE,G 0.10

1.80 M,P,RL

Place shirt on top of tablePlace shirt on top of table M,P,RL

1.7

Get the cut design RE,G 0.100.70 M,P,

RLPlace cut design on top of shirtPlace cut design on top of

shirtM,P,RL

0.60

Get the screen RE,G 0.10Place the screen on top of cut design and shirt

M,P,RL

1.50 1.50 M,P,RL

Place the screen on top of cut design and shirt

0.10 I Check if design,shirt and screen are properly oriented

Get the paint RE,G 0.100.25 G,U Open the paintOpen the paint H 0.15

Set aside the paint M,RL

0.05 0.05 RE,G Get the spoon

Hold the screen on top of the shirt

H 0.50 0.05 RE,G Get a spoonful of paint0.10 M Transfer the spoonful of paint

to the screen0.05 RE,G Get the spreader0.25 M,U Spread the pain all over the

screen area twice0.05 M,R

ESet aside the spreader

Take away the screen and design from the shirt

RE,G 0.25 0.25 RE,G Take away the screen and design from the shirt

Set aside the screen M,RL

0.05 0.05 M,RL

Set aside the screen

Pick up the printed shirt RE,G 0.05 0.05 RE,G Pick up the printed shirtBring to sun-drying area M,R

E0.20 0.20 M,R

EBring to sun-drying area

Flow Diagram- Present

Storage Area

DRY

12

Entrance

Working Table

Tool Box

Storage Area

2

1

3

5

6

8

11

4

7

9

Flow Diagram – Proposed

- - - - - - - - - - - - - - - - - - -Road -- - - -- - - - - - - - - - - - - - - --

DRY