PRODUCTIVITY ENHANCEMENT AND PROCESS WASTE ELIMINATION THROUGH THE USE OF MAYNARD OPERATION SEQUENCE TECHNIQUE BY SARAVANAN TANJONG TUAN A dissertation submitted in fulfilment of the requirement for the degree of Master of Science in Manufacturing Engineering Kulliyyah of Engineering International Islamic University Malaysia AUGUST 2014
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
PRODUCTIVITY ENHANCEMENT AND PROCESS
WASTE ELIMINATION THROUGH THE USE OF
MAYNARD OPERATION SEQUENCE TECHNIQUE
BY
SARAVANAN TANJONG TUAN
A dissertation submitted in fulfilment of the requirement for
the degree of Master of Science in
Manufacturing Engineering
Kulliyyah of Engineering
International Islamic University Malaysia
AUGUST 2014
ii
ABSTRACT
To sustain in business under the current fierce competition a company needs to
explore all avenues of improvement. In this respect, reduction or elimination of idle
and/or down time in operations and improvement of the working methods can play a
significant role. This research project is undertaken to address the problems and
challenges faced by an auto company in meeting the daily production target of a car
rear window assembly line. The operations performed in making this end product are
attributable to inefficient work methods with non-optimal capacity planning for
different workstations. In this respect Maynard Operation Sequence Technique
(MOST) is adopted to exploit the advantages of this PTS system in determining the
accurate work standard, analyzing job activity, planning capacity and manpower, and
designing workplace. This has helped in re-organizing and allocating jobs for work
balancing, and assessing the economic benefit through cost estimation of the existing
and proposed processes. Initial investigation shows that the whole assembly line has
been suffering from the absence of established standard time for activities carried out
by operators, the non-value added activities involved and the inefficient methods such
as manual screwing, unplanned aisle and walking distance, material wastages and
imbalance in the material flow. Subsequently, by application of MOST alternative
methods and work standards are developed which are conducive to capacity planning,
workplace layout design and manning analysis. Thus through the process flow
analysis, material handling and redistribution of activities among the four
workstations an improved process is designed and proposed. It has been revealed that
with this proposed method an enhanced workflow is achievable. Upon preliminary
introduction of the concept, it has been possible to reduce the production cycle time to
cater the higher level of demand with shorter takt time maintaining the current level of
manpower. As a result, the production rate is possible to be enhanced from the current
level of 54 units to 70 units per day with the suggested operational procedure. This
increased capacity is deemed to satisfy the daily production target of 66 units per day.
Thus this study also recognizes the effectiveness of the MOST technique to enable an
analyst to expose wastes and unproductive methods of work in a quicker manner and
help rectify problems at the workplace with an eventual improvement in productivity.
iii
(MOST) PTS
.
MOST
Takt
4507
66
MOST
iv
APPROVAL PAGE
I certify that I have supervised and read this study and that in my opinion, it conforms
to acceptable standards of scholarly presentation and is fully adequate, in scope and
quality, as a dissertation for the degree of Master of Science in Manufacturing
Engineering.
…………………………………..
A. N. Mustafizul Karim
Supervisor
I certify that I have read this study and that in my opinion it conforms to acceptable
standards of scholarly presentation and is fully adequate, in scope and quality, as a
dissertation for the degree of Master of Science in Manufacturing Engineering.
…………………………………..
Erry Y. T. Adesta
Internal Examiner
…………………………………..
A. K. M. Mohiuddin
Internal Examiner
This dissertation was submitted to the Department of Manufacturing and is accepted
as a fulfilment of the requirement for the degree of Master of Science in
Manufacturing Engineering.
…………………………………..
Md. Yusof Bin Ismail
Head, Advanced Engineering and
Innovation Centre
This dissertation was submitted to the Kulliyyah of Engineering and is accepted as a
fulfilment of the requirement for the degree of Master of Science.
…………………………………..
Md. Noor Bin Salleh
Dean, Kulliyyah of Engineering
v
DECLARATION
I hereby declare that this dissertation is the result of my own investigation, except
where otherwise stated. I also declare that it has not been previously or concurrently
submitted as a whole for any other degrees at IIUM or other institutions.
No part of this unpublished research may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise without prior written permission of the copyright holder except
as provided below.
1. Any material contained in or derived from this unpublished research may
be used by others in their writing with due acknowledgement.
2. IIUM or its library will have the right to make and transmit copies (print
or electronic) for institutional and academic purposes.
3. The IIUM library will have the right to make, store in a retrieval system
and supply copies of this unpublished research if requested by other
universities and research libraries.
Affirmed by: Saravanan Tanjong Tuan
……..……..…………… …………………..
Signature Date
viii
ACKNOWLEDGEMENTS
Thanks to God, with his will and blessings, I have been able to finish my dissertation
as the last module for the Master of Science in Manufacturing Engineering. I feel most
fortunate indeed, when given a chance and had a fruitful experience having done my
PG study at International Islamic University Malaysia. In this respect, first of all, I
would like to express my sincere appreciation and gratitude to my Supervisor, Prof.
Dr. A. N. Mustafizul Karim for his constant guidance, constructive suggestions,
encouragement, and his time in editing the chapters, during this long period in
preparation of this thesis. There are a number of people whose direct and indirect
support must be mentioned and in this regard I would like to extend my appreciation
to my co-supervisor Prof. Dr. A.K.M. Nurul Amin for his support and advice in ways
to improvise my studies and for having confidence in me throughout this period.
During the past few years, I have been through indescribable experience and it
would be difficult to achieve what I have today without the support from various
sources. I must recognize my lecturers who taught me the courses and transferred the
knowledge. My special thanks are due to Br. H. M. Emrul Kays and Br. Mekentichi
Abdesselam, PG students of MME department for being supportive in various phases
of this project. This study was conducted as a part of FRGS project (FRGS11-031-
0179) funded by Ministry of Higher Education (MOHE), Malaysia. I am grateful to
MOHE and RMC, IIUM.
Last but not least, I would like to thank my family members for their supports
and all my friends whom I have made from the beginning and along the way in IIUM.
Not forgetting all friends who gave me their sincere friendship. Thank you very much.
May God bless us all.
ix
TABLE OF CONTENTS
Abstract .................................................................................................................... ii Abstract in Arabic .................................................................................................... iii Approval Page .......................................................................................................... iv Declaration ............................................................................................................... v
Copyright Page ......................................................................................................... vi Dedication ................................................................................................................ vii
Acknowledgements .................................................................................................. viii List of Tables ........................................................................................................... xi List of Figures .......................................................................................................... xiii
List of Abbreviation ................................................................................................. xv
CHAPTER ONE: INTRODUCTION ................................................................. 1 1.1 General Background ............................................................................... 1 1.2 Productivity and Line Balancing ............................................................ 2 1.3 Brief Description of Most ...................................................................... 4
1.4 Problem Statement ................................................................................. 5 1.5 Aims and Objectives .............................................................................. 6 1.6 Scope of Work ........................................................................................ 7
1.7 Significance of the Study ....................................................................... 7
CHAPTER TWO: LITERATURE REVIEW .................................................... 9 2.1 Introduction ............................................................................................ 9 2.2 Work and Time Measurement Techniques ............................................ 9
2.2.1 Predetermined Motion Time System (PMTS) ............................. 10
2.3 Advantages and Benefit of Most ............................................................ 26
2.4 Production Line Balancing ..................................................................... 27 2.5 Summary ................................................................................................ 30
CHAPTER THREE: RESEARCH METHODOLOGY ................................... 31 3.1 Introduction ............................................................................................ 31
3.2 Research Approach ................................................................................ 31 3.2.1 Approach in Implementation of MOST ....................................... 33 3.2.2 Method for Assembly Line Balancing ......................................... 36
3.2.3 Evaluation of production rate and Balancing Efficiency ............. 37 3.3.4 Economic Validation of the proposed modification .................... 38
CHAPTER FOUR: DATA COLLECTION AND ANALYSIS ........................ 40 4.1 Introduction ............................................................................................ 40 4.2 Company Profile .................................................................................... 40 4.3 Current Practices within the Rear Window Assembly Line .................. 41
4.3.1 Current Process Layout ................................................................ 41 4.3.2 Sequence of Operation ................................................................. 43
x
4.4 Basic Steps of Assembling the Rear Window ........................................ 45
4.5 Work Element for Rear Window Assembly .......................................... 52 4.6 Overview of the Undertaken Assembly Line ......................................... 53 4.7 Takt Time of Rear Window Assembly (Present Situation) ................... 53
4.8 Line Balance Loss for Current Rear Window Assembly Operations .... 55 4.9 Summary of Current Situation Analysis ................................................ 56
5.3 Possible Scope of Improvement ............................................................. 66 5.4 Proposed Modifications in the Assembly Line ...................................... 68
5.4.1 Proposed Plan for Tool use and Workflow .................................. 69 5.4.2 Proposed Changes for Layout Plan .............................................. 73
5.5 Assessment of Improvement in Productivity ......................................... 74
5.5.1 Proposed WorkStation 1 – Elemental Task Times ...................... 74 5.5.2 Proposed Workstation 2 – Elemental Task Times ....................... 75
5.5.3 Proposed Workstation 3 – Elemental Task Times ....................... 77 5.5.4 Proposed Workstation 4 – Elemental Task Times ....................... 78
5.6 Summary of the Resulting Improvements .............................................. 80 5.6.1 Demand Satisfaction .................................................................... 80 5.6.2 Production Rate Improvement ..................................................... 82
5.6.3 Line Balance Loss Evaluation ...................................................... 83