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IRJET-Productivity Enhancement Using Method Study.pdf

This research paper mainly emphasize on the benefit of method study and how this technique helps in enhancing productivity.All the resources are optimally utilizes by this technique and it ensure that the operating cost are minimum. It changes the current way of working bu more efficient method.

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© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 170
Productivity Enhancement Using Method Study
Sahil Rajendra Bavdhankar1, Rushikesh Yuvraj Patil2, Pramod Suresh Patangaray3
1,2,3U.G. Student, Department of Mechanical Engineering, KIT’s College of Engineering, Kolhapur,
Maharashtra, India
--------------------------------------------------------------***---------------------------------------------------------------
Abstract - This research paper emphasizes on the
method study technique and its importance in organization for
increasing productivity. Method study helps the organization
to achieve competitive edge. The motion analysis was done
using two-handed process chart and the new improved way
utilizing both hands effectively was identified .This project
throws light on the concept that by utilizing the capacity
within your organization, you can increase the profit. The
capacity was increased from 5928 components to 6200
components by optimum utilization of available resources.
This increased the profit of the company by 1,01,728Rs per
month.
Key Words: Method study, Productivity, Two-Handed
Chart, Capacity, Profit, Recording, Optimum
1.INTRODUCTION :
Work study involves time study and method study.
Method study is a very much preferred approach for
improving the productivity of any company. Any
organization runs for profit so, identifying the
improvements and implementing it at the lowest cost
possible is very important. Any method of doing the work
which will improve the quality of the product or reduce the
cycle time will place the organization to another level. To
achieve competitive edge, it is necessary to evolve
continuously and improve the quality of the product at the
same cost or reduce the cost for same quality. Many
parameters hamper the quality of the final product being
produced. Proper and critical analyses of the parameters
which are increasing the cycle time, reducing the quality of
product should be done. All the non-value added activities
can be eliminated by innovation of new techniques. Many
organizations are lagging behind because of not following
proper methodology for quality control and reducing
rejection rate. The organization can excel and earn more
profit by making the loading and unloading time to zero
and thus enhancing the capacity of the particular
organization. Capacity can be enhanced by using the
available resources within the organization effectively .There
are numerous factors which affect productivity like
economic, human. Human factors affect largely, so it is
necessary to design the work system such that it will be
comfortable for human and will result in minimal fatigue
of an employee. Many people need to study and understand
the principles of motion economy and thus apply those
principles which will lead to smooth flow of materials
within different work centers and it will eliminate the
delays between the different operations
The method study technique helps to achieve all the
factors affecting the productivity and make you
understand the root cause for your problem easily.
1.1 Problem Identification:
The monthly order for the company to machine the
components is 6000. Operations 10 , 20, 30 to machine
the component on both the sides are carried out
separately on two VMC machines . This reduces the
number of components machined as well as it leads to
increase in cycle time. This method of doing the work
leads to underutilization of available resources within
the organization.
1.2 Objectives :
1. To study the existing method of doing the work.
2. To understand why this method is only
employed for doing the work.
3. To understand and implement possible
alternative.
4. To improve the productivity of organization by
developing and installing improved method of
doing work.
5. To increase the profit of the organization by
optimum utilization of available resources.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072
Fig.1 Engine Bracket (Top view) Fig.2 Engine Bracket (Bottom view)
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 171
1.3 Future Scope :
6. To eliminate the non-valueadded activities.
1. To simplify the operations.
1. To make the effective utilization of
men ,material and equipment’s.
2. Method Study :
The main aim of doing method study is to study and
understand the existing method of doing the work and
developingmoreefficientandeffectivemethodleading
to more profit , reduced cycle time , minimal material
handling , improved workplace design, better working
conditions ,lesser worker fatigue.
The method study technique involves following steps:
1. Selection of job :
2. Recording Techniques :
Table 1. TWO HANDED CHART ( BEFORE ) :
Description Symbol Symbol Description
IDLE Reach for the cast
component
IDLE Grasp the component
IDLE Reach to fixture
IDLE Place it on the fixture
Hold the cast component Reach for the spanner
IDLE Grasp the spanner
IDLE Carry to fixture
IDLE Tighten the component to
the fixture
IDLE Spanner to table
Table 2. Summary :
Symbol
Frequency (LEFT HAND) 5 4 -
Frequency(RIGHT HAND) - - 1
Table 3. TWO HANDED CHART (AFTER ) :
Description Symbol Symbol Description
Reach for spanner Reach for the cast component
Grasp the spanner Grasp the component
To machine Carry the cast component
Hold the spanner Place the component to fixture
Transfer the spanner to right
hand
Grasp the spanner
Hold the component
Tighten thecomponent using
spanner
to the fixture
Spanner to table
Table 4. Summary :
Symbol
Frequency (LEFT
HAND)
3 4 -
Frequency(RIGHT
HAND)
3 1 2
3. Critical Examination :
The critical examination of all recorded information
is carried out.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072
As any activity demands the human effort , time
as well as money , so one should be thoughtful
before selecting any job for method analysis.
Selection of proper job will give higher profit to
organization and the time and efforts invested by
the workers will be justified.
Table 5. Multiple Activity Chart
Table 6. Summary
3.1 Present Method
The worker used to initially use only right hand for
lifting of the job as well as lifting and carrying the
spanner to fixture keeping the left hand idle for
most of the time.
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 172
OP
10
OP OP
20 30
Operation Time = 4+5.5+2
= 11.5 minutes
For One Shift of 8 hrs :
8 hours = 440 min(working time) + 40 min (break)
Therefore,
Total Components Machined =440/11.5
= 38.26
= 38 components
3.2 Proposed Method
The workers both hands were effectively utilized
by using left hand for grasping and holding the
spanner while the right hand was utilized for
handling of component.
4. Develop
By studying all the operations, working pattern anew
method of machining the component is found.
When operation 10, 20, 30 are carried on single
VMC machine .
Table 7. Traditional Method
For 3 Shifts:
38 components*3=114 components
For a month:
114*26 = 2964 components
As the company utilizes 2 machines and the
operations 10, 20, 30 are carried separately on both
the VMC machines the total components machined
per month will be 5928 components.
But, the company is having the demand for around
60000 components which can’t be fulfilled.
So, the proposed solution is that by carrying the OP 10
on one VMC and the OP 20 and 0P 30 on another
machine , the number of components machined can
be increased.
For 1 shift :
440/5.5= 80 components
For 3 shifts = 240 components per day
For a month = 240*26
=6240 components
OP OP OP
10 20 30
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-005
Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072
5. Results and Discussions:
Table 8. Comparison of present method and
Proposed method
Two VMC machine
are used
simultaneously and
both of them operate
all the operations 10,
20,30
Two VMC machines
are used
simultaneously,
utilizing effectively
by splitting the
operation 10 on one
VMC and Operation
20, 30 on the other
VMC.
This method used to
machine only 5928
components per
month.
This method
machined 6200
components per
month
This method
machined only 98%
of the total
components
required.
Split operation
method machines
103% of the total
components
required.
The two VMC
machines were
under-utilized
because of traditional
method
Split operation
method utilizes both
the VMC machines to
the best of their
capacity.
The available
resources like
machine, manpower
were not utilized
effectively.
The available were
resources were
utilized optimally and
the machining
demand of the
component was
fulfilled by split
operation method
Present Method Proposed Method
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 173
Components machined by split operation
Method – Components machined by
traditional method
=6200-5928
=272 components
272 components more were machined using
Split operation method.
5.2 Increased Profit:
Table 9. Profit comparison
Profit gained by
traditional
method
Profit gained by
proposed method
Cost per job*total
components
machined
=374*5928
=22,17,072 Rs
Cost per job*total
components machined
= 374*6200
=23,18,800 Rs
6. CONCLUSIONS :
1. The optimum utilization of resources
available within the organization can lead to
increased profit which will ultimately
increase the productivity.
2. This study emphasizes that the method
study technique can replace the method of
doing the work by more efficient, effective
method
3. The capacity of organization can be
enhanced by focusing efforts in right
direction.
4. There is always a scope of improvement in
any process or method ,so all the parameters
should be critically examined.
REFERENCES :
[1] Martand Telsang “Industrial Engineering
and Production Management” S Chand, New
Delhi.
[2] V.Das, Harikrishna T K, “Productivity
Enhancementthrough Design and
Development of Milling Fixture” ,
International Journal of Engineering and
Innovative Technology, Vol 9, Issue 3,
September 2019, pp 25-32.
[3] A.Rajiwate , H.Mirza ,S.Kazi, “ Productivity
Improvement by Time Study and Motion
Study” , International Research Journal of
Engineering and Technology, Vol 7, pp.
5308-5312, March 2020.
5.1 Increased Productivity:
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072
BIOGRAPHIES :
[4] Hyun-Jong Kim, Ho-Young Hwang and
Jung- Wan Hong “A Study on the Method of
Task Management Using Motion
Analysis”, International Journal of Pure and
Applied Mathematics, Vol 117, pp. 389-
396, 2017
[5] S.Yadav and P.Chahal, “Micro-Motion of
Worker”, International Journal of
Research Publication and Reviews, Vol 3,
pp 3123- 3129, July 2022.
[6] C.Duran, A.Centindere, Y.Aksu,
“Productivity Improvement by Work and
Time study technique for Earth
Energy-glass Manufacturing company”,
Elsevier, 2015.
Mr. Sahil Rajendra Bavdhankar.
Under Graduate Student,
Department of Mechanical
Engineering,
KIT's College of
Engineering, Kolhapur.
Mr. Rushikesh Yuvraj Patil.
Under Graduate Student,
Department of Mechanical
Engineering,
KIT's College of
Engineering, Kolhapur.
Mr. Pramod Patangaray.
Under Graduate Student,
Department of Mechanical
Engineering,
KIT's College of
Engineering, Kolhapur.
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IRJET-Productivity Enhancement Using Method Study.pdf

  • 1. © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 170 Productivity Enhancement Using Method Study Sahil Rajendra Bavdhankar1, Rushikesh Yuvraj Patil2, Pramod Suresh Patangaray3 1,2,3U.G. Student, Department of Mechanical Engineering, KIT’s College of Engineering, Kolhapur, Maharashtra, India --------------------------------------------------------------***--------------------------------------------------------------- Abstract - This research paper emphasizes on the method study technique and its importance in organization for increasing productivity. Method study helps the organization to achieve competitive edge. The motion analysis was done using two-handed process chart and the new improved way utilizing both hands effectively was identified .This project throws light on the concept that by utilizing the capacity within your organization, you can increase the profit. The capacity was increased from 5928 components to 6200 components by optimum utilization of available resources. This increased the profit of the company by 1,01,728Rs per month. Key Words: Method study, Productivity, Two-Handed Chart, Capacity, Profit, Recording, Optimum 1.INTRODUCTION : Work study involves time study and method study. Method study is a very much preferred approach for improving the productivity of any company. Any organization runs for profit so, identifying the improvements and implementing it at the lowest cost possible is very important. Any method of doing the work which will improve the quality of the product or reduce the cycle time will place the organization to another level. To achieve competitive edge, it is necessary to evolve continuously and improve the quality of the product at the same cost or reduce the cost for same quality. Many parameters hamper the quality of the final product being produced. Proper and critical analyses of the parameters which are increasing the cycle time, reducing the quality of product should be done. All the non-value added activities can be eliminated by innovation of new techniques. Many organizations are lagging behind because of not following proper methodology for quality control and reducing rejection rate. The organization can excel and earn more profit by making the loading and unloading time to zero and thus enhancing the capacity of the particular organization. Capacity can be enhanced by using the available resources within the organization effectively .There are numerous factors which affect productivity like economic, human. Human factors affect largely, so it is necessary to design the work system such that it will be comfortable for human and will result in minimal fatigue of an employee. Many people need to study and understand the principles of motion economy and thus apply those principles which will lead to smooth flow of materials within different work centers and it will eliminate the delays between the different operations The method study technique helps to achieve all the factors affecting the productivity and make you understand the root cause for your problem easily. 1.1 Problem Identification: The monthly order for the company to machine the components is 6000. Operations 10 , 20, 30 to machine the component on both the sides are carried out separately on two VMC machines . This reduces the number of components machined as well as it leads to increase in cycle time. This method of doing the work leads to underutilization of available resources within the organization. 1.2 Objectives : 1. To study the existing method of doing the work. 2. To understand why this method is only employed for doing the work. 3. To understand and implement possible alternative. 4. To improve the productivity of organization by developing and installing improved method of doing work. 5. To increase the profit of the organization by optimum utilization of available resources. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072 Fig.1 Engine Bracket (Top view) Fig.2 Engine Bracket (Bottom view)
  • 2. © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 171 1.3 Future Scope : 6. To eliminate the non-valueadded activities. 1. To simplify the operations. 1. To make the effective utilization of men ,material and equipment’s. 2. Method Study : The main aim of doing method study is to study and understand the existing method of doing the work and developingmoreefficientandeffectivemethodleading to more profit , reduced cycle time , minimal material handling , improved workplace design, better working conditions ,lesser worker fatigue. The method study technique involves following steps: 1. Selection of job : 2. Recording Techniques : Table 1. TWO HANDED CHART ( BEFORE ) : Description Symbol Symbol Description IDLE Reach for the cast component IDLE Grasp the component IDLE Reach to fixture IDLE Place it on the fixture Hold the cast component Reach for the spanner IDLE Grasp the spanner IDLE Carry to fixture IDLE Tighten the component to the fixture IDLE Spanner to table Table 2. Summary : Symbol Frequency (LEFT HAND) 5 4 - Frequency(RIGHT HAND) - - 1 Table 3. TWO HANDED CHART (AFTER ) : Description Symbol Symbol Description Reach for spanner Reach for the cast component Grasp the spanner Grasp the component To machine Carry the cast component Hold the spanner Place the component to fixture Transfer the spanner to right hand Grasp the spanner Hold the component Tighten thecomponent using spanner to the fixture Spanner to table Table 4. Summary : Symbol Frequency (LEFT HAND) 3 4 - Frequency(RIGHT HAND) 3 1 2 3. Critical Examination : The critical examination of all recorded information is carried out. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072 As any activity demands the human effort , time as well as money , so one should be thoughtful before selecting any job for method analysis. Selection of proper job will give higher profit to organization and the time and efforts invested by the workers will be justified. Table 5. Multiple Activity Chart Table 6. Summary 3.1 Present Method The worker used to initially use only right hand for lifting of the job as well as lifting and carrying the spanner to fixture keeping the left hand idle for most of the time.
  • 3. © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 172 OP 10 OP OP 20 30 Operation Time = 4+5.5+2 = 11.5 minutes For One Shift of 8 hrs : 8 hours = 440 min(working time) + 40 min (break) Therefore, Total Components Machined =440/11.5 = 38.26 = 38 components 3.2 Proposed Method The workers both hands were effectively utilized by using left hand for grasping and holding the spanner while the right hand was utilized for handling of component. 4. Develop By studying all the operations, working pattern anew method of machining the component is found. When operation 10, 20, 30 are carried on single VMC machine . Table 7. Traditional Method For 3 Shifts: 38 components*3=114 components For a month: 114*26 = 2964 components As the company utilizes 2 machines and the operations 10, 20, 30 are carried separately on both the VMC machines the total components machined per month will be 5928 components. But, the company is having the demand for around 60000 components which can’t be fulfilled. So, the proposed solution is that by carrying the OP 10 on one VMC and the OP 20 and 0P 30 on another machine , the number of components machined can be increased. For 1 shift : 440/5.5= 80 components For 3 shifts = 240 components per day For a month = 240*26 =6240 components OP OP OP 10 20 30 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-005 Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072 5. Results and Discussions: Table 8. Comparison of present method and Proposed method Two VMC machine are used simultaneously and both of them operate all the operations 10, 20,30 Two VMC machines are used simultaneously, utilizing effectively by splitting the operation 10 on one VMC and Operation 20, 30 on the other VMC. This method used to machine only 5928 components per month. This method machined 6200 components per month This method machined only 98% of the total components required. Split operation method machines 103% of the total components required. The two VMC machines were under-utilized because of traditional method Split operation method utilizes both the VMC machines to the best of their capacity. The available resources like machine, manpower were not utilized effectively. The available were resources were utilized optimally and the machining demand of the component was fulfilled by split operation method Present Method Proposed Method
  • 4. © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 173 Components machined by split operation Method – Components machined by traditional method =6200-5928 =272 components 272 components more were machined using Split operation method. 5.2 Increased Profit: Table 9. Profit comparison Profit gained by traditional method Profit gained by proposed method Cost per job*total components machined =374*5928 =22,17,072 Rs Cost per job*total components machined = 374*6200 =23,18,800 Rs 6. CONCLUSIONS : 1. The optimum utilization of resources available within the organization can lead to increased profit which will ultimately increase the productivity. 2. This study emphasizes that the method study technique can replace the method of doing the work by more efficient, effective method 3. The capacity of organization can be enhanced by focusing efforts in right direction. 4. There is always a scope of improvement in any process or method ,so all the parameters should be critically examined. REFERENCES : [1] Martand Telsang “Industrial Engineering and Production Management” S Chand, New Delhi. [2] V.Das, Harikrishna T K, “Productivity Enhancementthrough Design and Development of Milling Fixture” , International Journal of Engineering and Innovative Technology, Vol 9, Issue 3, September 2019, pp 25-32. [3] A.Rajiwate , H.Mirza ,S.Kazi, “ Productivity Improvement by Time Study and Motion Study” , International Research Journal of Engineering and Technology, Vol 7, pp. 5308-5312, March 2020. 5.1 Increased Productivity: International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 12 | Dec 2023 www.irjet.net p-ISSN: 2395-0072 BIOGRAPHIES : [4] Hyun-Jong Kim, Ho-Young Hwang and Jung- Wan Hong “A Study on the Method of Task Management Using Motion Analysis”, International Journal of Pure and Applied Mathematics, Vol 117, pp. 389- 396, 2017 [5] S.Yadav and P.Chahal, “Micro-Motion of Worker”, International Journal of Research Publication and Reviews, Vol 3, pp 3123- 3129, July 2022. [6] C.Duran, A.Centindere, Y.Aksu, “Productivity Improvement by Work and Time study technique for Earth Energy-glass Manufacturing company”, Elsevier, 2015. Mr. Sahil Rajendra Bavdhankar. Under Graduate Student, Department of Mechanical Engineering, KIT's College of Engineering, Kolhapur. Mr. Rushikesh Yuvraj Patil. Under Graduate Student, Department of Mechanical Engineering, KIT's College of Engineering, Kolhapur. Mr. Pramod Patangaray. Under Graduate Student, Department of Mechanical Engineering, KIT's College of Engineering, Kolhapur.