Work sampling was conducted over 5 days to analyze resource usage in an excavator assembly line. Over 1,000 observations were recorded to classify worker activities as value-adding, non-value adding, or waste. Analysis found the most common non-value adding activities were operators leaving their work area, moving to pick up parts, sorting nuts and bolts, and asking supervisors questions. Recommendations included assigning supervisors to trainees, improving organization of hardware, and ensuring all necessary parts are provided to avoid work stoppages.

1. Work Sampling in the
excavator line
Observed and Complied by:
-Soumith S.M.
-Preethi
-Sreeguru Aithal
-Neethi
Project Guide:
Laxman

2. Work sampling- Introduction
• Defined as: Work measurement technique where observation about work is
collected at discrete time intervals(Periodic or Random).
• It is technique of Continuous flow process which comes under Just-in-Time in the
Volvo production system.
• Measures how resources such as people, equipment, machine and facilities are
used.
• Frequency of occurrence of every work element is noted at specified time over a
period.
• The work done can be classified as:
-Value addition
- Non Value addition
- Loss

3. Methodology
• Establish the Purpose: The objective of the study is established.
• Identify the Subjects: The people performing the task are identified.
• Identify the Measure of Output: The types of activities performed on the jobs
being studied.
• Establish a Time Period: Time period is established. Starting and stopping points
for the study are defined.
• Define the Activities: Definition of activities that are performed by the people
under study

4. • Number of Observations Needed: 1000 observations were recorded.
• Schedule the Observations: Once the actual observations are scheduled, 2-3
sessions of work sampling performed for 5 days.
• Inform the Personnel Involved: The personnel involved are informed about the
objective of the study and the methodology.
• Record the Raw Data: Actual recording of the raw data.
• Summarize the Data: After the data have been collected, they are summarized.

5. •The observations were made following accordingly to the points specified.
• 4 Analysts recorded the data at the end of every 3rd minute and wrote the reasons if its
concerning to Non value addition.
Dates Session 1 Session 2 Session 3 Total
Observations
15th July 4 4
16th July 4 4
17th July 3 3 6
20th July 3 3 3 9
21th July 4 4 1 9
32 sheets
•Each sheet contained 32 observations. Hence a total of 1000 observations were
recorded.
•Total Observation= (31*32) + (1*8) = 1000 observations.

7. Analysis
• The total of all respective VA and NVA are computed for all the days.
• A pie chart is constructed to display relative proportions of multiple classes of
data

8. 19.00%
13.80%
0.70%
1.40%
4.10%
0.20%
5.90%
6.30%
9.40%
7.10%
6.00%
1.80%0.20%
0% 1.40%
3.00%
1.60%
7.30%
5.50%
4.70%
Joining/Bolting
Installing
Fillling/Starting
Sealing/bonding/lubrication
Assembling small parts
Repairing
Moving/Walking
Waiting
Lifting/Picking
Transportation
Inspection/Measure
Modification/Adjusting
Stopping
Jig/Tools Change
Cleaning
5S/AM
Packing & Unpacking
Meeting/Discussing
Leaving work area
Personal allowance

9. Problems
The common Non value addition were noted and as follows:
• The operators leaving the work area, as they were done with the assembly in their
station and were waiting for the assembly from the previous station.
• Single operator working on the station and hence moving for picking the bolts and
other smaller assembly parts.
• Operators at the assembly line involved in sorting of the nuts and bolts.
• Operators moving from the work area to enquire about the doubts to the
supervisors.
• Packing and unpacking of the smaller sub assembly parts.
• Waiting for the subordinate to finish the task.
• Cleaning.
• Picking ( Tools,Bolts,Fixtures etc)
• Unnecessary discussions.

10. • When there is a change the model of the excavator being build the stores forget to
kit the required parts each of the feeder such as the harness at feeder 2 of the
excavator assembly resulting in the work to wait for the parts to be supplied.
(From 210 to 300)
• Production line Plant Roof having damages resulting in the inefficiency of the
operators. During heavy rains the plant roof at the sprocket sub assembly feeder
not intact resulting in operator to clean the chain of the sprocket assembly. Over
processing resulting in inefficiency of the worker.
• Meeting of all the operators during the work hours.
• Arranging parts on the hardware trolley for the next assembly.
• Fixing Eye bolt for transport.
• Reference to files by the operators when to ensure the right operations are being
done when new model of excavator is being assembled.( From 210 to 300).
• Door alignment using gauge
• Only one nose plier in the production line resulting in operators moving from their
respective feeders to get the nose pliers.

11. Improvements and Control
Category Problem Solution
Leaving Work
Area
The operators leaving the work area, as
they were done with the assembly in
their station and were waiting for the
assembly from the previous station.
•Operator must follow the takt
time
•Can involve himself in 5s work of
the hardware trolley for the next
assembly
Moving and
Picking
Single operator working in cabin
assembly station and hence moving
for picking the bolts and other
smaller assembly parts.
Hardware trolley must be placed next
to the operator over the platforms
such that they don’t have to move
from the cabin assembly to pick the
bolts necessary. It is seen that they
arent ergonomically placed in station
where the cabin is to be fitted to the
upper frame.
5s/AM Operators at the assembly line
involved in sorting of the nuts and
bolts.
Required hence no solutions
can be provided.
Move Operators moving from the work area to
enquire about the doubts to the
supervisors.
A supervisor must be assigned to
each of the trainee and must be
with them until they are confident
in the assembly.

12. Category Problem Solution
Pack/Unpack Packing and unpacking of the
smaller sub assembly parts.
Operators can be involved with the
unpacking of parts ince they are
done with their work.
Waiting Waiting for the subordinate to
finish the task.
Can involve himself in 5s work of
the hardware trolley for the next
assembly
Clean Cleaning. Necessary and hence no solutions
can be provided.
Pick/Lift Picking ( Tools,Bolts,Fixtures etc) Necessary (Layout of the line is
optimized and hence no
improvements can be suggested)
Discussion Unnecessary discussions. Motivate the workers to involve
themselves in work assigned.

13. Category Problem Solution
Cleaning Production line Plant Roof having damages
resulting in the inefficiency of the operators.
During heavy rains the plant roof at the
sprocket sub assembly feeder not intact
resulting in operator to clean the chain of the
sprocket assembly. Over processing resulting in
inefficiency of the worker.
The Roof of the production
line must be fixed.
Meeting Meeting of all the operators during
the work hours.
Meeting must be
conducted either pre-
production time or post
production time.
5s Arranging parts on the hardware
trolley for the next assembly.
Necessary and hence no
solutions can be provided.
Lifting and picking Fixing Eye bolt for transport. Necessary and hence no
solutions can be provided.
Inspection/
Measure
Door alignment using gauge Necessary and hence no
solutions can be provided.

14. Category Problem Solution
Inspection/Measur
e
Reference to files by the operators
when to ensure the right operations
are being done when new model of
excavator is being assembled.( From
210 to 300).
3*3*3 must be implemented.
The operators must be refer to
the SOPs,OPL,parts drawing as
and when they are free and not
during the assembly.
Move Only one nose plier in the
production line resulting in
operators moving from their
respective feeders to get the nose
pliers.
Provide the MCV sub
assembly with a nose pliers
so as to relegate the
unnecessary movement.
Waiting When there is a change the model
of the excavator being build the
stores forget to kit the required
parts each of the feeder such as the
harness at feeder 2 of the excavator
assembly resulting in the work to
wait for the parts to be supplied.
(From 210 to 300)
Stores must study the
Model in line being built
and must provide the
necessary parts for all the
stations and feeders.