1. A . STREAMLINING PROGRAM MANAGEMENT
TRACKING SYSTEM FOR ORIGINAL
EQUIPMENT MANUFACTURERS
B . TIME STUDY OF THE MUFFLER END
SPINNING MACHINE
Term Project
By,
Samhita K. Prajapati
B.E. Production
60012115020

2. Project Details
 Objective: Streamlining Program Management
Tracking System for OEMs
 Method: Creating a Dashboard Program using MS
Excel
 Aim: To form a centralised Database containing data
of multiple projects.

3. Problem Statement
 The Program Management Department has to
manage a large number of projects simultaneously.
 Monitoring of various projects becomes time
consuming.
 A centralised database which would be reviewed and
updated monthly was desired.

4. Method
 Dashboard is a single sheet displaying all the
compiled data dynamically.
 Visual Basic for Applications (VBA) language for MS
Excel was used to create codes for dynamic
programming of the various sheets.

5. Sheets
 The Sheets designed for the “Project Health Report”
are:
 Manager Input
 Pilot
 Paynter
 Customer Tooling and ED&T
 TAVA
 Status
 Customer Milestones
 Dashboard

6. Manager Input Sheet

7. Pilot Sheet

8. Paynter Sheet

9. Customer Tooling Sheet

10. Customer ED&T Sheet

11. TAVA Sheet

12. Status Sheet

13. Customer Milestones Sheet

14. Dashboard

15. Conclusion
 The Project Health Report is a handy management
tool.
 It is user-friendly and can be used by anyone with
minimal knowledge of MS Excel.
 It is colour coded for quick analysis with financial
data represented in the form of tables and charts.

16. Project Details
 Objective: To conduct a time study of the Muffler End
Spinning Machine
 Method: Video Time Study
 Aim: To compute production target for each shift of a
working day

17. Introduction
 A Time Study is conducted with the aim of boosting
productivity rates.
 Time study duration varies according to the product
being manufactured.
 Method study and Time study are usually conducted
together.
 It is initiated when:
 Desired productivity rate is not achieved
 An improvement is desired
 There is a change in layout/machinery
 A periodic review is to be conducted

18. The Process Layout
Storage Embossing
Spot
Welding
Notching
Lock-
Seaming
Flanging &
Stuffing
Welding
(if required)
End Cap
Fitting
(if required)
End
Spinning
Leakage
Test
(if required)
FG
Trolley

19. Method
Time and Method study was conducted in the following manner:
1. A video study of each of the individual operations in the
defaulting manufacturing cell was conducted
2. The station with operating time much greater than machine
cycle time was considered to be the bottleneck operation.
3. A thorough Method and Time Study is then carried out on
the bottleneck operation to determine the cause of delay
Note: Always conduct a the study with a highly skilled operator manning the
machine

20. Bottleneck
 The Spinning Machine was found to
have a much greater operating time.
 It was selected for further study.
Machine Cycle Time = 22 seconds
General Operating Time = 39.4 seconds (avg)

21. Next Step
 The End Spinning Machine was
further studied.
 The actions of the operator
were divided into the following
elements:-
 Walk, take muffler and load on
M/C.
 Take unloaded job and place on
table
 Press cycle start and observe 1
rotation
 Walk to LT & right LT value
 Unload job and put on table, load
new job, initiate test
 Check unloaded job and put in FG
trolley

22. The Table of Readings

23. Allowances
 An operator will not perform his operation with
100% consistency.
 The ISO Handbook has specified guidelines
regarding allowances for the worker’s safety and
welfare.
 These allowances are calculated into the machining
time.

24. Calculating Allowance

25. Cycle Time
Load 42
Process 81 On Table & Fixture
Unload 9
Idle Time 0
Allowance in seconds 29
Tea time Allowance in seconds 0
If all allowance is
considered in Idle time,
then only tea time
allowance is applicable
Total cycle time in seconds 132
Applicable cycle time 161.04
Actual Hourly Output (5%
allowance) 57 min hour 21
Shift Output 162
Cycle Time

26. Available Working Time
Time Calculation Mins
A Total Shift Time 510
Less Lunch Time 30
B Available time for work 480
C Personal Need Allowance 5% 24
D Available time for work 456
Less
E Shift Start, PM, Inspection 10
F Shift end Cleaning & Last off 10
G
Net Working Time (for
calculation of Output) 436

27. Shift I (7am – 3:30pm)
Time Available
Time
Net Time
including 5%
personal need
allowance
Net time
(Tea time
distributed)
Hourly
Output
7-8 am 60 47 48 18
8-9 am 60 57 58 22
9-10 am 60 57 58 22
10-11 am 60 57 58 22
11-12 am 30 28.5 29 11
12-1 pm 60 57 58 22
1-2 pm 60 47 48 18
2-3 pm 60 57 58 22
3-3:30 pm 30 18.5 19 7
Shift I 480 426 436 162

28. Shift II (3:30pm – Midnight)
Time Available
Time
Net Time
including 5%
personal need
allowance
Net time
(Tea time
distributed)
Hourly
Output
3:30-4 pm 30 18.5 19 7
4-5 pm 60 57 59 22
5-6 pm 60 42 43 22
6-7 pm 60 57 59 22
7-8 pm 60 57 59 11
8-9 pm 30 28.5 30 22
9-10 pm 60 57 59 18
10-11 pm 60 57 59 22
11-12 am 60 47 49 7
Shift II 480 421 436 162

29. Shift III (Midnight – 7am)
Time Available
Time
Net Time
including 5%
personal need
allowance
Net time
(Tea time
distributed)
Hourly
Output
12-1 am 60 47 47 18
1-2 am 60 57 57 21
2-3 am 60 57 57 21
3-4 am 30 28.5 29 11
4-5 am 30 57 57 21
5-6 am 60 57 57 21
6-7 am 60 47 47 18
Shift I 390 350.5 350.5 131

30. Conclusion
 A video study of the Muffler End Spinning Machine
was conducted.
 Ideal machining time is 32 seconds
 The Cycle Time for the entire Muffler Assembly Cell
for Product X was calculated to be 161.04 seconds.
 Hourly Output Rate for each shift are:
 162 products in Shift I
 162 products in Shift II
 131 products in Shift III