MANPOWER PRODUCTIVITY IMPROVEMENT IN …

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MANPOWER PRODUCTIVITY IMPROVEMENT IN MANUFACTURING INDUSTRY

USING INDUSTRIAL ENGINEERING TOOLS

VISHWAS KAMBLE & Dr. RASHMI SHAHU

Industrial Engineering, Shri Ramdeobaba College of Engineering and Management, Nagpur, India

ABSTRACT

Title: Productivity Improvement in Manufacturing Industry Using Industrial Engineering Tools Objectives: “To improve

manpower productivity by implementing Industrial engineering tools” for Mill Chock Servicing & Work roll Assembly

from 36 Man-hours to 24 Man-hours per work roll set. Methods: Initial workplace audit was conducted based on the 5’S,

Ergonomic aspects, Engineering tools & tackles, Maintenance practices, workplace layout, Material flow etc. This also

includes activities sequence and the activity time to analyse existing work patterns. As the objective was to implement best

workplace design with the world-class industry practices & improved manpower productivity using Industrial

Engineering tools.

Systematic Work study was carried out for each operation using the advanced Video recording techniques after

creating SIPOC (Supplier, Input, Process, Output & Customer) model of a process to eliminate non value added (NVA)

activities & time. Team brainstorming was carried out to identify internal and external activities, Manual, Auto, Waiting

& Walking time was mapped. Then Waste matrix was mapped to identify Value added and Non-Value added activities.

Finally actions were proposed based on Eliminate, Combine, Reduce & Simply (ECRS) Techniques followed by

standardization and training on Standard Operating Procedures (SOP) developed using Augmented (AR) & Virtual

Reality (VR). Results: With the application of various Industrial Engineering tools such as Work study, Ergonomic

Study, 5’S & Lean Management the “Manpower Productivity was improved for M4 Chock Servicing & Work roll

Assembly from 36 Man-hours to 25 Man-hours per work roll set.” Conclusion: From the project studies, it was found

that 1) Integrating ergonomics into the method study helps to standardize processes effectively & prevent worker

discomfort helps to improve productivity and product quality. 2) Eliminate, Combine, Reduce & Simply (ECRS)

Techniques helps to optimize the work sequence & activity time. 3) Unlike Single Minute Exchange of Dies (SMED)

separation of internal and external setups, performing simultaneous activities helps to reduce unproductive time. 4) Lean

tools when effectively combined with Work Study Methods can help to resolve problems regarding the productivity. If

implemented in proper order.

KEYWORDS: Work Study, Workplace Design, Ergonomics, Single Minute Exchange of Dies (SMED), 5’s, Elimination

of waste (MUDA), Industrial engineering tools, Standardization, Augmented Reality (AR) & Virtual Reality (VR)1

Received: May 25, 2020; Accepted: Jun 27, 2020; Published: Aug 05, 2020; Paper Id.: IJMPERDJUN2020638

1. INTRODUCTION

The paper is about study of productivity improvement techniques using industrial Engineering tools such as effective

modern Work Study using Video Recording, Use of Ergonomic study, 5’S, Standardization etc. In this project

modern video techniques for method and time study was used to carry out waste value analysis, Used SMED

Principles & work combination sheet to eliminate non-value added (NVA) by Eliminate, Combine, Reduce &

Orig

ina

l Article

International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249–6890; ISSN (E): 2249–8001

Vol. 10, Issue 3, Jun 2020, 6701-6716

© TJPR Pvt. Ltd.

http://www.tjprc.org/

6702 Vishwas Kamble & Dr. Rashmi Shahu

Impact Factor (JCC): 8.8746 SCOPUS Indexed Journal NAAS Rating: 3.11

Simplify (ECRS) principles, Developed new SOPs, OPLs, Check sheets & Augmented Reality (AR) & Virtual Reality

(VR) techniques for standardization and training.

Productivity improvement is a critical success factor for the business profitability. Management may be able to

produce a larger quantity with better quality or higher value products with the same input resources by using the industrial

engineering tools and techniques. Manpower/ Labour productivity is the amount of work done by the group of workmen in

a given amount of time. Manpower productivity depends upon how effectively workmen are utilized. Manpower

productivity can be higher or lower depending on factors like availability of resources such as material, working tools,

availability of power, work efficiency, level of motivation, level of training, level of working condition (comfortable or

poor) etc. Manpower productivity can be measured in terms of hours or money.

Industrial Engineering is a science of decision-making which concerned with the design, improvement, and

installation of the integrated system of men, materials, and equipment. It draws upon specialized knowledge and skills in

the mathematical, physical, and social sciences, together with the principles and methods of engineering analysis and

design, to specify, predict and evaluate the result to be obtained from such a system.

Application of Industrial engineering tools and techniques helps in reducing production costs, increasing

efficiency, improving the quality of products and services, ensuring worker health and safety and protecting the

environment. Work study is the systematic examination of the methods of carrying on activities so as to improve the

effective use of resources and to set up standards of performance for the activities being carried out by reducing

unnecessary or excess work, whereas Industrial ergonomics aims at achieving an optimal fitting of the work environment

and job activities to the worker.

5’S is a Japanese Philosophy of Workplace organization techniques which work on principles of Seiri (tidiness),

Seiton (orderliness), Seiso (cleanliness), Seiketsu (standardization) & Shitsuke (discipline). Similarly Lean principles helps

for elimination of 7-Waste in the processes namely transportation, inventory, motion, waiting, over processing,

overproduction, and defects.

At Hindalco Industries Ltd., Mouda, Quality of Chock services and delay in supply was resulting in performance

losses of Mill-M4 machine causing downtime. Initial workplace audit was conducted based on the 5’S, Ergonomic aspects,

Engineering tools and practices, workplace layout, Material flow etc. including Work Study to understand activity

sequence and the activity time which will give the fare idea about existing work patterns, Working spaces, material &

tools, material flow, ergonomics, workplace layout design, tooling, maintenance practices, material storage & handling

practices etc. and proposed the best workplace design with the suitable best industry practices and improve manpower

productivity using Industrial Engineering tools.

2. LITERATURE REVIEW

Productivity improvement is one of the core business strategy to achieve good financial and operational performance.

Basic techniques utilized would be review existing Workflows, upgrading processes, tooling and technology, Standard

maintenance practices, training and education to people, availability of resources at the point of use and ergonomically

designed workplace.

The scientific approach to solving business problems, with the use of time-study methods in standard setting and

the planning of work, was pioneered by Frederick Winslow Taylor, with emphasis on fair day work.

Manpower Productivity Improvement in Manufacturing Industry using Industrial Engineering Tools 6703


Following are the literature review of some of the papers which gives more information about their share in field

of application of Industrial Engineering tools and techniques in productivity improvement which are to be considered while

designing the workstation.

In order to work efficiently and to manufacture good quality products and to increase productivity, the workplace

wants to be designed by considering ergonomic principles (M. Muhundhan, 2013).

Marksberry, P., & Parsley, D. (2011), Toyota encourages an older version of IE, namely standardization.

Broberg, O. (2010), Workspace design: a case study applying participatory design principles of healthy

workplaces in an industrial setting talks about the industrial manufacturer case showed how the WSD concept might

contribute to an engineering design process.

Mr. Sujay Biswas, Dr. Abhijit Chakraborty, Mrs. Nabanita Bhowmik (2015), The manufacturing unit by doing

work study can make effective utilization of resources. Work study which comprises of method study and work

measurement will fulfill these requirements. By method study, one can determine the most effective method of performing

the job, the most logical layout for manufacturing facilities, uninterrupted flow of material throughout the organization;

will help to complete the job in least possible time and at optimum cost. Work measurement on the other hand determines

the time required by an operator to complete the operation of job for the standard method at the defined level of

performance.

Thus, work-study is the most effective tool to enhance productivity because of the fact that it is a straight-forward

way of increasing productive efficiency of the organization and considers all the factors influencing productivity.

Naveen Lohan, Sandeep Nandal, Anshul Bhandari, MAE Department, MRITM, New Delhi, India, (2016), We

presented the movements of the workers performing different activities on the floor. With the help of certain rules of

motion economy, there is advancement in the working of the worker. This advancement includes the reduction of

weariness and fatigue and also to enhance the safety of the workers.

Mr. Satish Keru Raut, Department of Mechanical Engineering/JSPM’S RSSOER, Narhe, Pune, Prof. Kedar M.

Relekar, Department of Mechanical Engineering /SSIET Ghogaon Karad & Mr. Vikas Sarjerao Dhane, Dean Polytechnic

Wing/AGCOE, MSBTE/Satara. The paper discusses the use of Industrial Engineering tools used for the purpose of

productivity improvement. The study’s most important finding is that the time of producing a unit of product is directly

proportional to the number of production stages involved and the time spent at each stage.

B. Naveen, Dr. PG Scholar, DoIE, CEG, Anna University, Chennai & T. Ramesh Babu, Associate Professor,

DoIE, CEG, Anna University, Chennai, India. This thesis presents the current performance of outputs and capacity of the

plant calculated using continuous data collected on shop floor. In each workstation the processing time is different and the

longest time consumption workstation will be identified as a bottleneck workstation. The identified bottleneck station will

be analyzed to reduce the processing time which increases production rate.

Prathamesh P. Kulkarni, Student (Final Year), Sagar S. Kshire, Student (Final Year) & Kailas V. Chandratre

Associate Professor & Head of The Department, Department of Mechanical Engineering, GES’s R. H. S. COE, Nashik.

This prescriptive paper proposes genuine solutions & concepts for implementing Work Study Methods and deploying

associated lean manufacturing tools in any enterprise or industry, covering the technical, engineering, and manufacturing




aspects as well as the business etiquette affairs. Lean Manufacturing together with Work Study Methods, being the most

sophisticated & vast area of studies

Md. Abdul Moktadir & Fatema-Tuj-Zohra, Department of Leather Products Engineering, Institute of Leather

Engineering and Technology, University of Dhaka, Sobur Ahmed & Razia Sultana, Department of Leather Engineering,

Institute of Leather Engineering and Technology, University of Dhaka. Work study is most important tools that can help to

increase productivity in leather products industry. Hence, this study helps to identify the bottleneck and suggest appropriate

system to improve productivity. For this purpose, method study has been carried out by applying questioning techniques

concept where recording and critical analysis of all related information has been performed in particular production line.

As a result considerable amount of work content is reduced in the new improved method.

From the above literature review, it is finalized that application of various Industrial Engineering tools & concepts

for implementing Work Study Methods and deploying associated lean manufacturing tools in any enterprise or industry,

covering the technical, engineering, and manufacturing aspects as well as the business etiquette affairs has a huge potential

to improve productivity and quality in any industry. This requires workplace to be design appropriately considering all

industrial principles so as to achieve optimum productivity, health and safety. It is found that various factors like

workstation height, sitting chair flexibility, anthropometry data, reach zone, ability of the workers are equally important

along with the cultural transformation.

3. METHODS

The paper is about improving manpower productivity in a manufacturing industry by application of various Industrial

Engineering tools and techniques. Initial workplace audit was conducted of chock servicing and Work roll assembly are of

Hindalco Industries Ltd., Mouda plant based on the 5’S, Ergonomic aspects, Engineering tools and practices, workplace

layout, Material flow etc. including activity sequence and the activity time to study to understand the existing work

patterns, Working spaces, material & tools, material flow, ergonomics, layout design, tooling & maintenance practices,

material storage & handling practices etc. and propose the best workplace design with the suitable industry practices and

improve manpower productivity using Industrial Engineering tools.

Systematic Work study was carried out for each operation using the advanced Video recording techniques after

creating SIPOC model of a process. Team members captured the start time and end time of each sequence for further

brainstorming to carryout waste analysis by segregating value added and non value adding activities.



Figure 1: Deployment Approach for Application of Industrial Engineering Tools & Culture Building

Team brainstorming was carried out to identify internal and external activities, Manual, Auto, Waiting & Walking

time was mapped. Then Waste matrix was mapped to identify Value added and Non-Value added activities. Finally actions

were proposed based on Eliminate, Combine, Reduce & Simply (ECRS) Techniques followed by standardization and

training on Standard Operating Procedures (SOP) developed using Augmented (AR) & Virtual Reality (VR).

Workplace Organization & Ergonomic Study

Initiation of Workplace organizing, 5S for search free and count free along with ergonomic study, Stores and Spares




Management. Facilitation for Developing Standard Maintenance practices (SMP’s). Development of

fixtures/racks/Systems/ workstation concept for ease in assembly and Maintenance, Visual Management and Daily Work

Management, Improve Lubrication Management Practices and Regular Training on Standard Operating Practices through

Virtual Reality (VR) & Augmented reality (AR) models.

4. DATA COLLECTION & ANALYSIS

Major Issues Identified as Mentioned Below:

a) Lack of Good Workplace Management Practices

b) Forced Deterioration and Lack of good Autonomous Maintenance Planned Maintenance Practices.



Data Analysis

SIPOC: Mill-M4 Chock Servicing & Work Roll Assembly

* According EN 12464-1 & IS 6665 -1972 Light and lighting - Lighting of workplaces -mechanical workshops is >300 lux











5. RECOMMENDATIONS & IMPLEMENTATIONS






6. RESULTS

From the above graphs the results depict that with the application of Industrial Engineering tools and techniques

“Manpower Productivity has improved for Mill-M4 Chock Servicing & Work roll Assembly from 36 Man-hours to 25

Man-hours per work roll set.” which is 30% Improvement in manpower productivity. This has also improved the quality of

chock servicing thereby improving performance of Mill-M4.

7. DISCUSSIONS

After studying the most relevant literature from various research papers, Industrial Engineering tools such as work study,

Ergonomics, 5’S, standardization methodology was applied to improve the manpower productivity of Work Roll chock

servicing and assembly. During brainstorming with cross functional team Man, Machine, Material, Method, Measure and

environmental factors were considered in designing the workplace. Ergonomic workplace simple however crucial changes

were suggested by team this has made operations easier for the operators,

Use of modern Video recording technique for work study, SMED Principles & work combination sheet,

elimination of Non-value added activities and time through Eliminate, Combine, reduce & Simplify (ECRS) techniques




found more efficient and useful in optimizing the productivity.

Sustainability of the solution identified is the standardization of that optimal solution hence the standardization of

process through visual Standard Operating Procedure (SOP), Augmented Reality (AR) and Virtual reality (VR) was found

the most effective tool for imparting required training to the operators. Use of appropriate pneumatic tools helped to

improve quality of servicing.

The main purpose of the project case study was to improve the manpower productivity of Mill-M4 chock

servicing and assembly which was achieved & we can conclude that design of tools and workstations helps to improve

productivity and quality thereby reducing the discomfort, integration of ergonomics & method study helps to standardize

processes much effectively, it can be further be concluded that, lean tools when effectively combined with Work Study

Methods in proper order can help to resolve productivity related problems.

This study will further help researcher and industries to evolve the application of Modern Industrial Engineering

tools and techniques to improve productivity and quality with optimum cost.

REFERENCES

1. Manivel Muralidaran, Arun, Sedhu Siddarth, Arjun Krishna, “Ergonomic Considerations for Design of Industrial

Workstation: A Review”, International Research Journal of Engineering and Technology (IRJET), Volume: 04 Issue: 10 | Oct

-2017, p-ISSN: 2395-0072

2. Marksberry, P., & Parsley, D. (2011), “Managing the IE (Industrial Engineering) Mindset: A quantitative investigation of

Toyota’s practical thinking shared among employees”. Journal of Industrial Engineering and Management, 4(4), 771-79

3. KULKARNI, SHANTANU, SHANTANU WELEKAR, and ARUN KEDAR. "PRODUCTIVITY IMPROVEMENT THROUGH

QUALITY CIRCLE: A CASE STUDY AT CALDERYS NAGPUR." International Journal of Mechanical and Production

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5. Mr. Sujay Biswas, Dr. Abhijit Chakraborty, Mrs. Nabanita Bhowmik (2015) “Improving Productivity Using Work Study

Technique”, International Journal of Research in Engineering and Applied Sciences (IJREAS), Vol. 6 Issue 11, November -

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6. Naveen Lohan, Sandeep Nandal, Anshul Bhandari (2016) “To Study The Principles of Motion Economy in Industry” ©

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7. Chhabra, J. A. T. I. N. D. E. R., and B. R. A. J. E. S. H. Tripathi. "Value engineering: a vital tool for improving cost &

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10. Prabhu, P. Ganesh, and D. Ambika. "Study on behaviour of workers in construction industry to improve production



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MANPOWER PRODUCTIVITY IMPROVEMENT IN …