IMPROVING PRODUCTIVITY BY REDUCING IDLE TIME PROJECT REPORT

INTRODUCTION

1.1PROJECT OVERVIEW

The project is being conducted at GROWELL CNC SYSYTEMS.

1.2AIM
To help improve productivity by analyzing the key causes for idle time on the shop floor and hence provide ideal remedies to reduce the idle time that lead to lesser productivity.

1.3METHODOLOGY

1.3.1Work Study
‘A generic term for those techniques, particularly method study and work measurement, which are used in the examination of human work in all its contexts, and which lead systematically to the investigation of all the factors which affect the efficiency and economy of the situation being reviewed, in order to effect improvement.’

Work study is the systematic study of an operation or process to ensure the best possible use of human and material resources available. The prime aim is to improve productivity. The application of work study to a department or company is made to improve the existing method of operation, as a result change will occur which will affect personnel irrespective of their status.

For all the application to be successful, due regard must be paid to the reactions of all
concerned.

1.3.2 Objectives of Work Study

The objective of applying Work Study is to obtain the optimum use of the human and material resources, which are available to it. The benefits may stem from improvements in one or more of the following:
i. Increased production and productivity
ii. Reduced costs-labor, material, overheads
iii. Improvements of conditions, which involve an element of excessive fatigue or danger
iv. Improved quality
v. Better control of costs
vi. The Benefits of work study

Work Study can considerably increase productivity. People can benefit from, less tiring work, better working conditions and because an efficient company can meet competition successfully, better employment prospects.

Work study raises efficiency by re-organization of work. It therefore need /involve little or no capital expenditure. Yet, where such an outlay is desirable. Work study can ensure that it is spent to the best advantage.

Work study is systematic; its procedures are designed to ensure that no factors affecting the situation are overlooked.

It is the best means available for setting standards of performance, and although often seen as the basis for incentives, the real value lies in the information provided for work scheduling, estimating deliveries and for accurate costing.

Work study produces savings very quickly and these gains continue as long as the improved methods evolved are maintained.

Work study is an universal tool, it is not confined to the workshops but can be equally effective in the office, warehouse, and in distribution, etc.

Work study is the most searching technique available because it takes every fact into account. It reveals weaknesses often overlooked in the day to day working.

1.3.3 Method study
This is defined as:
‘The systematic recording and critical examination of existing and proposed analysis of doing work, as a means of developing and applying easier and more effective methods and reducing costs.
The basic approach of method study is to follow a simple six step procedure:
i. SELECT the work to be studied
ii. RECORD all the relevant facts
iii. EXAMINE the facts critically
iv. DEVELOP the most effective method
v. INSTALL that method
vi. MAINTAIN by regular checks

1.3.4 Activity Sampling
Activity sampling is the name given to the process of collecting information about machine or human activities by making a large number of instantaneous observations of the subject instead of by continuous timing, as in the case of time study. This technique provides a rapid and effective means of studying the pattern of almost any type of activity and its usefulness increases as the number of subjects to be observed becomes greater.

The degree of confidence and accuracy in the results can be varied at will to known levels by varying the number of observations in accordance with a statistical formula. If the stage of activity or inactivity only is recorded, the process is called ‘Activity Sampling’ and this may be used to obtain estimates of:

 The utilization of plant or labor and the reasons for losses in utilization.
 The proportion of a given period that machines or persons are occupied by specific activities.
If, in addition to the state of activity, an estimate of the working pace of the operators is recorded, the technique becomes known as ‘Rated Activity Sampling’ and this may be used for:
 Setting standard times for which several people are engaged as a team.
 Checking the overall validity of existing time standards for a number of products or
activities.