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INTRODUCTION
The great deal of effort is required in industry for effective production that includes
less production time and higher efficiency. Work study is 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 e fficiency and economy of the
situation being reviewed, in order to effect improvement. Work study is thus
especially concerned with productivity. It is most frequently used to increase the
amount produced from a given quantity of resources without further capital
investment except, perhaps, on a very small scale.
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Work study was widely known for years as "time and motion study", but with the
development of the technique and its application to a very wide range of activities it
was felt by many people that the older title was both too narrow and insufficiently
descriptive.
The research and development necessary to develop a new process or a machine
of higher performance are usually expensive and take a long time, and there is always
the risk that the improvements achieved may not justify the time and money spent.
Even to achieve worth-while improvements in existing processes may take
considerable time and money. In countries where there is little capital to spare and
where the need for increased productivity is urgent this approach to the problem may
not even be possible.
Method study
Work measurement
Motion study
Time study
Figure 1.1 Time study
CASE STUDY
OBSERVATION
After deep study and observation of existing processes, plant layout and collection of
data about process time. Every factor is discussed with labour, engineer and higher
level management. Every process time recording individual. XYZ Ltd is a battery
production industry. Manufacturing process of the XYZ Ltd is described as followsBrought up the lead alloy from supplier and store it to company godown. Also
purchase container, packing cartoon, separator and terminals from other suppliers.
Now firstly mix water to lead alloy by workers and then the mixture is enter to the
casting machine hopper and casting the plate by old casting machine. Now the casting
plates placed outside for two days for drying. Then plates are taken away for pasting.
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In pasting, cathode and anode are pasted on the plates. Cathode and a node powder
mix with sulphuric acid to make the paste. Now the paste is entered in the hopper and
casting plate is placed on belt conveyor of pasting machine. Then pasting of the plates
have been done. Place the plates for drying for 2 to 3 days. Furthermore, these plates
are stored in rack-trolley for curing purpose. Now carry these plates to curing section
for curing purpose and store them for 72 hours and generate 90% humidity. After
curing store these plates to outside for 1 day. Take these plates to oven for drying
because only 1% humidity allowed in plates. Then take these plates to outside from
oven for cooling. Finishing of plates by workers and plates ready for assembling in
one day.
Carry the plates by using lift conveyer to assembly section. In as sembly section, a
separator is placed between cathode and anode. Then combination of plates is done
for producing the cell. And welding the cells. Make the holes in container by high
temperature flame and the cells are taken into the container. All the cells are soldered
each other and connect the terminal as cathode to cathode and anode to anode by
soldering. Now the container is covered and sealed buy heating machine. Now testing
of leakage is done by testing machine. Dry battery is ready now. Punching of codes
on battery container.
Dry battery is carried in charging section using lift conveyer. Fulfill the electrolyte
automatically to dry battery. 36 batteries are connected to a charging panel for
charging and the batteries are charged to 100%. Now the se rial number and a unique
codes are given to the batteries, then these batteries are packed in cartoons. Store the
battery in company godown for transport. These batteries carried to ware house by
transport. Battery come to distributer and dealer .finally at last customer purchase the
battery.
Raw material
lead alloy
Casting the
plates
Co mbination of
plates
Plate separator
Jig bo x burring
Dropping of
cell in bo x
Dry battery
ready
Code punch
Air leakage
testing
Fill
electrolyte
Fin ished goods
Curing the
Pasting the
plates
plates
Remove
mo isture
Inter cell
weld ing
Heat sealing of
container &
cover
Charged 100%
Put unique code and
serial no.& code
Battery packing
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Summary
Activity
Subject:
Charted:
present
Proposed
saving
Time
Symbo l
labour
Operation
Transport
Delay
Activity:
Receive,
Check,
Inspect,
Store
and
transfer
method present
Location
Operative
Clock no.
Inspection
storage
Distance in
meter
Time in min.
Cost
labour
material
Total
description
Lead alloy
,Separator and
jig bo x co me
into plant
Store raw
material in
company by
worker
Lead alloy
mixing with
distilled water
Qty
(1 case)
Distance
10000
meter
50meter
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2 hours
10 min
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10 meter
6 sec
2 hour
11 meter
10 meter
2 days
2 sec
30 sec
1 min
3 days
1 day
6 hour
40 sec
2 min
15 min
5 min
5 min
1 meter
3 min
1 meter
3 min
Dropping the
cell in
container
1 meter
2 min
Welding of
intercell and
terminal
1 meter
5 min
3 meter
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1 meter
5 min
1 meter
3 min
1 meter
2 min
5 meter
10 min
20 meter
15 min
10 meter
1 min
20 meter
1 min
8 meter
24
hours
5 min
10 meter
2 min
50 meter
10 min
10min
2
4
Improvement in process
After implementation XYZ Ltd is started use of advance casting machine which has
high production rate. It neglect the delay time. Second major improvement is install
automated plate finishing machine. XYZ Ltd is now started purchasing the battery
container with hole and complete ready to use condition which reduce the process
time.
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Summary
Activity
present
Proposed
Saving
operation
18
17
Transport
Delay
Activity:
Receive,
Check,
Inspect,
Store and
transfer method
present
inspection
Location
Distance in
meter
Time
in
min.
Cost
labour
material
Total
Qty
(1 case)
10214
10213
12957min 18sec
12833min 36sec
123min
42 sec.
56
50
Symbo l
Labour
Subject:
Charted:
Operative
Clock no.
description
Lead alloy
,Separator and
jig bo x co me
into plant
Store raw
material in
company by
worker
Lead alloy
mixing with
distilled water
storage
distance
Time
10000
meters
2 hours
10 min
Leads alloy
enter in casting
hopper and
start casting by
advance
casting
mach ine
2 sec
No Delay
Storage
0hour
2 days
the
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11 meter
10 meter
2 sec
30 sec
1 min
3 days
Store plates
after curing
Remove
mo isture fro m
plates using
oven
Fin ishing
plates surface
by automated
mach ine
Store the
fin ishing plates
1 day
6 hour
2 sec
2 min
15 min
5 min
5 min
0min
Move the
fin ishing plates
to assembly
section through
lifts
Put the jig on
roller conveyor
for further line
assembly
Co mbination
of plates and
separator
Already
purchase hole
container and
eliminated
operation
Made the cell
3 meter
1 meter
3 min
Dropping the
cell in
container
Welding of
inter cell and
terminal
Covering of
container and
air seal by
heating
Testing of air
leakage
Code punch on
container
1 meter
2 min
1 meter
5 min
1 meter
5 min
1 meter
3 min
1 meter
2 min
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5 meter
10 min
20 meter
15 min
10 meter
1 min
Further move
the battery for
charging by
trolley
Charging the
battery
Inspection of
batterys
gravity and
voltage
20 meter
1 min
8 meter
5 min
10 meter
2 min
10 min
Store the
Fin ish goods
for selling
50 meter
10min
24 hours
CALCULATION
i.
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If we will using automated finishing m/c we use only 2 workers and around
12000 plate finishing one day.
Finishing rate increases per day (12000-5400/5400)*100 = 6600 = 122%
Therefore we use automated m/c our production rate increase and save 5 labours.
At the end of discuss about the present and proposed methods, and the benefits of
proposed methods are highlighted.
Present
i.
Molded casting machine
production rate 24 plate
per min.
ii.
Delay time for pasting
machine is high.
iii.
Plate finishing by worker
and finishing rate is low.
iv.
v.
vi.
vii.
viii.
ix.
x.
Proposed
Advance casting machine production
rate 36 plates per min.
Delay time reduce for pasting
machine.
Plate finishing by automated
finishing machine and finishing rate
is high.
CONCLUSION
During the study of the process of the battery manufacturing plant, existing processes
are examined critically with method study & layout technique. It is observed that the
battery plant is not using optimum layout and there are chances for improvement.
Various layout and method study tools are applied and flow process charts, flow
diagram and existing layout has been prepared. New technologies are used to reduced
production cost, process time, cost and energy consumption. With the help of
recorded observation and discussion with manager of the company, improved layout
and flow process chart and new devices are suggested.
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REFERENCE
[1]
[2]
[3]
[4]
[5]
[6]
[7]
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