To Improve Productivity By Using Work Study &

Design A Fixture In Small Scale Industry

Mayank Dev Singh, Shah Saurabh K, Patel Sachin B, Patel Rahul B & Pansuria Ankit P

Abstract – The purpose of this research is to improve  This study concentrates on small scale industry,
production capabilities for small scale industry and this which is the company produced Stay vane of
research focused on the company, which produce Stay Francis turbine.
vane of Francis turbine. This research used work study
technique to improve work process in company, and the  The research is focused on time and the flow of
research objectives towards accomplished this study is to work process in production department from
identify problems in the production work process and the start until it produces finish products, which
improved it in terms of production time, number of it will concentrate on production time and
process and production rate by proposing an efficient number of work process.
work process to company. This research used systematic
observation, flow process and stopwatch time study as The data that needs to be carried out in this study is
research methodology. Pro-E model software used for flow process of the work, the details for each process,
model testing and develop new model. The improvement of the required time for specific process, number of stay
work process was executed by eliminating and combining
vane that they produced in specific time.
of work process, which reduces production time, number
of process and space utilization.
II. LITERATURE REVIEW
Field of research: Production time, Productivity, Work study,
Work measurement, Design of model According to Abdul Talib Bon and Aliza Ariffin
they are working on “An impact of time and motion
I. INTRODUCTION study on small medium enterprise”.The purpose of this
research to improve work process in small medium
1.1 Background of study enterprise industries. In that they use time and motion
Industry consists of small numbers of employees study to improve work process in small medium
and annual turnover. They can categorize into three enterprise industries. The improvement of work process
criteria – primary agriculture, manufacturing and was executed by eliminating and combining of work
services. The company produces Stay Vane on vertical process, which reduces production time, number of
machining center. The small of its enterprise caused process and space utilization.
difficult for them to competing with other firmed They conclude that these modeling techniques are
companies. Thus, this research takes initiative to used not designed to facilitate productivity measurement and
work study technique to improve the work process in analysis as they focus on the availability of the
order to permit them to compete with international unit/equipment, which is only one aspect of the system
rivalry. The work study will examine the work process performance. Among all the continuous improvement
and eliminate nonproductive process, which can reduce methodologies surveyed, no single methodology can be
number of process, space utilization and production and crowned as the best. The approach would help factory
operation time. Time is important in production industry professionals to systematically perform factory
because according Fred (1992), time is money and time diagnostics by quantitatively focusing on critical areas
tells us exactly how much money was used. Besides constraining manufacturing system productivity.
that, this research was conducted based on industry
development strategies and encouragement. According to Charles F. Keberdle set up reduction
is to reduce machine down time. Reducing setup time
1.2 Scope of study will boost your company‟s capacity, increase your
The scopes of this research are: manufacturing flexibility, and help increase overall

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output. A simple saying I often use is, “If the machine is 4. Rate the performance of the operator in each
not running, you are not making money”. element and repeat measurement through a
statistically, determined number of cycles of
They conclude that there are several benefits of
the job.
reduction of machine setup and changeover time which
are listed below: 5. Based on the observations, compute the normal
time for a unit of out.
1. Shorter lead time and increased capacity
2. Better quality/more-consistent processes III. PROBLEM STATEMENT AND OBJECTIVE
3. Lower manufacturing costs 3.1 Problem statement
4. Fewer inventories The company use vertical machining center in
producing their stay vanes, where most of their
5. Increased flexibility
work process was done manually by their workers.
6. Better workforce utilization Sometimes, the production takes extra time in
producing the stay vane. Moreover, the production
7. Less process variability
department does not have any fixed or standard
2.1 Productivity time for each process. They just decide and estimate
the time for each process. Because of that, they
According to Eatwell and Newman (1991) defined often take longer than the time estimated. Also they
productivity as a ratio of some measure of output to have not proper methods for setting up the job on
some index of input use. Put differently, productivity is the machine bad. So the position of job may change
nothing more than the arithmetic ratio between the at every cycle of production. This will affect the
amount produced and the amount of any resources used total job setup time at every cycle of machining,
in the course of production. overall number of production of stay vane and also
Productivity = total output/total input which is affect the overall production rate. Thus, it might be
identical to total results achieved/total resources difficult for them to increase productivity and
consumed or effectiveness or efficiency. competes with other rivals.
2.2 Time study The production method used currently in the
company is time consuming as well as
According to Frederick W. Taylor (1880) they are cumbersome. In order to reduce time and make the
working on time study by using a stopwatch to study process simple, we applied various methodologies
and measure work content with his purpose to define “a (Work study) and designed the new fixture
fair day‟s work.” Among his study is „Taylor Shovelling accordingly. The new fixture so designed reduced
Experiment‟ which they studied between 400and 600 the overall time period from job set up time to final
men that using their own shovel from home to moving dispatch.
material from mountains of coal, coke and iron ore in
around two mile-long yards. Purposes of Taylor to 3.2 Objectives
identify that there have different size of shovels and 1. Identify the proposed methodology which
which shovel was the most efficient. Thus analyzing it reduces manufacturing lead time.
using stopwatch the results were fantastic which it
reduced time, saving numbers of workers and budgeting 2. To design the template fixture in pro-e for
for every year. vertical machining center.
2.2.1 Stop-watch time study 3. Compare time study of both method and
analyses on production.
This method involves making direct observation by
means of a stop-watch.the main steps that are required 4. Improve productivity by implementing new
to be taken under this method are: method.
1. Check that the prescribed method is being 5. Cost analysis of fixture components and
followed in doing the job. analysis of net profit to the company.
2. Divide the job observable and distinct element. \
3. Choosing an appropriate operator, record the
timing for each the work elements.

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4: DATA COLLECTION 4.3 Flow process of raw material to finished stay vane
4.1 Plant layout
Transfer row material from storage to welding section
Plant layout refers to the arrangement of physical
facilities such as machines, equipment, tools, furniture
etc. in such a manner so as to have quickest flow of
Welding section
material at the lowest cost and with the least amount of
handling in processing the product from the receipt of
raw material to the delivery of the final product. Transfer job from welding section to vmc machine-3

Completed one side on vmc machine-3

Job travel from vmc machine-3 to vmc machine-4

Figure 4.1 Plant layout Completed second side on vmc machine-4

4.2 Details of job (Stay vane)
4.2.1 Final stay vane after machining
Transfer job to grinding section
After machining of stay vane there are four welded
road are attached to the stay vane which are used for the
job setup on the bed of the VMC machine. This welded
rod is required to remove and then final grinding require Transfer job to inspection department
for final finishing of the stay vane

Transfer job to finished goods section

Chart 4.1 Flow process of raw material to finished stay

vane

4.4 Actual job setup used before implementation

This is the actual position the job setup in the
machine in which four welded rod is used to setup the
job on the bed with the help of some clamps and metal
BEFORE GRINDING blocks.

AFTER GRINDING
Figure 4.3 Actual job setup
Figure 4.2 Final stay vane

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V. DATA ANALYSIS
5.1 Comparison of new designed machining setup with
company setup
5.1.1 For first side machining setup

Figure 5.1 Company setup

Figure 5.2 New designed setup

5.1.2 For second side machining setup

Figure 4.4 Clamps used for holding the job Figure 5.3Company setup

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4 Job loading time 00:10:00 00:10:00

5 Setup time 00:35:00 00:30:00
Giving position of job to
6 00:20:00 00:00:00
machine
7 Machining for one side 10:15:32 10:15:32
8 Job unloading time 00:10:00 00:10:00
Job travel from vmc-3 to
9 00:10:00 00:10:00
welding section

Figure 5.4 New designed setup 10 Welding time 00:45:00 00:30:00

5.2 Difference between company setup and new design Transfer from welding
11 00:10:00 00:10:00
setup section to vmc-4
First side setup Second side setup
12 Job loading time 00:10:00 00:10:00
Company New design Company New design
setup setup setup setup 13 Setup time 00:35:00 00:20:00
Giving position of job to
Required No Required Required 14 00:20:00 00:00:00
machine
four welded requirement four welded two welded
rod of welded rod rod 15 Machining for second side 12:15:25 12:15:25
rod
16 Job unloading time 00:10:00 00:10:00
Requirement No Requirement No Job transfer to grinding
of job requirement of job requirement
17 00:10:00 00:10:00
section
positioning at of job positioning at of job
every cycle positioning every cycle positioning
18 Grinding time 00:45:00 00:30:00
at every at every Transfer job to grinding
19 00:10:00 00:10:00
cycle cycle section

Possibility of Possibility Possibility of Possibility 20 Total time 28:15:57 26:00:57

failure is of failure is failure is of failure is 21 Total reduced time 02:15:00
more less more less
Table 5.1 Time study comparison

5.3 Time study comparison

This table shows the comparisons of times which 5.4 Analysis of monthly production of stay vane
was reduced according to new implementation
Sr
Description Before After
Sr Activity Time study no
no comparison (hr: total time for
min: sec) 28:15::57(hr: 26:00:57 (hr:
1 complete stay
min: sec) min: sec)
Before After vane

Transfer material from 2 number of job 19(546/18=19) 21(546/26=21)

1 00:10:00 00:10:00 produced in
storage to welding section
one month
2 Welding time 00:45:00 00:00:00
Here 546 is the total working hours in one month
Transfer material from
3 welding section to vmc 00:10:00 00:10:00 Table 5.2 Analysis of monthly production of stay vane
machine-3

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VI. COST AND PROFIT ANALYSIS .

6.1 Cost of fixture
Sr Part name No. of Volume Cost(Rs)

No Part mm3 Raw Machining Welding Drilling and Total

material cost cost threading cost
cost

1 L-shape clamp- 1 1300000 560 100 20 40 770

1(width 200 mm)

2 L-shape clamp- 1 1950000 840 100 20 40 1050

2(width 300 mm)

3 L-shape clamp 3 850000 370 100 - 40 1530

(without rib)

4 T-clamp 5 200000 90 50 - 20 800

5 Bright flat plate-1 1 225000 100 - - 60 160

6 Bright flat plate-2 1 112500 50 - - 40 90

7 Bright flat plate-3 1 191250 80 - - 40 120

8 45° taper clamp 4 301000 130 100 - - 920

9 45° taper plate use 2 400000 180 20 - - 400

for welding

10 Fixture base plate 2 16200000 7000 - - 80 14160

Total cost of fixture =20,000

Table 6.1 Cost of fixture

6.2 Profit analysis
Sr no Detail Before implementation After implementation

1 No. of job per month 19 21

2 No. of job per year 19*12=228 21*12=252
228*6600 252*6600
3 Profit per year
=15,04,800Rs =16,63,200Rs

Net profit per year :1663200-1504800=1,58,400Rs

Here 6600 is the total machining cost of manufacturing of one stay vane in Rs
Table 6.2 Profit analysis

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6.3 Net profit analysis after deducting cost of fixture VIII. REFERENCES
[1] Iyaniwura, O. and Osoba, A.M. (1983) “Measuring
Sr
Detail Net profit Productivity; Conceptual and Statistical Problems:
no Improvement of Statistics” in Osoba A.M. (ed.)
„Productivity in Nigeria‟ Proceedings of a National
1 Profit per year 158400-20000=1,38,400Rs Conference‟ NISER, Ibadan.

2 Profit per month 138400/12=11,500Rs [2] Antle, M. J. and Capalbo, S.M. (l988) “An Introduction
to Recent Development in Production Theory and
Productivity Measurement” in Capalbo, S.M. and
Table 6.3 Net profit analysis after deducting cost of Antle, M.J. „Agricultural Productivity: Measurement
fixture and Explanation‟ Resources For the Future, Inc.,
Washington, DC.
VII. SUMMARY & CONCLUSION [3] Eatwell, J.M. and Newman, P. (1991) “The New
Palgrave: A Dictionary of Economics” vols. 3, 4. & 12,
7.1 Summary Macmillan, Tokyo.
1. After applying work study and making design [4] Amadi, A.O. (1991) “Recipe for Productivity
of fixture for stay vane total time reduced for Improvement” in Umeh, P.O.C. et al (1991)
manufacturing one stay vane from “Increasing Productivity in Nigeria” Proceedings of the
28:15:57(hr:min:sec) to 26:00:57(hr:min:sec) First National Conference on Productivity 1sty-3rd
shown in table 5.1. December 1987, National Productivity Centre,
Macmillan, Nigeria. Pp. 98 -106.
2. By analysis of working hour for month,
[5] Concept and Measurement of Productivity By
improving method study of stay vane and
“Gboyega A. Oyeranti” NECA (1991), {page no 2 to
applying time study total number of job 3} http://www.cenbank.org/OUT/PUBLICATIONS/
increased per month 19 to 21 shown in table OCCASIONALPAPERS/RD/2000/ABE-00-1.PDF
5.2.
[6] Gershwin, S.B. (2000) „Design and operation of
3. After calculating machining cost and deducting manufacturing systems: the control-point policy‟, IIE
cost of fixture from profit then net profit for Transactions, Vol. 32, pp.891–906.
company for producing stay vane per year is [7] Int. J. Industrial and Systems Engineering, Vol. 1, No.
1,38,400 Rs as shown in table 6.3. 4, 2006 By Kanthi M.N. Muthiah* and Samuel H.
7.2 Conclusion Huang, {page no 1}http://pqprc.org/userfiles/groups
/A%20review%20of%20literature%20on%20manufact
From the discussion of the above parameters, it can uring%20systems.pdf
be concluded that this process can be improved based on [8] Text book of Industrial Engineering, Tech max
the five parameters (work process, method study, time publication By Dr. Pradip Kumar Sinha, {page no 3-
measurement, fixture design and cost analysis) it will 18, 3-19, 3-22,3-23}
improve the current work process. These modifications
[9] An Impact Time Motion Study on Small Medium
are made by eliminating the wasted time and reduction
Enterprise Organization By Abdul Talib Bon1 , Aliza
of the work contents. From the comparison between Ariffin, {page no 3} http://www.academia.edu
current and new work process shown in topic 5.2, it /1277107/AN_IMPACT_TIME_MOTION_STUDY_O
indicates that the best alternative towards this problem N_SMALL_MEDIUM_ENTERPRISE_ORGANIZAT
by new method. After implementing new method on this ION
stay vane job production it will increase production (2
[10] Reducing Machine Setup & Changeover Times By
stay vanes) as compare to company method. (In Charles F. Keberdle, CPIM, {page no 2 & 3}
company method it would produce 19 stay vanes and
after applying new method they can produce 21 stay http://www.leansolutionsgroup.com/images/Setup_Red
vanes per month see table 5.2). This improvement was uction_Master.pdf
successfully implemented and it achieves the project [11] UNIT- 4 Jigs and Fixtures, manufacturing process-III,
goals and objectives, which improve processes, {page no 47, 48 & 49}
production layout, economy in human effort and the
http://www.ignou.ac.in/upload/jig.pdf
reduction of unnecessary fatigue.

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