ANNEXURE A

D3INDS Engineering Work Study - EWY260S

PROJECT ASSESSMENT RUBRIC

Check correctness of your report against this rubric before submission.

LAB Project No: P1 Project Name: PROCESS

CHARTING

SURNAME: Ndaba INITIALS: Sinqobile STUDENT NUMBER: 221627685

ASSESSMENT FOR WRITTEN REPORT.

MAX % ATTAINED %

1. Supporting theory: -
Background theory on application principles, & time study of the:
5
● Outline process charting,
5
● Worker type flow process charting, and
5
● Process flow diagrams as a recording technique.

2. Application of Industrial Engineering principles & data

analysis: -

● Evidence of outline process chart & recorded times/operation, 25

● Evidence of worker type flow process chart & recorded 25

times/operation, and 20
● Evidence of process flow diagram & recorded times/operation.

3. Coherence, reasoning, flow of information: -

● Ability to breakdown elements in a convincing manner. 10

4. Logical conclusions & recommendations: -

● Information is relevant, within context & links data to conclusions. 5

TOTAL 100% ………… %

LECTURER: WK NGETICH

Due Date:
Lop AND SHOE ASSEMBLY - PROCESS CHARTS
- METHOD STUDY THEORY
- ORIGINAL OUTLINE PROCESS CHART
- ORIGINAL WORKER FLOW PROCESS CHART
- ORIGINAL FLOW DIAGRAM
By

Ndaba Sinqobile
Student Number: 221627685

Full Time

Project Report
Submitted in fulfillment of the requirements for the

Subject:

ENGINEERING WORKSTUDY: EWY260S

Qualification:

D3INDS: INDUSTRIAL ENGINEERING

In the
Faculty of Engineering and the Built Environment

Department of Industrial and Systems Engineering

At the

CAPE PENINSULA UNIVERSITY OF TECHNOLOGY

Lecturer: NGETICH WK

Cape Town: Bellville Campus

Submitted: 15 April 2022

Table of contents: (Add / remove headings, subheadings, and page no. as required Page
List of tables iv
List of figures v
1. INTRODUCTION TO CARTON AND SHOE ASSEMBLY e.g., 1
1.1. Background to the study (Refer to project manual specifications) 1
1.1.1. Study objectives 2
2. WORKSTUDY PROCESS CHARTING e.g., 3
2.1. Work study literature review 3
2.1.1. Method study literature review 3
2.1.2. Element breakdown literature review 3
2.1.3. Recording technique literature review 4
2.1.4. Process charting literature review
5
2.1.5. Flow diagram literature review 5
3. DATA COLLECTION AND ANALYSIS 6
3.1. Carton and shoe element breakdown 8
3.1.1. Original element breakdown 8
3.2. Carton and shoe process charting
9
3.2.1. Original outline process chart 9
3.2.2. Original worker flow process chart
9
3.2.3. Original flow diagram 9
4. CONCLUSIONS AND RECOMMENDATIONS 13
4.1. Conclusions
13
4.2. Recommendations 13
REFERENCES (In alphabetical order) 14
BIBLIOGRAPHY (In alphabetical order) 15
ANNEXURE A 16
ANNEXURE B (Video recording of your pen assembly) 17

3
List of Tables: (Add / remove table headings and page numbers as required) Page

Table 1. Situational factors determining IS in the organization 1

Table 2. SWOT analysis of a computer system 6

4
List of Figures: (Add / remove figure headings and page numbers as required) Page

Figure 1. Carton and shoe assembly drawing 1

Figure 2. Linear hydraulic actuator 2

Figure 3. Computer system diagram

4

Figure 4. System structure diagram for a computer

4

Figure 5. Computer product life cycle phases 7

Figure 6. Example of a Cost Break Down Structure (CBS)

7

Figure 7. The evolution from mission need to functional analysis

8

Figure 8. Online shopping user FFD 10

Figure 9. Example House of Quality QFD 13

Figure 10. Example TPM prioritization matrix

14

5
1. INTRODUCTION TO CARTON AND SHOE PROCESS CHARTING

We have carried out a work study of a carton and shoe assembly done by an operator ,we
want to determine the standard time of the operator carrying out a task also make surety
that the method used is effective. (method study techniques) we used element breakdown
to construct worker flow process chart, outline process chart (carton and shoe assembly)
and a flow diagram (carton and shoe assembly) so that we are able to document a process
for better understanding. We have been given a project where by we are assembling a
carton and a shoe. We have used equipment and techniques (mentioned above) to collect
data and record data.
1.1. Background to the study (Project manual specifications)

The study is about a assembly of a carton and shoe. The purpose of the study is to determine
the best method of performing each operation and to eliminate wastage so that production
increases with less fatigue.

We have gathered all the facts and recorded the information using this techniques :
● Element breakdown

● Outline process chart

● Worker process chart

● Flow diagram

We have used this techniques to document data ,so that the study is in a logical sequence.
Further description (more information) of these techniques will be discussed in this report.

Figure 1:Carton ad shoe assembly(drawing)

1.1.1. Study objectives

study aims to achieve

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● Method improvement

● To eliminate wasteful and ineffiecient motions in operations

How are we gonna achieve the above

● Eliminating, rearranging, and combining the elements.

● Making use of elemental breakdown,process chart and flow diagram for removal
unproductive operations from productive work.

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2. WORKSTUDY PROCESS CHARTING
The operation process chart shows the chronological sequence of all operations,
inspections, time allowances, and materials used in a manufacturing or business process,
from the arrival of raw material to the packaging of the finished product.The chart depicts
the entrance of all components and subassemblies to the main assembly.
Several charts and diagram have been used to record information regarding the carton and
shoe assembly we gonna do review for each of them, these are:

● Work study literature review

● Element breakdown literature review

● Process charting literature review

● Flow diagram literature review

There are 9 participants in our research, we worked together to collect data regarding our
report.
Below there’s more explanation .

2.1. Work study literature review

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 (Kanawaty , 1992: 9).It is one of the most penetrating tools which is useful
when modifying method of operations which reduces wasteful use of resources (4M’s) , excess
work content, improve productivity and setting standard time to carry out a task at a defined
rate. Basically ,Work study embraces two techniques which is method study and work
measurements. Method study is based on simplifying the job and developing more economical
methods of doing it while work measurement is used to develop standard times needed to
perform operation. Further elaboration of these techniques will be discussed below.

2.1.1. Method study literature review

Method study is the systematic recording and critical examination of ways of doing things in
order to make improvements (Kanawaty, 1992: 75-80).it is related with the study of methods of
work to design effective and efficient work system in order to achievements in processes,
improved layout and a better working environment. when considering a method study there are
eight steps:
1. SELECT- the work to be studied

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 2. RECORD- all relevant information about the work and additional data from aproapriare
sources
3. EXAMINE-the recorded information.
4. DEVELOP-the most practical, economic and effective method.
5. EVALUATE-perfomance of the methods then select an improve method which will be
dertemined by cost-effective comparisms.
6. DEFINE-the new improved method to the management, supervisors and the workers.
7. INSTALL-the new method as a practice ,also provide training to person who gonna
apply it.
8. MAINTAIN-the new method results and introduce new control procedures which
maintain the new method

Purpose of work study

to investigate methods of performing work and the time taken to do it .

There are three factors that should be kept in mind when selecting a job
1. .Economic or cost-effective considerations.

● The economic importance must be high to select the job.

● Pareto analysis is used to assess and prioritize different problems or tasks by

comparing the benefit that solving each one will provide.

2. Technical considerations.

● The desire by management to have advance automation for operations.

3. Human considerations.

● dissatisfaction by workers may induce fatigue or monotony or may be unsafe or clumsy

to operate. This causes method study to be taken (Kanawaty, 1992 : 79).

Objectives of method study

● To develop a better physical working environment

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 ● To achieve an economy in human efforts
● To reduce the unnecessary fatigue
● Improving use of the 4M’s.
● To improve the design and condition of the workspace
● To improve the workspace layout
● To finally improve the processes and procedures

method study is useful for:

● Improving work methods and procedures

● Smoothening workflow

● Determining the best sequence of working

● Reducing monotonous work

● Eliminating unproductive operations

● Reducing manufacturing costs by reducing the cycle time of operations

There are five basic method study symbols which are used in process chart which are use

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 Figure :

2.1.2. Element breakdown literature review

Elemental breakdown provides a detailed investigation and determine the time consumed in
value added and non-value added activities.

Purpose of elemental breakdown

● To separate unproductive activity from productive work

● To provide a detailed job specification

● The rate of performance is assessed accurately

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 ● Different are classified and standard time is dertemined

● Rate of performance is assessed more accurately

● It ease the checking of the standard time in future

How to do elemental breakdown

● By braking an operation into smaller Idefiable part.

● Also to classify the element into different categories for simplicity (motion).

● Use a stop watch/timer to record standard time for each element.

2.1.3. Recording technique literature review

Recording techniques are designed to simplify and standardize the recording of work.

Purpose of recording technique

● Is to record the sequence of activities.

● the time relationship between different activities.

● the movement of materials and the movement of staff.

Several chart and diagrams are used to record information

1. Outline process chart

● Which overall picture by recording in sequence only the main operations and
inspections
2. Flow process chart (man-type, material-type and equipment-type)

● This is the use of symbols and description to chart the sequence of work. The
process, then, show what is happening at different stages. The distances and time
may be given.
3. Flow diagram

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 ● which is the use of symbols for flow process charts, superimposed on drawings and
the "descriptions" are not necessary.

Equipment used

● stop watch (cellphone)

● table and chair

● A3 papers for motion sheet (drawings)

2.1.4. Process charting literature review

A flow process chart is a chart of all the activities involved in a process. those basic
activities are are inspections, delay, storage, transport and operations. Sometimes the
activies are combined e.g operation and inspection. here’s an example below:

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 (Kanawaty, 1992: 85)

Combined activities

Flow process types

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● Worker type: A flow process chart which records what the operator does.

● Material type: A flow process chart which records how material is handled or treated.

● Equipment type: A flow process chart which records how the equipment is used.

2.1.5. Flow diagram literature review

A flow process chart is a process chart setting out the sequence of the flow of a product
or a procedure by recording all events under review using the appropriate process chart
symbols (Kanawaty, 1992: 81-137).
Purpose of a flow diagram

● To document a process for better understanding, quality control and training of

employees.

● To standardize a process for optimal efficiency and repeatability

● To study a process for efficiency and improvement.

A flow diagram shows :

● layout of a facility.

● flow of work through that area

● overcrowding areas, crossing worker paths, total travel.

● Identify how layout can be redesigned to reduce travel, motion, collisions, etc.

● Store materials near where they are used.

● Also Increase efficiency and safety.

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3. DATA COLLECTION AND ANALYSIS
Data collection and analysis is referred as a series of charts and diagrams designed to collect,
interpret, and present data. There are three basic research methods (quantitative, qualitative
and mixed) for data collection.
What the purpose for data collection and analysis

● It enables one to answer stated research questions.

● test hypotheses.

● evaluate outcomes.

Steps to collects data

1. Determine what information you want to collect.
2. Set a timeframe
3. Dertemine your data gathering method
4. Collect data
5. Analyse the data and implement your findings

How is data collected and analysed

● charts

● diagrams

● surveys

● experiments

● observations

● critical appraisal of texts

● literature or works of art or other artefacts

on behalf of group 8, we collected data ,firstly we did elemental breakdown using equipment
which I have already stated under recording technique literature review. We used chart and
diagrams to record information and then it easy for us to do analyse data.

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Below I have given original chart, diagrams and element breakdown for clarity.

3.1. Carton and shoe element breakdown

On the section below we recorded elements for a assembly of a shoe and carton, done by a
worker.our aim is to be able to identify unproductive work and remove it from productive
operations.

Purpose for elemental breakdown

Is to show elements (Operations, Inspections, Transport, Delays, or Storage)where by a
qualified worker assembles a carton and shoe, for each element we recorded the time it takes.

3.1.1. Original element breakdown

Table 2: Activity: Carton Shoe Packing process (Extract from Ngetich, 2021: 3)
TIME
ELEMENT (Operations, Inspections, Transport, Delays, or Storage) (hrs/min./sec.
)
1. Transport 1: the worker moves left and right hands from home 0.008min
position to flap 1 and 2 located at the extreme of the grid sheet.
2. Operation 1: the worker fold flap 1 and 2 at the same time. 0.017min

3. Operation 2: the worker fold flap 3 and 4 0.008min

4. Operation 3: the worker fold flap 5 0.033min

5. Operation 4: the worker fold flap 6 and 7 0.033min

6. Delay 1: the worker repositions the assembled carton ready to pack 0.033min
shoes.
7. Transport 2: the worker moves the right hand from home position 0.017min
to the extreme right corner K17 to collect shoe 1 and moves back to pack in
carton.
8. Transport 3: the worker moves the right hand from home position 0.033min
to the extreme right corner K17 to collect shoe 2 and moves back to pack in
carton.
9. Operation 5: the worker fold flap 8 to complete the assembly of the 0.017min
flat carton.
10. Operation 6: the worker proceeds to close and seal the carton 0.017min
package.
11. Inspection 1: the worker inspects the carton package if it is closed 0.004min
properly.

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 12. Transport 4: the worker moves the package to K17. 0.021min

13. Storage 1: the package is store in K17. 0.025min

TOTAL (recorded) TIME 0.267min

TOTAL (theoretical) TIME 0.3min

Deviation (must be less than or equal to 20% of the theoretical time) 11.11 %

3.2. Carton and shoe process charting

On this section I will be showing original outline process chart, Original worker flow
process chart ,original flow diagram. This information will be showing all the data we have
collected.

3.2.1. Original outline process chart

● gives an overall view of a shoe and carton assembly operation.

● main operations and sequences in proper sequence have been recorded.

Purpose

● it is useful when recording essential features of a work situation for subsequent

analysis.

Table 3: Original: carton shoe assembly Outline Process Chart (Extract from Kanawaty, 1992: 81)
Original Outline Process Chart for carton shoe
Chart Type (Worker/Material/Equipment): Worker Type
assemby
Chart Date: 13 Apr.
Sheet No.: X of 2 Summary Drawing/Illustration:
22
Subject Charted: Im Sa
Material process Sy Ori pr vin
TASKS
mb gin ov gs
ol al ed
Operation 6

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 Transport 4
Activity: Delay 1
Shoe packaging
Inspection 1
Storage 1
Dist. (cm/m) -
Location: workplace 0.2
Time (min)
67
Number of Worker(s): Cost (R):
1 worker
Labour (R): _ _

Charted By: Group 8 Material (R): _ _ _

Date: 13 Apr. 22 _

KEY:
1- FLAP 1
2- FLAP 2
Approved By: Ngetich Date: - - - 3- FLAP 3
4-FLAP 4
5-FLAP 5
6-FLAP 6
7-FLAP 7
TOTALS - 8-FLAP 8

Shoe
Rubber Carton
L = 31cm (L = 79.5 X W= 62.5)

2 Page 14 of 30 1
 (0.017) (0,008)

(0.017)
(0,033)
(0.008)

(0.033)

(0.033)

(0.033)

(0.017)

(0.017)

(0.004)

(0.021)

(0.021)

(0.025)

3.2.2. Original worker flow process chart

We have used worker flow process chart of which it represent:

● the use of symbols and description to chart the sequence of work.

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 ● shows what is happening at different stages.

● analog model of the assembly process.

Table 4: Original: carton shoe packing Worker Flow Process Chart (Extract from Kanawaty, 1992: 93)
Original Flow Process Chart for carton shoe packing Chart Type (Worker/Material/Equipment): Worker Type
Chart Date:13 Apr. 22 Sheet No.:1 of 2 Summary Drawing/Illustration:
Subject Charted: I Sa .
Skill of Worker m vin
p gs
r
TASKS
o
Sy v
mb Origi e
ol nal d
Operation 6
Transport 4
Activity: Delay 1

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assembling a prefabricated Carton to package a pair Inspection 1 Figure 3 carton shoe packing
of shoes KEY
Storage 1
1-FLAP 1
Dist. (cm) 350 2-FLAP 2
Location: Ergonomic study Room: Assembly Table 3-FLAP 3
Time (s) 16
4-FLAP 4
Number of Worker(s): 1 Worker Cost (R): 5-FLAP 5
6-FLAP 6
Labour (R): 180
7-FLAP 7
Charted By: GROUP 8 Date: 13 Apr. 22 Material (R): _ 8-FLAP 8
Approved By:Ngetich Date: TOTALS R180
Symbol
Dist. Time
No Elements(element breakdown) Qty. (m) (min) Comments:
The worker moves left and right hands from home position
1 1 1.84 0.008 Use both hands
to flap 1 and 2 located at the extreme of the grid sheet.
The worker fold flap 1 and 2 at the same time.
2 0.017
the worker fold flap 3 and 4
3 0.008
the worker fold flap 5
4 0.06 0.033
the worker fold flap 6 and 7
5 0.033
The worker repositions the assembled carton ready to
6 0.033
pack shoes.
The worker moves the right hand from home position to
7 the extreme right corner K17 to collect shoe 1 and moves 1 0.04 0.017 Use right hand
back to pack in carton.
The worker moves the right hand from home position to
8 the extreme right corner K17to collect shoe 2 and moves 1 0.04 0.033 Use right hand
back to pack in carton.
The worker fold flap 8 to complete the assembly of the flat
9 0.017
carton.
The worker proceeds to close and seal the carton package.
10 0.020
The worker inspects the carton package if it is closed
11 0.004
properly.
The worker moves the package to K17.
12 1 0.04 0.021 Use both hands
The package is store in K17.
13 0.025

TOTALS 4 2.02 0.267 6 4 1 1 1

3.2.3. Original flow diagram

● The flow diagram below shows the movements of the worker’s hands while assembling
carton and shoe.this is where we able to dertemine distance travelled by a worker to the
storage. we have used a scale for accurate representation.

X-Axis

Flow diagram motions sheet (Each block represents 0.6 cm * 0.6 cm)

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 Scale size to real size 10.2 cm:86.36 cm (1 :8.5)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Y
-
A A
xi
B1 s
B
0
C

E
F7 F1
F
3
G

I
J1
J
0
HOME HOME
STAR STAR
T T K
Figure 4: Original: shoe and carton assembly Flow Diagram (each block represents 2” x 2”) (Extract from
Ngetich, 2008, 2013: 5)

KEY:
1. FLAP1 - F7
2. FLAP2 - F13
3. FLAP3 - D7
4. FLAP4 - D12
5. FLAP5 - B10
6. FLAP6 - B7
7. FLAP7 - B12
8. FLAP8 – J10
9. (storage) – k17

Page 18 of 30
Page 19 of 30
4. CONCLUSIONS AND RECOMMENDATIONS
(Introduce every heading and subheading first before discussing anything else following it).
Briefly mentioning what will be discussed in the conclusion and recommendation section
below. This is a summary introduction of what you will say in detail in your subheadings
below.
(Conclude every heading and subheading first before leaving to start another heading or
subheading).

4.1. Conclusions
(Introduce every heading and subheading first before discussing anything else
following it).
On the data I have collected so far I used recording techniques which I stated above
how I used them. For data that I have collected so far we were more focused on
method study. The problem is that we haven’t solved any problem.
Describe the summary of your project here. You may show the summary of findings
here with all the components you discussed in a summary form.
When discussing the data recorded under their relevant recording techniques, brings
everything together here, showing how your findings respond to all the subheadings,
and the brief you explained in your introduction. This is the place to mention if there
were any problems (e.g., your results were different from expectations, you could not
find important data, or you had to change your method or participants) and how they
were or could have been solved.
What were your findings? What does the system product or service finally look like?
Did you achieve the design of the system method and the product spec you intended to
capture? This section needs you to discuss if you achieved your objectives stated in
section 1.11, study objectives. What cost, time etc., performance measure did you
identify? Are there any potential for improvements?
(Conclude every heading and subheading first before leaving to start another heading
or subheading).
4.2. Recommendations
I believe
(Introduce every heading and subheading first before discussing anything else
following it).
Based on your objectives in the conclusion. What are the recommendations you
propose for the system and product / service you were studying? Here you are
expected to show the final product process. It can be a table showing broad system
specifications that the system will operate under etc, a figure of your final design
product / service design etc. You will recommend further analysis for the examination
technique to be done.

Page 20 of 30
(Conclude every heading and subheading first before leaving to start another heading
or subheading).

Page 21 of 30
REFERENCES
Applied Ergonomics, 1990. Work design and work measurement: Implications for
advanced production systems. 21(4), p.343.
HOFFMANN, L., 2007. Data Collection Online: Techniques and Traps When Searching for
(Treaty-Related) Data on the WWW. International Studies Perspectives, 8(2), p.iv-vi.
Kim, S., 2019. Time and Motion Study of Cutting Tool Production: Process Charts and
Layouts (I). International Journal of Innovative Research in Computer Science &
Technology, 7(3), pp.27-31.
Kanawaty, G. ed., 1992. Introduction to work study. International Labour Organization
Winkelmann, A. and Weiß, B., 2011. Automatic identification of structural process
weaknesses in flow chart diagrams. Business Process Management Journal, 17(5),
pp.787-807.

Page 22 of 30
BIBLIOGRAPHY
Sairammech.weebly.com.2022.[online]Availableat:<http://sairammech.weebly.com/
uploads/1/6/0/7/16078520/unit-1_ppce.pdf> [Accessed 13 April 2022].
Ngetich, W., 2021, Semester 1: Method Study: Lecture notes, Recording techniques,
Examination techniques EWY260S, Cape Peninsula University of Technology, delivered 01
June 2021.

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ANNEXURE B
The video is attached on L1

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