GROUP - D

“Associate Fatigue Reduction in Door

Installation Process”

MEMBERS INSTITUTE

MUHAMMAD HAZIQ SAJJAD UET LAHORE

TAHA ANEES UET LAHORE

SHAYAN RAFI GIKI

DEPARTMENT: SUPERVISOR:
ASSEMBLY FINAL (AF) SHAHBAZ AHMANAT

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Table of Contents
General Overview:.............................................................................................................3
AF Layout...........................................................................................................................4
Problem Identification.......................................................................................................5
Current Situation at the AF Department.............................................................................6
Cause and Effect Diagram..................................................................................................7
Proposed Ideas..................................................................................................................8
Idea 1................................................................................................................................9
Idea 2...............................................................................................................................10
Idea 3...............................................................................................................................11
Idea 4...............................................................................................................................12
Strategy for application of Idea 4.....................................................................................13

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General Overview:
Fatigue:
 Extreme tiredness resulting from mental or physics exertion or illness
 Weakness in mental or other materials caused by repeated variations of stress
 Lack of energy and motivation but not drowsiness

Effects:
 Reduced decision making ability
 Reduced communication skills
 Reduced productivity
 Failed to respond to changes in surroundings or information provided
 Increased accident rates

Methods of Reducing Fatigue:

 Rest pauses
 Less hours of work
 Proper lightning
 Improving environmental conditions
 Reduction of noise
 Proper selection of employees
 Counseling of employees

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AF Layout

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Problem Identification
The associate fatigue is a governing and limiting factor in any factory. If the workers are not
giving their 100%, it becomes very difficult to achieve targets and thus whole unit suffers.

This report is a brief explanation of what method(s) could be used to improve the working
efficiency at the industry. However, there were certain barriers that the team had to keep in
mind before proposing a good idea to the AF team.

Few of those limitations were:

1. Area of Production Line

2. Budget
3. Number of associates required

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Cause and Effect Diagram

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Proposed Ideas
After brainstorming the team came across following ideas that were good enough to be
proposed:

 Idea 1: Increase workforce.

Number of associates installing the doors to be increased from 4 to 5 or 6 so that the
work load on each associate is divided which means less fatigue

 Idea 2: Additional Trolleys

Use of 2 trolleys instead of a single trolley. Right side door on one trolley, left side
doors on the other one. This reduces the time to install the door and causes less
fatigue for the men pulling the trolleys to the targeted place.

 Idea 3: Sub-assembly of doors

The sub-assembly of the door can be made near to the door installation area. This
would require lesser effort since the distance to drag the doors on the trolleys is
reduced

 Idea 4: Electric chain air hoist

Machine aided hoist to move the doors rather the associates carrying the doors
themselves. This reduce man effort and this causes less fatigue

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Idea 1
Increase workforce

The idea was analysed by using certain parameters:

Area Marking Reason

Cost NG 2 more associates must be added per shift
with each consuming another 25k-28k per
month

Quality of work OK Less fatigue on each associate would mean

greater quality

Management Imp Management of an additional work force

might be a problem for the senior members

Safety OK Each additional associate would have his

own safety measures

Environment NG Congested workstation due to increase in

associates

Following observations were made

• It was too costly to add 4 more associates in the whole day (2 shifts). This would cost
additional Rs 650,000 annually

• It would lead to a messy and congested work station which may add to mental fatigue

So, IDEA 1 WAS REJECTED

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Idea 2
Using Additional Trolleys

Use of 2 trolleys instead of a single trolley. Right side door on one trolley, left side doors on
the other one. This reduces the time to install the door and causes less fatigue for the men
pulling the trolleys to the targeted place.

Area Marking Reason

Cost OK Creation of new set of trolleys from original

ones

Quality of work OK Improved quality because of lessening in the

load carried by the associate

Management OK Less fatigue due to not having to carry doors

Safety OK Handling of trolleys

Environment NG Preparation of tool kit holder result in

difficulty of delivering right side doors at
right side.

• There was restriction in delivering the doors on the right side due to the moving
conveyor belt

• Other jobs such as preparation of tool kits were in the path of the trolley

So, IDEA 2 WAS REJECTED

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Idea 3
Sub-assembly of doors

The sub-assembly of the door can be made near to the door installation area. This would
require lesser effort since the distance to drag the doors on the trolleys is reduced

Area Marking Reason

Cost NG Whole set up of the work station will have to

be changed

Quality of work OK Improved quality because the associate has to

carry the trolley for shorter distance

Management OK Easy management, all door subassembly is

near to the main assembly

Safety OK More safety of the associates

Environment NG A less messy environment

 It was highly impractical and too costly to change the whole layout of the AF for
reducing fatigue of the associates only

So, IDEA 3 WAS REJECTED

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Idea 4
Electric chain air hoist

Machine aided hoist to move the doors rather the workers carrying the doors themselves. This
reduces man effort and this causes less fatigue

Area Marking Reason

Cost Improvemen A little costly but very efficient

t
Quality of work OK Excellent quality of work can be achieved
with very little fatigue of the associates

Management OK Easy management, only one man is required

to inspect the hoist regularly

Safety Improvemen Very safe as this is a small air hoist with less
t electricity consumption

Environment OK Clean environment since everything is

electrically controlled

IDEA 4 WAS SELECTED

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Strategy for application of Idea 4

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Conclusion

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