I.

INTRODUCTION
Background of the Plant Study
Jocker's Foods Industries (JFI) is a sole proprietorship that manufactures and distributes high-quality
snack foods. JFI, which was founded in 1992, has grown to become one of the country's leading snack
food manufacturers for the CDE market. Sugo Peanuts, Mik-Mik Milk Powder, and Mik-Mik Polvoron
are some of the company's best-known products. Sugo Peanuts are one of the most popular snacks among
Filipinos, having been around for years and still providing us with high-quality nuts at a reasonable price.
These peanuts do not simply appear and are ready for consumption. It necessitates a variety of processes
or operations, ranging from raw peanuts to cooked and packaged peanuts ready for shipment to various
parts of the Philippines. One of the most critical steps is sorting, because peanuts naturally have nutshells
that must be sorted because they will not be used in the production of Sugo peanuts. The sorting is done
by a machine at the company. This, however, is not sufficient. The sorted nuts from the machine still have
nutshells, implying that they must be manually picked out by workers. The frying process is similar to the
nut sorting process, not only in terms of time commitment, but also in terms of the importance and
difficulty of the task. This method is largely responsible for the Sugo nuts' quality. Workers must focus
entirely on the task at hand, especially while determining if it is sufficiently cooked. Because each batch
of nuts has a different cooking time, it is the worker's responsibility to assess the nuts' readiness. Because
the frying process takes so much longer to complete, there are delays between the two. This in which
slows down the whole operation and develops too much work-in-process.
Motion and Time Study will be used to evaluate the movement of the machine, the workers, and the area
itself. Finding ways to reduce inefficiencies in the work place and work stations. Eradicating waste to
enable the process to flow smoothly. The aim of this case study is to diminish the delays between the nut
sorting and frying process. To reduce the time of the whole frying process. To identify and minimize the
delays in between the sorting and frying process. In which will essentially maximize productivity and
reduce waste.

Objectives of the Plant Study

The objective of method improvement is to diminish the delays in between the nut sorting and frying
process and thus further improve the whole production time. By the completion of gathering of data
through observation the following are to be identify:

 To pinpoint and eliminate the non-value activities in the sorting and frying process.
 To improve the work station of the sorting process.
 To determine how and what procedure is to be taken to reduce the frying time.
 To identify and minimize the delays in between the sorting and frying process.
 To reduce the overall time of the frying process
Significance of the Plant Study
This study aims to examine the processes in the chosen workplace and identify the difficulties to
provide ideas by applying the knowledge in Motion and Time study. The result of the study will be
beneficial and relevant to the following:
To the Company. From the findings of this study, the researchers will be able to provide ideas and also
present recommendations from the observed and gathered data. This will help the management to
improve the current system by applying the methods suggested with respect to the principles of Motion
and Time Study.
To the Workers. The employees will now be more aware on how things can work more efficiently in the
workstation. They will be able to do their task in the most effective way without wasting time, cost and
energy.
To the Researchers. This will benefit the researchers in helping them to analyze the processes and apply
their understanding in Motion and Time Study. It will serve as their training ground for their selected
careers in the near future and will improve their skills about the course chosen.
To the Future Researchers. This study will serve as a useful basis for the next or future researchers who
aims to conduct new studies in line with this topic or have similarities in variables. It will also provide
guidance to help them think more crucial for the further improvements of future studies to be conducted.

Scope and Limitation

The study covers only the delay time that happened in the frying process and other issues in the
company that the researcher may improve. The researcher's major focus is on reducing the time delay
between sorting and frying processes using time study and solving the existing issue in sugo peanut
production using motion study. All procedures under the sorting and frying process may be observed by
the researcher, including the operator. Since there was a technical problem in frying machine 1 during the
observation, the observation time in the sorting and frying process was limited to only four machines:
four frying machines and four sorting machines. Other processes in sugo peanut production are not
addressed in this paper, such as peeling nuts and packaging nuts.
2. PRESENTATION OF PRESENT SYSTEM
Jocker’s Foods Industries is a company involved with the manufacturing and distribution of
quality snack food in the greater part of Luzon and recently to some parts of Visayas and Mindanao. The
top products that company produces includes Sugo Peanuts, Mik-Mik Polvoron and Mik-Mik Milk
Powder. This study focuses on Sugo Peanuts Production which is the most popular among all of their
products.

Figure 2.1 - Sugo Peanuts

Sugo Peanuts Production is subdivided into different working stations including boiler section,
screening, water separation, sorting, frying, flavoring and packaging (which is in different room). The SP
Production area is illustrated by the provided layout below (figure 2.2). The researchers will focus on the
processes of sorting and frying of peanuts since the frying station is observed to be the bottleneck of the
production area. Note that the sorting machine 5, fryer 1 & 2 is not included in the observation because of
some operational issue.

Figure 2.1 – SP Production Layout

The sorting process will begin by transferring peanuts from the cage trolley into the sorting
machine using buckets with a time process of 19.08 minutes (per cage). It will therefore be sorted
manually in a conveyor belt system by 2 workers positioned at different sides. There are total of 4
working sorting machine, 2 workers that are assigned to transfer nuts from the cage trolley into all the
sorting machine, and there are 2 workers in each machine that sorts the peanuts by hands (may change if
its breaktime). There are total of 66 buckets of nuts per cage trolley and each sorting machine has
capacity of 8 buckets per set. At the end of 2 conveyors there’s one cage trolley where the sorted nuts go
into. The whole sorting process have an average time of 34 minutes given that it is done by 2 sorting
machines and with consistent speed of conveyor belt machine. After those procedures, it is then
transferred into the frying station.
In frying station there are total of 5 working frying machine, but as for the study 4 machines are
observed. The ratio of frying machine and worker is 1:1, meaning there is a 1 worker assigned per
machine. The process will start after a cage trolley is transferred from the sorting station into the frying
station. Each cage trolley of peanuts will be cooked in 2 frying machines. So, for every cage trolley there
are 8 sets of 8 buckets of peanuts. This means that both frying machines will have to cook 4 sets of 8
buckets each to finish one cage trolley.
For fryer 3 the average time in initial observation is 20.1667 minutes, for fryer 4 is 19.6667
minutes, 17.8333 minutes for fryer 5 and 16.6667 minutes for fryer 6. The time process for every fryer is
identified to be different from each other due to difference in temperature and machine condition like its
oldness. Given below is the average temperature of each fryer. (Table 2.1)

Initial Final
Temperature in Temperature in
Fryer °F °F
No. (Peanuts are (Peanuts are
placed in removed in
machine) machine)

3 149 132

4 170 140
 5 151 133

6 152 137

Table 2.1 – Average Temperature of Frying Machines

It is observed that the time for the sorting process is much lower that the frying time that leads to
pending cage trolleys in the frying area. This causes domino effect of delays in other station like flavoring
and also results to idle time of some workers. This study aims to diminish the time between the sorting
and frying to lessen delays and idle time.

The Sorting Process’ Layout as observed by the researchers:

Figure -Nut Sorting Work Station

The figure above shows the present working station of the sorting process. There are 5 sorting machines
each with a conveyor belt to help the nuts travel from the unfinished area to the cage of sorted nuts. Two
workers are tasked with each machine to manually sort the remaining nutshells. Each machine and
conveyor belt has a bucket attached near it where the nutshells are placed. The controls for the conveyer
belt are located directly above the sorting machines.

Figure – Present Design of Chair

The figure above shows a closeup on the chairs of the workers in the sorting process. As seen, it is a plain
Monoblock stool chair with no foot rest and back rest which can be uncomfortable for the workers in the
long run.
Figure – Present Design of Cage Trolley (Front View)

Figure – Present Design of Cage Trolley (Front View)

The figure above shows the current shape of the cage trolley in which is made of steel and has wheels to
allow movement. It is also is smaller in height and has a flat bottom. The figure also shows the design of
the nut scooper, it is bucket like in shape and is made of plastic.

3. RESULTS AND DISCUSSIONS

This chapter focuses on discussing the problems seen and approach them one by one to clearly see what
needs to be addressed. A plant visit was conducted to help the researchers ascertain the issues and delays
encountered within the processes. Motion and Time Study was used in order to understand what is
causing the inefficiencies.
Statement of the Problem
Statement of the problem the greatest phase of the Sugo peanut production process has been the frying
time. As a solution to this challenge, the researcher gathered all of the data necessary to determine the
overall delay caused by the frying process in comparison to the sorting time. Initial samples were
analyzed to develop a standardized time that corresponds to the real frying time in each fryer capability,
using time study as a method to define the standard time. As has been discovered, each fryer has a
different frying time depending to machine conditions such as period of use. Some current issues in work
station design must be addressed, such as the arrangement of the workstation, where the transportation of
trolley cages in sorting 3 and 4 is quite far from its line in process, which is the frying 5 and 6. The
uncomfortable position of the operator in the sorting machine, which causes them discomfort, must also
be improved. Moreover, when the trolley cage is ready to be empty, the height of the trolley cage makes it
difficult for the operator to reach the nuts.
4. RECOMMENDATION
In this chapter, time and motion studies are used to analyze and address a problem in sugo peanut
production. The researchers present problems with solutions and must determine whether or not the
solution is valuable and effective for the company.
PROBLEM 1: Established standard time in frying process to reduce the delay time between
sorting and frying process.
Frying time has been the major contributor of delay in the whole process of Sugo peanut production. As a
response to this problem the researcher gathered all the data needed to identify the total delay that the
frying process contribute in contrast to the sorting time. Using time study as a tool to determine the
standard time, initial sample have been analyzed to establish a standardized time that corresponds similar
to the actual frying time in each fryer capability. As it has been identified that each fryer differs in frying
time due to machine condition like oldness of the machine. After the standard time has been identified it
will now be compared to the current process to determine how much delay time has been reduced and
save.

COMPUTATION OF REQUIRED SAMPLE

Fryer Initial Observe Time Average Samples
Time
Number 1 2 3 4 5 6

Fryer 3 19 23 20 20 21 18 20.1667 11.2091

Fryer 4 18 20 22 21 19 18 19.6667 10.5944

Fryer 5 18 19 18 19 18 15 17.8333 10.4689

Fryer 6 17 17 16 16 15 19 16.6667 10.3262

The initial observe time is collected in the four fryers machine to determine the required sample to be
used in standardizing the time. The answer must be rounded up. In fryer 1 the requires sample is 12 and
11 sample in fryer 4,5 and 6. The formula used in getting the required sample is:
2
zs
sample=( )
hx
Where:
z= number of standard deviations required for desired level of confidence=1.96(95% Confidence level)
h=accuracy level desired in percent of the job element expressed as decimal (5%=0.05)
x= mean of the initial sample
s=standard deviation of initial sample.

STADARD TIME PER FRYER MACHINE

Fryer Observe Time Average Normal Standard

Time Time(w/ Time(w/
Number 1 2 3 4 5 6 7 8 9 10 11 12 80% 15%AF)
PR)

Fryer 3 1 23 20 20 21 18 17 20 17 16 19 18 19 15.2 17.48

9

Fryer 4 18 20 22 21 19 18 20 19 17 16 17 18.8182 15.0546 17.3128

Fryer 5 18 19 18 19 18 15 18 18 19 17 17 17.8182 14.2546 16.3928

Fryer 6 17 17 16 16 15 19 18 16 15 17 18 16.7273 13.3818 15.3891

After determining the required sample. the normal time will be determine using the mean of observe
time and performance rate of 80%. The researchers rate the workers performance as 80% classified as
below average because there is a time that the workers are often idle or not working during working time.
Formula for normal time:
Normal Time= OT*R/100
Where:
OT= mean observe time
R= performance of operator expressed as a percentage (80%)

Standard time of every fryer machine are determine using the normal time and allowance factor. The
formula to get the standard time is:
Standard Time=NT*(1+AF)
Where:
NT= Normal Time
AF= Allowance Factor of 15%
Atmospheric condition= 5%
Use of force or muscular energy= 3%
Personal allowance= 2%
Noise level= 2%
 Delay allowance= 3%
Total: 15%

CURRENT PROPOSE

Cages SORTING FRYING Delay Cages SORTING FRYING Delay

MACHINE(1 MACHINE(3& time MACHINE(1 MACHINE(3& time
&2) 4) &2) 4)

Cage 1 34.12 82 47.88 Cage 1 34.12 69.92 35.8

Cage 2 34.26 76 41.74 Cage 2 34.26 69.92 35.66

Cage 3 34.51 69 34.49 Cage 3 34.51 69.92 35.41

Total 102.89 227 124.11 Total 102.89 209.76 106.87

SORTING FRYING SORTING FRYING

MACHINES(3 MACHINE(5& MACHINE(3& MACHINE(5&
&4) 6) 4) 6)

Cage 4 34.23 74 39.77 Cage 4 34.23 65.5712 31.34

Cage 5 34.27 69 34.73 Cage 5 34.27 65.5712 31.30

Cage 6 34.43 72 37.57 Cage 6 34.43 65.5712 31.14

Total 102.93 215 112.07 Total 102.93 196.71 93.78

TOTAL DELAY TIME IN LINE IN PROCESS OF CURRENT AND PROPOSE

This table shows the total delay time in current system and propose standard time. In current system,
the sorting machine 1 and 2 have total of 102.89 minutes process time in 3 cages of nuts while in frying
machine 3 and 4 have 227 minutes process time in the same number of cages of nuts, the total delay time
of sorting machine 1 and 2 in process line with frying machine 3 and 4 is 124.11 minutes. In propose
standard time, sorting machine 1 and 2 have a same total time in current system while the frying machine
3 and 4 have a total time of 209.76 minutes, the total delay time in proposed standard time is 106.87
minutes.
In current system, the sorting machine 3 and 4 have total of 102.93 minutes process time in 3 cages of
nuts while in frying machine 5 and 6 have 215 minutes process time in the same number of cages of nuts,
the total delay time of sorting machine 3 and 4 in process line with frying machine 5 and 6 is 112.07
minutes. In propose standard time, sorting machine 3 and 4 have a same total time in current system
while the frying machine 5 and 6 have a total time of 196.71 minutes, the total delay time in proposed
standard time is 93.78 minutes.
REDUCE DELAY TIME USING PROPOSE STANDARD TIME
 This table shows the reduce delay time of proposed standard time compare to the current system. The
total delay time of sorting machine 1 and 2 in line with the frying 3 and 4 is 124.11 minutes compare to
the proposed standard time with only total delay to time of 106.87 minutes. It means that in propose
standard time the total delay time of 3 cages is reduce by 17.24 minutes. In sorting machine 3 and 4 in
line with frying machine 5 and 6 the total delay time is 112.07 compare to propose standard time with
only 93.78 total delay time. It shows that using proposed standard time the total delay time in sorting 3
and 4 in line with frying 5 and 6 is reduce by 18.29 minutes. Since these 2 pair of fryers has been working
at the same time therefore, researchers only need to consider the reduced time of the pair fryer which has
the longest total frying time. Comparing fryer 3 and 4 to fryer 5 and 6, the fryer 3 and 4 has the longest
total frying time of 124.11. Therefore, the reduced time that this study will consider is 17.24 minutes.

CURRENT PROPOSE REDUCE TIME

SM(1&2)AND SM(1&2)AND
FM(3&4) FM(3&4)

TOTAL DELAY TIME 124.11 106.87 17.24

SM(3&4)AND SM(3&4)AND
FM(5&6) FM(5&6)

TOTAL DELAY TIME 112.07 93.78 18.29

PROBLEM 2: THE SORTING PROCESS’ WORKING STATION

According to two new studies by Alan Hedge, Ph.D., CPE and Cornell University, a pleasant working
environment can do more than make employees happy: it can also boost productivity. During their plant
visit, the researchers noticed a few issues, one of which is the layout of the said working station. At first
glance, the workers appear to be doing an excellent job; no one can see that they are in any discomfort.
However, as the hours pass, the simple task becomes increasingly difficult. A simple waste of movement
can make the job appear much more difficult than it is. The following are the proposed work station
design to adhere to the needs of the workers.

Figure -Proposed Layout of Trash Bins

The figure above shows the proposed layout of the sorting process. In which the number of buckets for
the waste/ nutshells are now 2, one at each end of the conveyor. And the controls are moved a few inches
down for easier access to the worker

Figure -Proposed Design of Chair

The figure above shows the propose chair for the workers in the sorting process. The chair has a backrest
and footrest so the workers will not be put into too much strain. The arms are bent minimally about 90 to
100 degrees. The back rest supports the upper and lower back. The seat is slightly tilted and cushioned to
be more comfortable. The chair is also adjustable in terms of height to cater the differences of the
employees/workers. An ergonomically correct chair not just supports the posture but also reduces risk of
neck and back pain.

Figure – Proposed Layout of Cage Trolley (Top View)

Figure – Proposed Layout of Cage Trolley (Front View)

The figure above shows the proposed design of the cage trolley and the nut scooper. The cage increased
in height, has a wheel stopper, and is slanted inside allowing all the nuts to fall in one place making it
easier to scoop, since the nuts will be placed in 45 degrees sloped bottom container While the nut
scooper...

5. CONCLUSION
Diminishing the delays in between the nut sorting and frying process required a plant study in order to
gather the necessary data for the motion and time study to further understand the challenges affecting the
Sugo Peanuts Production. Observing the vast processes first and scrutinizing each step to find out which
is the bottleneck. As the researchers took time to study the two processes, they found out what the real
problem is. The issue is specifically the time-consuming frying process in which creates loads of work-in-
process and results to delays in the operation.
The proposal of having standardized time per fryer, the researchers reduced the delay time for 3
cages for about 17 mins per 2 fryer which occupy half of the total working hours in a day. So, in one
whole day the 2 fryers have a quota of 6 cage trolleys per day. In total 12 cages of peanuts are being fried
every day. And a total time of 34 mins is being save and reduced. Multiply by 30 days in a month, we
have now a total 17 hours been saved and reduced compared to the current process.
In addition, the work station design becomes important as it not only affect the operation itself
but also the workers safety and well-being. The proposed layout of the sorting process is composed of
adjusting the controls located overhead for better reach, doubling the trash bins where you can put waste
nutshells, improving the chairs layout to be ergonomically correct, and also developing a design that will
make the cage trolley more efficient to use. By changing the job to fit the person, there will be zero to
little setbacks both physically and mentally. It will also result in a higher-quality, and more efficient
outcome when the performance is observed.
Acknowledgements
The completion of this case study could not have been possible without the participation and assistance of
many people. We would like to express our deepest appreciation and indebtedness particularly to the
following:
To our God, thank you for keeping us safe and healthy all throughout. Thank you for the people
you use to make everything possible.
To Sir Jeremy Bañez, for his support and full guidance from the beginning until the end of our
study. His expertise in the field showered us knowledge, passion and determination to learn new lessons,
grab opportunities and gain experiences.
Jocker's Foods Industries (JFI), for allowing us to conduct our case study in their company. We
would also like to thank the people inside the company for their patience in attending questions and
providing information to fulfill our study.
To our Family, for their love and support in everything that we do. Thank you very much
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