Pamantasan ng Cabuyao

Laguna, Philippines 4025

College of Engineering
INDUSTRIAL ENGINEERING

EXERCISE 1 – MIDTERM
IDENTIFYING 8 WASTES (TIMWOODS)

Submitted by:
CAPULONG, JHEP R.
MERCADO, JON KELLY R.
PERILLA, MARIAN ELAISA S.
RONDA, JESSICA A.

3IE – B
GROUP NO. 9

Instructor:
ENGR. KEITH RALDEN M. AYOP

A.Y. 2023 -2024

 Pamantasan ng Cabuyao
Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

Introduction
The TIMWOODS ( Transportation, Inventory, Motion, Waiting,
Overproduction, Overprocessing, Defects, and Skills) framework is a useful
tool for analyzing and improving several parts of the business operations.
These components are essential for identifying waste in any business
process and decreasing it.
Darlington is a manufacturer of socks that offers the best foot
protection and minimizes discomfort as its technology is developed to
make wearing socks more enjoyable.
The Darlington sock stall may identify wasteful processes and
implement targeted improvements by using the TIMWOODS framework.
This framework is extremely significant to a socks company or other
manufacturing company. The business can improve overall efficiency,
streamline its production process, and minimize waste by addressing each
component of this framework. As a result, there are cost benefits,
increased customer satisfaction, and a market competitive edge. For a
socks firm to be successful in the long run, adhering to the lean
manufacturing principles and continually looking for ways to reduce waste
is a crucial approach.

Background of the Study (150 words)

The effectiveness and responsiveness of an organization to client
requests are essential for its success in a competitive business
environment. Many firms, including Darlington, a well-known sock
manufacturer, face operational difficulties and waste in their cycles. The
TIMWOODS structure, which addresses Transportation, Inventory, Motion,
Waiting, Overproduction, Overprocessing, Defects, and Skills, offers areas
of strength to manage smooth out tasks. Darlington perceives the meaning
of addressing these eight kinds of waste to deal with its tasks. By doing so
they will be able to achieve cost saving, customer loyalty and
competitiveness in the market.
This investigation will dig into every part of the TIMWOODS structure,
recognizing explicit issues inside Darlington's operations and
recommending potential solutions. The objective is to provide Darlington
 Pamantasan ng Cabuyao
Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

with a far-reaching comprehension of how the TIMWOODS system can help

their cycles and lead to waste reduction and further developed proficiency.
Narratives
TIMWOODS 8 Wastes
Type of Waste Kind of Waste Description Possible
Solution

Transport 1. Mr. Trinidad frequently 1.(a) Implement

moving sock inventory an inventory
1. Mr. Trinidad, from one storage management
Excessive movement location to another, system that
of sock inventory which seems inefficient optimizes
between storage and time-consuming storage
locations. 2. When doing a weekly organization.
2. Repeatedly, Mr. replenish Mr. Trinidad (b) Place
Trinidad always appears that socks are frequently sold
transfers socks from constantly being sock styles
the stockroom to the transferred from the closer to the
sales floor. stockroom to the sales sales floor,
3. Ms. Abrencillo, floor, which may lead to reducing the
unnecessary back-and delays in restocking. need for
-forth between 3. Ms. Abrencillo often constant
departments when needs to go back and movement
fulfilling customer forth between infant between
orders. section to ladies section storage areas.
4. Mr. Trinidad spent when fulfilling customer 2.(a) Schedule
time traveling to the orders for multiple sock regular
stockroom and from styles. restocking
module to replenish 4. Mr. Trinidad, might be times and keep
sock stock. spending a lot of time a buffer stock
5. Mr. Valenzuela, traveling to the on the sales
frequently stockroom to restock floor to
repositioning of sock sock inventory. minimize the
displays in the store. 5. Mr. Valenzuela, need for
frequently repositioned constant
sock displays, which can restocking. (b)
be disorienting for Consider having
customers looking for staff assigned
specific styles. to restocking
duties during
peak shopping
hours.
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Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

3.(a)Implement
a centralized
order fulfillment
system or pick-
up area to
minimize back-
and-forth
movement. (b)
Use efficient
software and
communication
tools to
coordinate
order pickups
seamlessly.
4.(a)Establish
more frequent,
scheduled
deliveries from
suppliers to
reduce the need
for frequent
travel. (b)
Consider
working with
local suppliers
to minimize
travel time and
costs.
5.(a)Plan sock
displays
strategically,
taking into
account
customer traffic
patterns and
seasonal
changes. (b)
Minimize
unnecessary
repositioning
and ensure that
displays are
visually
appealing and
 Pamantasan ng Cabuyao
Laguna, Philippines 4025
College of Engineering
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easily
accessible.

Inventory 1. The management of 1. Employees of darlington 1.(a) Implement

darlington, complain that there is a a data-driven
sometimes, surplus of specific sock inventory
overstocks on certain styles that don't seem to management
sock styles that be selling, leading to a system that
aren't selling well. cluttered and tracks sales
2. Due to overstocking, disorganized display. trends and
socks become 2. Some socks appear old, adjusts orders
obsolete or damaged, or discolored, accordingly. (b)
damaged. likely due to being Consider
3. Understocking overstocked for an offering
popular sock styles, extended period. promotions or
leading to missed 3. Some customers discounts on
sales opportunities. experienced slow-selling
4. Carrying excessive disappointment when sock styles to
varieties of sock trying to buy popular clear excess
colors or sizes that sock styles that were out inventory.
don't align with of stock. 2. (a) Regularly
customer demand. 4. Darlington offers many assess the
color and size options, condition of
but some seem rarely socks in stock
chosen by customers, and mark down
leading to cluttered prices on older
displays. inventory to
encourage
sales. (b)
Adjust inventory
levels to
prevent
overstocking of
styles prone to
damage or
obsolescence.
3. (a) Use
historical sales
data and
customer
demand trends
to forecast and
stock popular
sock styles in
larger
 Pamantasan ng Cabuyao
Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

quantities. (b)
Implement a
reordering
system that
ensures timely
restocking of in-
demand socks.
4. (a) Conduct a
customer
survey to
understand
preferred color
and size
options. (b)
Based on the
feedback,
reduce the
variety of less
popular options
and focus on
stocking the
colors and
sizes in high
demand.

Motion 1. Employees frequently 1. Darlington Employees 1.(a)Reorganize

bending, reaching, or often need to stretch, sock displays,
stretching to access bend, or use stools to ensuring that
socks on high shelves. access socks on high commonly sold
2. Repeatedly rearranging shelves, which can be sock styles are
sock displays to keep physically straining and placed at eye
them visually time-consuming. level for easy
appealing. 2. It's evident that access. (b)
3. Inefficiently designed darlington staff Implement
store layout requiring frequently rearrange adjustable
customers to sock displays to shelving or use
backtrack or cover maintain a visually rolling ladders
extra ground. appealing look, which to make
4. Multiple employees of can disrupt the shopping stocking and
darlington performing experience. retrieval safer
similar tasks, resulting 3. The module layout often and more
in duplicated efforts. forces customers to efficient.
backtrack or cover extra 2. (a) Use
ground to find sock flexible shelving
styles or related and display
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Laguna, Philippines 4025
College of Engineering
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accessories, which can fixtures to

be frustrating. easily adapt to
4. It appears that multiple changing styles
darlington staff are or seasons. (b)
performing similar tasks Train
such as restocking, employees to
folding, and assisting make
customers, which can be adjustments
inefficient. during non-peak
hours to
minimize
customer
disruption.
3. (a) Redesign
the module
layout to create
clear and
logical
shopping paths.
(b) Group socks
and related
accessories
together and
use signage to
guide
customers.
4. (a)
Implement
clear job roles
and
responsibilities
to avoid
duplication of
efforts.
(b) Use a
communication
system to
coordinate
efforts and
assign tasks
based on
demand and
priority.

Waiting 1. The manufacturer and 1. After customers make 1.(a) Assign

 Pamantasan ng Cabuyao
Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

management of purchases, there are dedicated staff

darlington delays in noticeable delays in members to
restocking socks on restocking the sock monitor sales
the sales floor after a styles they've bought, floor inventory
purchase. leading to empty shelves and restock
2. Socks waiting in the and missed sales socks
stockroom for an opportunities. immediately
extended period before 2. Socks seem to spend a when they run
being shelved. considerable amount of low. (b)
3. Wasted time for time in the stockroom Implement a
darlington employees before being placed on system where
while waiting for the sales floor, which employees
inventory deliveries. can lead to inventory receive
inefficiencies. automatic
3. Darlington employees notifications
often wait for inventory when
deliveries, which can be restocking is
unproductive and lead to needed,
inefficient use of their ensuring a
time. timely response
to customer
demand.
2. (a) Establish
a "first in, first
out" (FIFO)
stocking policy
to ensure that
older stock is
prioritized for
shelving. (b)
Implement a
regular
schedule for
transitioning
stock from the
stockroom to
the sales floor
to minimize
holding times.
3. (a)
Coordinate with
suppliers to
establish more
predictable
delivery
 Pamantasan ng Cabuyao
Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

schedules and
improve
communication
about delivery
times. (b)
During periods
of expected
deliveries,
employees can
be assigned to
other
productive
tasks, such as
inventory
checks, store
maintenance, or
assisting
customers.

Overproductio 1. Producing more 1. The store seems to 1.(a) Implement

n products than the produce an excessive a just-in-time
customer demands. quantity of socks, which (JIT) production
2. Building up excessive can lead to waste and system, where
inventory to meet potentially higher socks are
perceived future prices. produced in
demand. 2. There's a noticeable response to
3. Wasting resources on buildup of sock actual
goods that may not inventory in the store, customer
sell. which can tie up capital demand. (b)
and storage space. Regularly
3. The store may be review sales
investing resources in data and trends
producing and stocking to adjust
sock styles that have a production
low demand or risk quantities
becoming obsolete. accordingly,
avoiding
overproduction.
2. (a) Focus on
demand
forecasting and
inventory
planning to
maintain
optimal stock
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Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

levels. (b)
Consider lean
inventory
management
practices and
maintain a
buffer stock for
unexpected
demand spikes
while avoiding
excessive
accumulation.
3. (a) Conduct
regular product
reviews to
identify slow-
moving or low-
demand sock
styles. (b)
Implement a
clearance or
discount
section for
these socks to
encourage
sales and
reduce waste.

Over- 1. Applying too many 1. Socks often have 1.(a) Streamline

Processing pricing or tagging multiple pricing or the pricing and
labels to socks. tagging labels attached, tagging process
2. Multiple layers of which can be confusing by using digital
approval processes and time-consuming for price tags or
for simple both customers and barcodes,
promotional employees. reducing the
campaigns. 2. Darlington appears to need for
3. Excessive have complex and time- physical labels.
administrative tasks consuming approval (b) Train
for store employees processes for running employees to
that don't add value. promotional apply tags
campaigns, leading to efficiently,
delays and missed ensuring clarity
opportunities. for customers
3. Darlington employees and a more
seem to spend streamlined
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Laguna, Philippines 4025
College of Engineering
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significant time on process.

administrative tasks 2. (a) Simplify
that do not directly the approval
contribute to customer process for
service or sales. promotional
campaigns,
particularly for
routine or
simple
promotions. (b)
Empower store
managers to
make decisions
within
predefined
guidelines,
reducing the
need for
multiple layers
of approval.
3. (a) Evaluate
and streamline
administrative
tasks to
eliminate those
that don't add
value to the
customer
experience. (b)
Automate
routine
administrative
processes
when possible,
freeing up
employee time
for more
customer-
facing tasks.

Defects 1. Socks with quality 1. Some socks have 1.(a) Consider

issues leading to quality problems that working with
returns or lead to customer reputable
exchanges. returns or exchanges, suppliers to
2. Incorrect sock which can be ensure
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Laguna, Philippines 4025
College of Engineering
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orders resulting in frustrating for consistent sock

customer customers and costly quality. (b)
complaints. for the store. Offer a clear
3. Damaged socks in 2. There are instances and hassle-free
the store due to where customers return/exchang
mishandling. receive socks that e policy to
4. Errors in don't match their address
promotional orders, leading to customer
materials or complaints and concerns.
signage. dissatisfaction. 2. (a) Double-
5. Mistakes in pricing 3. Employees observed check orders
or billing, leading to that damaged socks before
customer disputes. in the store, likely due packaging and
to mishandling by ensure clear
customers or labeling. (b)
employees. Address
4. There have been customer
noticeable errors in complaints
promotional materials promptly and
or signage, which can offer quick and
lead to customer accurate
confusion. resolution.
5. Pricing or billing 3. (a) Use
errors have resulted in signage and
disputes with displays that
customers, causing protect socks
inconvenience and from damage
frustration. and theft. (b)
Offer clear
instructions to
customers
regarding sock
care and
handling.
4. (a) Establish
a review
process for
promotional
materials and
signage to
minimize
errors. (b)
Consider using
digital signage
systems that
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Laguna, Philippines 4025
College of Engineering
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can be easily
updated and
corrected.
5. (a)
Implement a
thorough price-
checking
system, ensure
price accuracy,
and regularly
audit billing
processes. (b)
Train
employees in
handling pricing
disputes and
empower them
to provide swift
and fair
resolutions.

Skills 1. Newly hired like Mr. 1. Newly hired 1.(a)Develop a

Valdez, Ms. employees of comprehensive
Angeles, Ms. darlington may lack training
Cerdana, had the necessary program that
inadequate training knowledge about the covers both
for store sock products or the sock product
employees on sock customer service knowledge and
knowledge or skills required to customer
customer service. assist shoppers service skills.
2. Mr. Valdez lacking effectively. (b) Provide
necessary skills to 2. Mr. Valdez may ongoing
handle customer struggle to handle training and
inquiries or resolve customer inquiries or resources to
issues efficiently. resolve issues, keep
3. High employee leading to customer employees
turnover, leading to frustration. updated on the
constantly training 3. Frequent turnover of latest sock
new staff. employees results in styles and
4. Skill mismatches, the need for constant trends.
such as assigning training and 2.(a) Invest in
employees with orientation of new customer
strong sales skills staff. service training
to inventory tasks. 4. Skill mismatches can programs to
5. Failure to cross- occur, with enhance
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Laguna, Philippines 4025
College of Engineering
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train employees for employees being employees'

multiple tasks, assigned tasks that problem-solving
leading to don't align with their and
bottlenecks.. strengths. communication
5. Few employees may skills. (b)
lack versatility, Provide them
resulting in with clear
bottlenecks when guidelines for
specific tasks need to addressing
be handled. common
customer
inquiries and
resolving
issues.
3. (a)
Implement
measures to
improve
employee
retention, such
as offering
competitive
compensation,
creating a
positive work
environment,
and providing
career
advancement
opportunities.
(b) When
turnover does
occur,
streamline the
onboarding
process to
expedite
training for new
hires.
4. (a) Assess
employees'
strengths and
assign tasks
that align with
their skills. (b)
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Consider cross-
training
employees for a
range of tasks
to enhance
flexibility and
efficiency.
5. Implement a
cross-training
program that
equips
employees to
handle multiple
tasks.

Conclusion
In conclusion this study has highlighted the importance of utilizing
lean manufacturing principles, particularly the TIMWOODS framework, to
tackle operational challenges within Darlington, a well-regarded sock
manufacturing company. By conducting a thorough examination of
transportation, inventory management, movement, waiting, overproduction,
overprocessing, defects, and skills, we've pinpointed areas where
inefficiencies and waste have a negative impact on operational
effectiveness and financial performance. These findings highlights the
significance of waste reduction as a means to unlock various substantial
advantages, including cost reductions, enhanced customer satisfaction,
and increased competitiveness. Through the diligent implementation of
lean methodologies, fostering a culture of continuous enhancement,
streamlining processes, enhancing quality control, and investing in
employee development, Darlington is well-positioned to harness these
benefits.
This study not only highlights operational inefficiencies but also
furnishes practical recommendations that can steer Darlington toward
sustained growth and long-term prosperity. By upholding its dedication to
product quality while simultaneously eliminating waste, the company can
establish itself as an industry leader, delivering exceptional products and
 Pamantasan ng Cabuyao
Laguna, Philippines 4025
College of Engineering
INDUSTRIAL ENGINEERING

achieving operational excellence.

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