Task 1: (P4)

Product chair
a) Draw the bill of material (BOM) for this product.

BOM Chair
Level L0 L1 L2
chair Leg Assembly Front Legs (2)
Cross Bar (1)
Seat
Back Assembly Side Rails (2)
Cross Bar (1)
Back Supports (3)
b) Draw the flow process chart.
c) Draw the operation process chart.
Task 2: P3, P5
a) Display the procedure for collecting and measuring operators'
performance data in a company.

1. Develop an evaluation form.

2. Identify performance measures.
3. Set guidelines for feedback.
4. Create disciplinary and termination procedures.
5. Set an evaluation schedule.

A performance evaluation system can motivate staff to do their best for

themselves and the practice by promoting staff recognition and improving
communication.

Evaluations should be conducted fairly, consistently and objectively to protect

your employees and your practice.

An effective performance evaluation system has standardized evaluation forms,

performance measures, feedback guidelines and disciplinary procedures.

b) Illustrate the procedure to conduct the above observations.

• This method considers four factors in evaluating the performance of the

operator: Skill, effort, conditions and Consistency.
• Skill may be defined as proficiency at following a given method. A
person skill in given operation increases with his experience on the job,
because increased knowing with work brings speed, smoothness of
motions.
• Each factor is then subdivided into skill, excellent, good, average, and fair.
The average time obtained from time study is normalized by applying the
sum of the ratings of the four factors.
c) Calculate the standard time.

From the performance rating table of Westinghouse system

Skill Average D 0
Effort Excellent B1 0.1
Condition Fair E -0.03
Consistency Good C 0.01
Total rating 0.08

Rating factor = 1 + Total rating = 1 + 0.08 = 1.08

Normal time = observed time X rating factor

Normal time = 1.4 * 1.08 = 1.512 min

𝟏𝟎𝟎
Standard time = normal time X
(𝟏𝟎𝟎−𝐭𝐨𝐭𝐚𝐥 𝐚𝐥𝐥𝐨𝐰𝐚𝐧𝐜𝐞𝐬)

100
Standard time = 1.512 * = 1.718 min
(100−12)
d) The average actual time for 6 elements of a task were measured and
tabulated below. The Predetermined motion time for two elements is also
given. Calculate the standard time if the allowance is 10%.

P 0.75
Performance rating (R) = = ∗ 100 = 93.75 % for second element
A 0.8

P 0.45
Performance rating (R) = = ∗ 100 = 112.5 % for fourth element
A 0.4

(93.75+112.5)
Average rating = = 103.13 %
2

Normal times for the element are:

Element Actual Normal time = Actual X Average rating

1 0.6 0.6 * 103.13 = 0.6188
2 0.8 0.8 * 103.13 = 0.825
3 0.5 0.5 * 103.13 = 0.5156
4 0.4 0.4 * 103.13 = 0.4125
5 0.7 0.7 * 103.13 = 0.7219
6 0.6 0.6 * 103.13 = 0.6188
Total 3.7126

𝟏𝟎𝟎
Standard time = normal time X
(𝟏𝟎𝟎−𝐭𝐨𝐭𝐚𝐥 𝐚𝐥𝐥𝐨𝐰𝐚𝐧𝐜𝐞𝐬)

100
Standard time = 3.7126 * = 4.125 min
(100−10)
Task 4: P8, M3.1

a) Describe the ISO9000-based quality systems.

ISO 9000 is defined it is a principle-based international standard that describes a

quality management system that organizations can use to be more efficient and
improve customer satisfaction.

What are ISO 9000 Standards?

Generic standards that provide guidance for:

- Implementation of effective quality systems

- Assurance for products and services
- Improvement of existing quality systems

What are the benefits of ISO 9000?

- Higher perceived quality of customer service

- Improved customer satisfaction
- Competitive edge over non-certified competitors
- Increased market share
- Improved employee morale
- Better documentation

b) Demonstrate the main principles of TQM.

1. Produce quality work the first time

2. Focus on the customer
3. Have a strategic approach to improvement
4. Improve continuously
5. Encourage mutual respect and teamwork
6. Relationship Management
c) Construct a cause-and-effect diagram showing the main and root causes
of the problem? Write recommendation for the management based on
your analysis.

(Fish pone for Bad coffee)

Write recommendation for the management based on your analysis.

Your water quality isn’t great.

➢ A good basic rule of thumb is that when you’re making coffee, you want to
use water that you’d be happy to drink.

Your equipment is dirty.

➢ The equipment used to make coffee and clean the cups must be cleaned

Coffee machine doesn’t work properly

➢ The problem must be solved and the coffee machine maintained in order
for it to work properly so that it can produce a huge amount of coffee and if
you want good tasting coffee you want to drink it freshly brewed.