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Journal of Industrial Mechanics
Volume 2 Issue 1

Productivity Improvement By Cycle Time Reduction Using Time

And Motion Study A-Case Study Of Electrode Manufacturing
Company
Pankaj Bhagat1 and F. Ujjainwala2
1
Pg Scholar, IPE Dept, SGSITS Indore
Asst. Professor, IPE Dept.
SGSITS,Indore
Email: 1 Pankajbhagat83@Gmail.Com
Email: 2Fujjain@Gmail.Com

Abstract
The systematic application of time study, and method study to improve productivity, reduce
cost and improve profit. The productivity can be improved by reduction in cycle time. The
Cycle time can be defined as the time required completing any process. Work study is the
scientific research involving work techniques with the objective of identifying the best way of
doing a work. Time study is used to eliminate the Ineffective time while operation is being
performed. This study performs a work study analysis at the product finishing shop of with
the aim to offer suggestions to improve its operational and production efficiency. Primary
data was collected in PFS shop of Electrode machining process, through observation method
(time study sheet using stop watch). Afterward it concludes the summarized data by various
charts and time study sheet.

Keywords: work study, time study, method study, cycle time, productivity, idle time, non value
added time.

INTRODUCTION the non value added activity it’s also help

The world is constantly changing. In this improvement of productivity.
changing world, the industries are willing
to retain the customer and provide the The company has six shops in the plant.
product the right time, with right quality The product finishing shop (PFS) is the
and quantity. The roles and responsibilities last shop of the company. Where work
of the industries are converging toward the performed is finishing and machining of
customer in order to be the global player. electrode. Company used three machines
namely facing, centering, and threading
Frederick W. Taylor is considered as the machine, and final assembly of electrode
“Father of Modern Industrial Engineering. with nipple, The nipple used to join of two
He put forth his ideas on “scientific electrode, a nipple machining by fully
management” and “Work measurement” in automatic CNC machine. But electrode
1881. In 1885, Frank B. Gilbreth machining used to semiautomatic machine.
introduces “Motion Study” and constructs This study was focused on productivity
the process chart. He defines motion study improvement of electrode machine chain.
as the science of eliminating wistful result Company used heavy electric crane for
from unnecessary, ill direction and material movement, the electric crane
inefficient motion. operated by two operators with wireless
remote control,
The time and motion study tool for The electrode manufacturing company
reduction of unwanted process and identify final output product is ultra high power

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 Journal of Industrial Mechanics
Volume 2 Issue 1

electrode. This electrode using iron therefore, company earn more profit and
processing industries for malting iron ores increase living standard of people.
and also using nuclear power plant. Productivity is the ratio of aggregate
output to aggregate input; the output may
Productivity be any product or service and input like a
The productivity of any organization is natural resources land, building, raw
cost effective activity. The principal aim of material or machine, equipment.
work study is to increase productivity. The Output
productivity of any production system is a Productivity =
better use of recourses and more efficiency Input
of the machine. The work study is an The enterprise using to certain resources or
intelligent application for increase inputs with which it produces the desired
productivity its can produce more product output. These are:
at a same available working time so as cost 1. Land and Buildings, 2.Material,
of per product reduced and increasing 3.Energy. 4.Machines and Equipment,
purchasing power of consumer in, 5 Manpower
Work Study simplify the way to accomplish a work and
“Work study is the systematic examination to improve the method of production it
of the methods of carrying on activities so employs a systematic approach involving:
as to improve the effective use of
resources and to set up standards of Select – Record – Examine – Develop –
performance for the activities being carried install – maintain.
out.”(ILO 2014) Work Measurement- Work measurement
The term "work study" embraces several study is a general term used to describe the
techniques, but in particular method study systematic application of industrial
and work measurement. engineering technique to establish the
The aim of work study is to examine all work content and time it should take to
the activity and process to running by man complete the task or series of task. There
or machine. Its gives a simple and are many techniques to use work
effective method and its can modify when measurement, the stop watch one of the
any operation has unnecessary or excess best method because it is simple to use and
work. Reducing in wasteful work through effective.
work study to better use of resources and Work Content “Work content means, of
set up a time, standard for a process that course, the amount of work contained in a
activity. given product or a process measured in
work-hours or machine hours” (ILO 2014)
The work hour for the labor is one person
take one hour
The machine hour for the running machine
is a piece of the plant for one hour.

Cycle Time Calculation

Each event was broken down in to element
and the observed reading of each element
Method Study- Method study is the was noted with its description. Observed
systematic recording and critical reading was taken in minutes and second
examination of ways of doing things in by stopwatch.
order to make improvements. It is use to Element taken to account are: loading,
unloading, machining, material movement,

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 Journal of Industrial Mechanics
Volume 2 Issue 1

air cleaning, inspection, worker movement observations of each activity at seconds

observe activity such as on line inspection, and the average time in minutes was
and data entry on computer etc. Take 10 calculated.

Types of Charts Used in Method Study

Fig 1.5 Types of charts used in method study

Product of Company (Electrode)

Fig: Finished Product in PFS Shop(Graphite Electrode)

Problem Formulation performed by to operator with using three

The product finishing shop have three crane namely C1, C2, C3.
machines and machines installed in line 1. There are many problem in current
layout, the row material start flow from layout, the perform operation with
input conveyer and passed through three cranes between two operators is
centering, facing, turning and last some time interference each other and
threading, and last go for inspection in waiting while first operated carry
outlet conveyer. The machining process crane. It results increase the cycle time

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 Journal of Industrial Mechanics
Volume 2 Issue 1

and more idle time for man and also 6. company for workers.
machine. a. Standard time = Basic time +
2. The threading machine cycle time is Allowance(% of basic time)
more than other two machines its 7. vi. Construct the multiple activity
causes increase waiting time of other charts and calculate the idle time for
two machines. man and machine.
8. Implement of flow process chart to
RESEARCH OBJECTIVES reduction in Idle time non value added
The main objective of project time.
1. Productivity improvement by reducing Data Collection All the process and cycle
cycle time. time of man and machine are calculated by
2. Calculate the standard time of every true data collection. The data collection is
manual work. the initial process of any improvement and
3. Elimination of non-value added time help to decide solution of problem. The
on the process data collection is methodological study of
4. Reduce the operator idle time for better past for arriving at conclusion for work
use of man machine system. study. Taken observation to time study by
stop watch in all process of machining.
METHODOLOGY Construct the current man type flow
1. Understand the current working process chart to first and second operator
procedure and entire material flow of all the machining process.
process from input (raw material) to
output (finished product). Layout of Product Finishing Shop and
2. Construct Man and Machine type flow Flow of Material
process chart of two operators. In this layout of machining shop, material
3. Prepare time study observation sheet, flow from right side to left side. The
elemental time data has been collected product flow from input conveyor via 3
by the cumulative method of stop machines to inspection conveyor. For
watch. using product flow using 3 electric crane
4. Then observed time data has been machine. The operation performed by two
converted to basic time by multiplying operators. Job assign to first operator
with the rating factor of worker. perform on centering and turning machine,
a. Basic time = observed time x (rating/ and job assign to second operator on
standard time) threading and doing inspection.
5. Calculation for standard time to added
basic time with allowances which
given the

Fig: Plant layout of Product Finishing Shop

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 Journal of Industrial Mechanics
Volume 2 Issue 1

Table: Prepare time study sheet to every work element (Total no of sheet made 10)
1 Product: Electrode Time study sheet Date :
27/06/16
Operation: loading and turning
machine
Section: PFS Shop Operator: 1
S.N Element Description Cycle time in seconds Averag
o 1 2 3 4 5 6 7 8 9 10 e time
in
second
1 operator move crane (C1) for 7 6 4 7 6 8 5 6 5 4 5.8
loading on turning machine
2 crane move down side with 8 10 8 7 8 9 8 7 9 8 8.2
electrode
3 electrode loading on turning m/c 17 14 16 16 14 15 14 14 16 15 15.1
4 belt open over the electrode 5 6 5 6 6 6 7 7 5 6 5.9
5 crane (C1) move up side and hold 4 6 5 3 4 3 4 5 3 5 4.2
6 operator give command for 4 3 2 3 3 4 3 3 3 2 3
turning
7 turning operation cycle time 28 28 28 28 28 28 28 28 28 28 285
5 5 5 5 5 5 5 5 5 5
Total time 33 33 32 32 32 33 32 32 32 32 327.2
0 0 5 7 6 0 6 7 6 5

Flow process chart for first operator

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 Journal of Industrial Mechanics
Volume 2 Issue 1

Flow process chart for second operator

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Volume 2 Issue 1

Constricting Multiple Activity Chart for Both Operator

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RESULTS the company saved 60 second (1 minute).

From the above various charts it can be The percentage improvement of
concluded that the process can be productivity of the system is 18.9 %. The
improved based on method study, work proposed system can reduction in idle time
procedure and proper utilization of man for man and machine system and work
machine. The machining cycle time will be performed in a systematic manner
reducing from 405 (6.75 minutes) seconds respectively.
to 345 (5.75minutes) second per electrode

Table: Cycle time reduction for first and second operator

410 405
400
390
380 375
370 current
360
350 345 343
340 Proposed
330
320
310
First Operator second Operator

cycle time in seconds

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 Journal of Industrial Mechanics
Volume 2 Issue 1

Table: Idle time reduction for man and machine system

180 155
160 135
140 118
107 112 108
120
100 89
80 59
60 current
40
20 Proposed
0
Man Machine man machine

first operator second operator

Idle time in seconds

CONCLUSION understand performing method and easy to

The time and motion study is effective calculate idle time for man and machine
tools of industrial engineering to give a system. The cycle time reduction through
standard time to perform any process at eliminate unproductive activity. Its result
minimum time. the flow process and is increase productivity of the system.
multiple activity chart help easy to
3. Prathamesh P. Kulkarni, Sagar S.
Future Scope Kshire, Kailas V. Chandratre (Feb 2014)
When preferring paper select some of tools “Productivity improvement through lean
and technique for future work like Work deployment & work study methods”
study techniques are quite expensive to IJRET: International Journal of Research
implement in a small scale industries but this in Engineering and Technology. Volume
method gives better results than any other 3.
technique. These techniques can be useful 4. Mihir B Patel, Prof. Dr. Hemant R.
not only to reduce the cycle time but also in Thakkar, Mr.Rajput (2015) “Reducing
various other departments in industries like Manufacturing Cycle Time of Milk
inventory control, productivity, quality , Tanks by Work Study Technique in
labor work, at various machines in machine Small Scale Fabrication Industry”
shop to get process variation etc. International Journal of Innovative
Research in technology. Volume 04.
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Volume 2 Issue 1

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