4.

FLOW PROCESS CHART

SUMMARY
ACTIVITY

PRESENT

OPERATION

TRANSPORT

DELAY

INSPECTION

STORAGE

TOTAL

13

PROPOSED

SAVINGS

DESCRIPTION

QTY

TIME

DISTANCE

REMARKS

Insertion of jacklift to
Gaylord Pallete

8000

3.36

Gaylord Box to PreForm Loader*

8000

45.09

Loading of Gaylord
Box*

8000

Pre-Form Materials to
Pre-Form Feeder*

8000

28.85

Machine Operation

Pre-Form Materials to
Pre-Form Elevator*

8000

0.27

Machine Operation

Pre-Form to
BlowMax10*

8000

1.61

Machine Operation

Blowing Process*

8000

2.82

Machine Operation

Plastic bottles to
Airveyor

8000

141.04

50

Machine Operation

Bottles of Flatveyor

8000

2.61

2.5

Machine Operation

10

Segregration of
Bottles*

8000

1.23

Machine Operation

11

Palletizing

8000

274.8

Machine Operation

12

Transport to Conveyor

8000

15.7

13

Sealing

8000

249

16.54

Manual Operation
Done by the assistant
operator.
Transport using jack lift
Machine Operation

2.5

Machine Operation
Machine Operation

83

4.2

OBSERVED CYCLE TIME

IDENTIFICATION OF OPERATION: BLOWING PROCESS

OBSERVED BY:
VEJAR, PAULINE O.
SANTOS, KRISTOFFER E.

PRELIMINARY OBSERVATION
OBSERVED TIME (min.)

CYCLE
ELEMENT
DESCRIPTION

10

SUM

AVE

Insertion of Jacklift to Gaylord

Palette

3.36

3.4

3.29

3.28

3.33

3.28

3.32

3.34

3.38

3.35

33.33

3.333

Gaylord Box to Pre-Form

Loader

45.09

45

45.11

45.15

45.06

45.03

45.1

45.13

45.06

45.03

450.76

45.076

Loading of Gaylord Box and to

the Pre-Form Feeder

28.79

28.88

28.8

28.85

28.78

28.81

28.83

28.87

28.85

28.82

288.28

28.828

Pre-Form materials to PreForm Elevator

0.2

0.25

0.27

0.29

0.23

0.19

0.21

0.25

0.17

0.2

2.26

0.226

Pre-Form to BloMax10

1.7

1.61

1.59

1.68

1.63

1.6

1.61

1.57

1.63

1.6

16.22

1.622

Blowing Process

2.82

2.82

2.82

2.82

2.82

2.82

2.82

2.82

2.82

2.82

28.2

2.82

Plastic Bottles to Airveyor

141.04

141.1

141

141.08

141.08

141.05

141.04

141.03

141.06

141.02

1410.5

141.05

Plastic Bottles to Flatveyor

2.61

2.63

2.56

2.83

2.56

2.77

2.64

2.89

2.71

2.54

26.74

2.674

Segregration of Bottles

1.23

1.2

1.1

1.35

1.37

1.28

1.19

1.08

1.02

1.33

12.15

1.215

196.8

201.1

203.21

202.35

198.5

203.64

205.5

201.9

197.7

197.69

2008.39

200.839
15.778
194.867

10

Palletizing

11

Transport to Conveyor

15.7

16.32

16.14

15.66

15.98

16.2

15.75

14.94

16.85

14.24

157.78

12

Sealing

189

188.69

181.41

205.03

203.75

203.97

201.16

194.02

193.28

188.36

1948.67

84

4.3

WORK SAMPLING

USEABLE NUMBER
AS SELECTED FROM
THE
RANDOM TABLE

ARRANGED
IN

TIME

NUMERICAL
ORDER

OF
OBSERVATION

26
45
38
0
4
9
15
25
16
28
32
1
8
14
17
33
34
40
16
8
2
5
26
9
30

0
1
2
4
5
8
8
9
9
14
15
16
16
17
25
26
26
28
30
32
33
34
38
40
45

6:00
6:01
6:03
6:07
6:12
6:20
6:28
6:37
6:46
7:00
7:15
7:31
7:47
8:04
8:29
8:55
9:21
9:49
10:19
10:51
11:24
11:58
12:36
1:16
2:01

Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Working
Idle
Working
Working

COMPUTATION
% IDLE TIME =
=
% IDLE TIME =

No. of Idle Time

Total No. of Observation

100

1/25 x 100
4%

% PRODUCTIVE TIME

No. of Productive Time

Total No. of Observation

x 100

85

=
10/20 x 100
& Productive Time
=
96%
Determining the sample size using Statistical Method:

pq
n

=
Where:

standard error of production

p
=
percentage of idle
q
=
percentage of working time
n
=
no. of observation sample size.
% Idle Time = 4.00%
% Productive Time = 96%
Marginal Error
=
10
A 95% confidence level
1.96

= 10

=5

pq
n

(4) x(96)
52

n
=
15.36
n
=
15 observations
n
=
15-10
n
=
Therefore, 5 more observations are needed in order to establish
a standard time for the whole cycle of the Blowing Process.

4.4

FINAL OBSERVATION
CYCLE

ELEMENT DESCRIPTION

SUMMARY

AVE

PR

NT

AF

ST

3.63

3.4

3.39

3.59

3.33

3.38

0.85

2.87

0.01

2.90

45.09

45

45.11

45.15

45.06

45.08

0.82

36.96

0.01

37.34

28.79

28.88

28.8

28.85

28.78

28.83

0.90

25.94

0.01

26.20

Insertion of Jacklift to Gaylord Palette

2
3

Gaylord Box to Pre-Form Loader

Loading of Gaylord Box and to the Pre-Form
Feeder

Pre-Form materials to Pre-Form Elevator

0.2

0.25

0.27

0.29

0.23

0.23

0.92

0.21

0.01

0.22

Pre-Form to BloMax10

1.7

1.61

1.59

1.68

1.63

1.63

0.95

1.55

0.01

1.56

Blowing Process

2.82

2.82

2.82

2.82

2.82

2.82

0.98

2.76

0.005

2.78

Plastic Bottles to Airveyor

141.04

141.1

141

141.08

141.08

141.05

0.95

134.00

0.01

135.35

Plastic Bottles to Flatveyor

2.61

2.63

2.56

2.83

2.56

2.66

0.90

2.40

0.01

2.42

Segregration of Bottles

1.23

1.2

1.1

1.35

1.37

1.23

0.85

1.04

0.01

1.05

196.8

201.1

203.21

202.35

198.5

200.69

0.80

160.55

0.01

162.17

10

Palletizing

11

Transport to Conveyor

15.7

16.32

16.14

15.66

15.98

15.84

0.82

12.99

0.01

13.12

12

Sealing

189

188.69

181.41

205.03

203.75

194.44

0.85

165.27

0.01

166.94

TOTAL

546.55

552.06

87

4.5

COMPUTATION OF NORMAL TIME

NORMAL TIME = AVE. OF OBSERVED TIME x PERFORMANCE RATING
=
637.87 x 0.88
=
561.33 sec. or 9.36 mins. For a PET Bottle at the
blowing Process
4.6
COMPUTATION FOR THE STANDARD TIME
STANDARD TIME
=
NORMAL TIME/1-ALLOWANCE
=
561.33/(1-0.115)
=
634.27 sec. OR 10.57 mins for a PET Bottle at
the Blowing Process
4.7
ALLOWANCES
The proponents assumed only a 1% allowance factor since the whole cycle
involves machines, thus, having only Machine Allowance as a factor, ergo, assigning
it to 1% except for the blowing process which they gave 0.5% since its machine has
minimal capability of having less delays.