ASSOCIATE FATIGUE REDUCTION AT

DOOR INSTALLATION PROCESS

DEPARTMENT:
ASSEMBLY FINAL (AF)
 THE TEAM
GROUP MEMBERS:

MUHAMMAD HAZIQ SAJJAD TAHA ANEES SHAYAN

RAFI

INCHARGE: SUPERVISOR:
MR. QAISER NADEEM SHAHBAZ AHMANAT
 AF LAYOUT
PA Fuel
Pipe

Rout

VQ
INT
Door
Installation
Shed
Chass PC store
EXT & comp Office Meeting Room

Chass
Office
CURRENT SITUATION
 REASON FOR TOPIC SELECTION

• FATIGUE REDUCTION IS MOST IMPORTANT FOR IMPROVED QUALITY OF THE

PRODUCTS
• ACCOUNTS FOR HEALTH OF THE ASSOCIATES
• FATIGUE REMOVAL RESULTS IN QUICK PRODUCTION
 PROBLEM IDENTIFICATION

• DEVISING A METHOD THAT REDUCES ASSOCIATE FATIGUE

• THE NEW PROPOSED IDEA MUST BE IN LIMITS OF

1. AREA OF PRODUCTION LINE
2. BUDGET
3. NUMBER OF ASSOCIATES REQUIRED
 Cause and Effect Diagram

Method
Manpower
Tact time
requirement
Lack of skill should be Proposing an
met idea to reduce
Old and associate
Lack of sleep traditional
method fatigue
Negligence

Complicated
Old and weary
layout
trolleys
The Scratches
Door sub- conveyor on doors
assembly is belt
far away Heavy (35 kg) doors

Layout Material and

Measurement
Increase
Brain Storming
Workforce
 IDEA 1
INCREASE WORKFORCE

• NUMBER OF WORKERS INSTALLING THE DOORS TO BE

INCREASED FROM 4 TO 5 OR 6 SO THAT THE WORK LOAD ON
EACH WORKER IS DIVIDED WHICH MEANS LESS FATIGUE
 IDEA 1

Area Marking Reason

Cost NG 2 more associates must be added per shift with each
consuming another 25k-28k per month

X
Quality of work OK Less fatigue on each associate would mean greater
quality

Management Improvement Management of an additional work force might be a

problem for the senior members IDEA
Safety OK
REJECTED
Each additional associate would have his own safety
measures

Environment NG Congested workstation due to increase in associates

REJECTION OF IDEA 1

IDEA 1 WAS REJECTED BECAUSE:

• IT WAS TOO COSTLY TO ADD 4 MORE ASSOCIATES IN THE WHOLE DAY (2

SHIFTS). THIS WOULD COST ADDITIONAL RS 650,000 ANNUALLY

• IT WOULD LEAD TO A MESSY AND CONGESTED WORK STATION WHICH MAY

ADD TO MENTAL FATIGUE
Additional
Brain Storming
Trolleys
 IDEA 2

ADDITIONAL TROLLEYS

• USE OF 2 TROLLEYS INSTEAD OF A SINGLE TROLLEY. RIGHT SIDE

DOOR ON ONE TROLLEY, LEFT SIDE DOORS ON THE OTHER ONE.
THIS REDUCES THE TIME TO INSTALL THE DOOR AND CAUSES
LESS FATIGUE FOR THE MEN PULLING THE TROLLEYS TO THE
TARGETED PLACE.
 IDEA 2

Area Marking Reason

Cost OK Creation of new set of trolleys from original ones

X
Quality of work OK Improved quality because of lessening in the load carried by
the associate

IDEA
Management OK Less fatigue due to not having to carry doors
REJECTED
Safety OK Handling of trolleys

Environment NG Preparation of tool kit holder result in difficulty of

delivering right side doors at right side.
REJECTION OF IDEA 2

IDEA 2 WAS REJECTED BECAUSE:

• THERE WAS RESTRICTION IN DELIVERING THE DOORS ON THE RIGHT SIDE DUE
TO THE MOVING CONVEYOR BELT

• OTHER JOBS SUCH AS PREPARATION OF TOOL KITS WERE IN THE PATH OF THE
TROLLEY
Sub-assembly
Brain Storming
Doors
 IDEA 3

SUB-ASSEMBLY OF DOORS

• THE SUB-ASSEMBLY OF THE DOOR CAN BE MADE NEAR TO THE

DOOR INSTALLATION AREA. THIS WOULD REQUIRE LESSER
EFFORT SINCE THE DISTANCE TO DRAG THE DOORS ON THE
TROLLEYS IS REDUCED
 IDEA 3

Area Marking Reason

Cost NG Whole set up of the work station will have to be changed

X
Quality of work Improvement Improved quality because the associate has to carry the trolley
for shorter distance

Management OK IDEA
Easy management, all door subassembly is near to the main
assembly
REJECTED
Safety OK More safety of the associates

Environment OK A less messy environment

REJECTION OF IDEA 3

IDEA 3 WAS REJECTED BECAUSE:

• IT WAS HIGHLY IMPRACTICAL AND TOO COSTLY TO CHANGE THE WHOLE

LAYOUT OF THE AF FOR REDUCING FATIGUE OF THE ASSOCIATES ONLY
Electric-Chain Air Hoist
Brain Storming
with end effector
 IDEA 4

ELECTRIC-CHAIN AIR HOIST WITH END EFFECTOR

• MACHINE AIDED HOIST TO MOVE THE DOORS RATHER THE

WORKERS CARRYING THE DOORS THEMSELVES. THIS REDUCES
MAN EFFORT AND THIS CAUSES LESS FATIGUE
 IDEA 4

Area Marking Reason

Cost Improvement A little costly but very efficient

Quality of work OK Excellent quality of work can be achieved with very little
fatigue of the associates

Management OK Easy management, only one man is required to inspect the IDEA
hoist regularly
SELECTED
Safety Improvement Very safe as this is a small air hoist with less electricity
consumption

Environment OK Clean environment since everything is electrically controlled

 DIMENSIONS
Dimension Value

Car height 1.43 m

Total height from U-beam 2.69 m

Length of door 1.07 m

Width of door 1.10 m

Distance of carrying the door 4.85 m

Max time for carrying the door 14 sec

  4. 85 𝑚 𝑚
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 𝑚𝑎𝑛𝑢𝑎𝑙 𝑐𝑎𝑟𝑟𝑦𝑖𝑛𝑔 𝑜𝑓 𝑡h𝑒 𝑑𝑜𝑜𝑟 = =34.6 = 𝟐𝟎. 𝟖𝟏 𝒎 / 𝒎𝒊𝒏
14 𝑠𝑒𝑐 𝑠
 DRAWBACKS

• SINCE THE DISTANCE BETWEEN U-BEAM RAILINGS AND TOP THE THE CAR IS
TOO LESS FOR THE DOOR TO BE CARRIED ABOVE THE CAR BODY.

• IT IS NECESSARY TO HAVE A MECHANISM THAT HOLDS AND ROTATES THE DOOR

AT SOME ANGLE SO THAT EASY CARRYING OF THE DOOR IS POSSIBLE FOR THE
GIVEN DISTANCE
Air Hoist

Actual Mechanism
End Effector
 AIR HOIST SPECIFICATIONS

Brand Name TXK

Model Number SSDHL01-01
Certification CE ISO SGS
Place of Origin China(JIANGSU)
Load of chain Japan chain
Protection Grade M5
Lifting speed 6.6 m/min
Travelling speed 21m/min
Lifting Motor 1.5 kW
 TIME AND COST FOR INSTALLATION
Process Distance (m) Speed (m/s) Time (s)
Lifting ↑ 1.43 + 0.5 = 1.73 0.11 0.1903
Travelling → 4.85 + 0.5 = 5.35 0.35 1.8725
Descending ↓ 1.43 + 0.5 = 1.73 0.11 0.1903
Time for rotating the door 2 x 6 = 12
twice
TOTAL 14.25 sec

• Time for installation with air hoist is 14.25 sec which is almost equal to that by manual
installation of approx. 14 sec

• The approximate cost for the whole set up is USD 1500