PRODUCTIVITY IMPROVEMENT USING WORK STUDY

TECHNIQUES AT ASSEMBLY WORKSTATION

Guided by: Presented by:

Prof. Ramu Rajendran
Asst.Professor.
Vishal P
Department of Mechanical TVE20IE060
Engg S7 IE

Department of Mechanical Engineering

College of Engineering Trivandrum
Contents
• Abstract
• Introduction
• Literature review
• Motivation
• Objectives
• Methodology
• Results
• Conclusion
• Reference
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 ABSTRACT
Work study, which includes time study and motion study, is a systematic and structured approach
used in industrial engineering and management to improve the productivity in organisations. The
system considered for this work is the unit for assembly of alternators at the Vaibhav Vidyuth
Company,Hubli. The assembly area had significant inefficiencies,prompting the choice for work
study.
This work aims at reducing ineffective time with the operations by eliminating unwanted motions
involved. Alternate method for performing job is also suggested. The methodology involves memo
motion study and video motion study techniques. Tools like the Work Pro software and Video Work
Study techniques, these tools enable to gain comprehensive insights into the assembly area's
operations. The work study procedure involves defining objectives, selecting and recording data,
examining and evaluating the current work process, developing and defining specific improvements,
and subsequently installing and monitoring these changes.
As a result of this approach, productivity is improved. A standardized method is established for
assembly workstations.This is found to reduce inefficient time, promote smoother component flow
and reduce worker fatigue.
Key words : Productivity, Work Study, Cycle Time, Motion Study, Work Pro, Video Work Study.

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Introduction
• In the rapidly evolving industrial landscape, it is vital to optimize
productivity and efficiency.

• The objective of the seminar is to explore Work Study techniques at

Vaibhav Vidyut Company Pvt. Ltd., Hubli.

• Work study includes Time or Motion studies in order to improve the

productivity.

• Video analysis and software tools are used to conduct the work study at
the assembly processes.
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Objectives
● To Analyze Existing Work Processes

● To Implement Work Study Techniques

● To Enhance Component Flow by Suggesting New Methods

● To Calculate the Productivity improvement after implementation of

Proposed method using WorkPro software.

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 Literature review
Name
Workstudy Ind. and Prod. Engg.
Dept, BVB College of
Engineering, Hubli, Karnataka.
(n.d.). Productivity Improvement
by Workstudy. Journal of Work
Study,
Ghodki, A. K. (2021).
Productivity Improvement in
Manufacturing Industry Using
Work Study Technique.
International Journal of Science,
Engineering and Technology,
9(1).
Remarks
Aims to improve productivity at the
assembly workstation of Vaibhav
Vidyut Company Private Limited,
Hubli.
The study illustrated in this work
does measure the work content and
cycle times but also helps in
analyzing the different elements
consuming non value added time.
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Motivation
• Need to boost assembly workstation productivity.

• Driven by intensified market competition and cost-efficiency demands.

• Work study techniques hold promise: shorter cycle times, reduced

worker fatigue, and streamlined assembly methods.

• Research provides practical solutions for enhancing performance in

similar manufacturing settings.

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 Meaning of Work Study

● Work study is an important management tool to achieve higher

productivity

● International Labor Organization (ILO) defines work study as the

technique of method study and work measurement employed to
ensure the best possible use of human and material resources .

● It is classified into Method study and Time study which are used to
examine people's work and indicate the factors which affect
efficiency.

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 Video Workstudy
• The Economical, effective, and fast, Video Work Study, facilitated
by Work Study Professional software.

• Initially we are going to work manually by using traditional

methods, such as 2 hand process chart, etc.

• Then we use the software to analyse and propose the better ways
of doing the job or operations.

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 Procedure of Video Workstudy

• List of Equipments :
1. Camera of model nikon 1-120 with a specification of 600 * 820
pixels.
2. Tripod
• The tripod was placed at the right place with the camera and the
video was taken.
• The analysis of the video was done by the work pro software.
• The video was further divided into operations, process and activities.
value added activity, non-value added activity, required non value ad
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 Fig 4. Alternator

Fig 3. Workpro Software Interface

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Analysis of existing method:

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Discussion on the analysis
After the analysis of the video using work-pro software the
following are the facts examined:
• The transportation involved in the assembly section is 34.50%.
• The movement of the worker at the assembly section is more.
• The worker goes each time to the baking section to get the magnetic
frame.
• The delay involved in the assembly section is 8.5% .
Hence it can be concluded that the Assembly section is the Bottleneck.

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 :
Proposed Methods at Assembly Workstation
• Reorganize Workstations: Redesign the layout of the assembly area to
minimize worker movement. Place tools, equipment, and materials closer to
the assembly stations.
• Kanban System: Implement a Kanban system to ensure a smooth flow of
materials and parts to the assembly line, reducing the need for workers to
fetch materials themselves.
• Standard Work Instructions: Develop clear and concise standard operating
procedures (SOPs) for assembly tasks. This will reduce errors and make it
easier for workers to perform their tasks.
• Cross-Train Workers: Cross-train assembly workers to perform multiple
tasks. This can minimize the need for workers to travel to other sections.

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Flow Analysis Chart after Proposed model

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 Results
Productivity by Present method:
• Working hour of one operator =8 hours=480 minutes.
• Present productivity For one model of KGA- 108 alternator it takes=74
minutes
• In a day the worker assembles 6 alternators
• Existing productivity:
10 workers *6 alternators=60 alternators

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 Productivity by Proposed Method
( Based on the Data Provided by the Workpro Software )
• For one model of KGA-108 alternator it takes=58 minutes
• In a day the worker can assemble-8 alternators .
• Hence there is productivity improvement from 6 alternators per day
per workers to 8 alternators per day per worker.
• The productivity by proposed method is:
10 workers *8 alternators=80 alternators .
• So productivity improvement per day at assembly section is 20
alternators.

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Conclusion
• The Work study techniques enhance operator productivity and increase
component production.

• Establish the standard performance methods and standard cycle time

involved

• Additional benefits: Improved work layout, reduced cycle time, and

reduced worker fatigue by eliminating unnecessary motions.

• Overall, work study proves profitable and beneficial for the organization.

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References
1. Workstudy Ind. and Prod. Engg. Dept, BVB College of Engineering, Hubli,
Karnataka. (n.d.). Productivity Improvement by Workstudy. Journal of Work
Study,
2. International Labour Office. (1992). Introduction to Work Study (4th ed.).
International Organisation.
3. Dalela, S. (1983). A Textbook of Work Study (3rd ed.). Standard Publishers.
4. Work Study India. (n.d.). Work Study Programs.
http://www.workstudy.in/workpro.html
5. VVCPL. (n.d.). Introduction to Work Study. http://vvcpl.co.in/introduction.html
6. Ghodki, A. K. (2021). Productivity Improvement in Manufacturing
Industry Using Work Study Technique. International Journal of
Science, Engineering and Technology, 9(1).
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THANK YOU

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