CHAPTER I

DATA COLLECTION AND PROCESSING

1.1 Stopwatch Time Study

Stopwatch is one method in Time Study. The objective of this method is to
measure how long does the operator complete the work assigned. Stopwatch
will be implemented to gain accurate (until decimals, to recover until 0.01
minute) in understanding the time study.

The step of the Stopwatch Time Study is as follows :

a. Analyze the job to establish desired quality
b. Identify key operation that will be measured
c. Improve the procedure from method study department
d. Plot the resource and describe the goal to the employee and supervisor
e. Explain the improved working procedure to the worker
f. Break operation to separate constant and variable elements
g. Observe and record the time required
h. Determine number of cycle to be timed in order to find average or
representative time
i. Rate performance of worker during observation
j. Calculate normal time by using performance rating factor
k. Add allowance of rest, personal and special to the normal time to obtain
standard or allowed time
l. Standard time determined by sum up the normal and allowance time (N,
n.d.)

1.2 Initial Method

The initial condition of the practicum where 10 products of souvenir box

was manufactured, is performed by five Departments, which each work element
will be explained below. The sub-subchapters will also provide the data
collection, recapitulation, and processing of the actual operation time from the
practicum.

1
1.2.1 Departementalization and Work Flow of Initial Method
Here is the initial method’s Departementalization that shows operations
and activities in each Departement.

Table 1 Departement 1

Departement 1: Pattern Drawing and Cutting

Operation 1: Draw patterns of the souvenir box

Working Element 1: Draw basic patterns of souvenir box on paperboard

Working Element 2: Mark part of the patterns that will be folded

Operation 2: Draw pattern of the mica that will cover the souvenir box

Working Element 1: Draw basic patterns of mica cover

Working Element 2: Mark part of the patterns that will be folded

Operation 3: Patterns Cutting

Working Element 1: Cut patterns of souvenir box on the part that have been
marked

Working Element 2: Cut patterns of mica on the part that have been marked

Allowance

Material Handling

Table 2 Departement 2

Departement 2: Souvenir Box Assembling

Waiting

Operation 4: Fold the patterns of souvenir box

Working Element 1: Fold the top side of the souvenir box pattern that have been
marked

Working Element 2: Fold the side part of souvenir box patterns that have been

2
Departement 2: Souvenir Box Assembling

marked

Operation 5: Stick souvenir box with glue

Working Element 1: Stick the top of right and left side of the patterns

Working Element 2: Fold the top of the patterns that is longer than the others part
to the inside

Working Element 3: Stick the top of fastening part to the inside

Allowance

Material Handling

Table 3 Departement 3

Departement 3: Pen Assembling

Waiting

Operation 6: Pen Assembling

Working Element 1: Assembly the lower part and body part

Working Element 2: Put the content of the pen into the body part

Working Element 3: Close the upper part of the pen

Working Element 4: Close the lower part of the pen

Allowance

Material Handling

Table 4 Departement 4
Departement 4: Pen and Souvenir Box Assembling

3
Waiting

Operation 7: Put pen inside the souvenir box

Operation 8: Cover souvenir box with mica

Working Element 1: Adjust mica with souvenir box

Working Element 2: Fold the patterns of mica on the part that have been marked

Working Element 3: Cut the part of mica that is not appropriate with souvenir box

Working Element 4: Stick the mica with souvenir box using glue

Allowance

Material Handling

Table 5 Departement 5

Departement 5: Finishing

Waiting

Operation 9: Inspect the souvenir box

Inspection

Allowance

Material Handling

Here is the workflow process for assembling souvenir box based on the
Departementization above.

1.2.2 Data Recapitulation of Initial Method

Here is the data recapitulation of operation time from each Departement.

4
Departement 1: Pattern Drawing

Table 6 Data Recapitulation of Departement 1

Departemen
t 1: Pattern Averag
Drawing 1 2 3 4 5 6 7 8 9 10 e
and Cutting

Operation 1: Draw patterns of the souvenir box

Working
Element 1:
Draw basic
patterns of 109 87 67 70 76 35 41 66 56 22 62.9
souvenir box
on
paperboard

Working
Element 2:
Mark part of
51 39 94 59 17 4 2 33 47 32 37.8
the patterns
that will be
folded

Operation 2: Draw pattern of the mica that will cover the souvenir box

Working
Element 1:
Draw basic 80 75 35 84 101 128 33 22 45 62 66.5
patterns of
mica cover

Working
Element 2:
Mark part of
29 17 17 11 16 12 57 15 29 30 23.3
the patterns
that will be
folded

Operation 3: Patterns Cutting

5
Departemen
t 1: Pattern Averag
Drawing 1 2 3 4 5 6 7 8 9 10 e
and Cutting

Working
Element 1:
Cut patterns
of souvenir
68 54 61 48 57 49 46 45 80 62 57
box on the
part that
have been
marked

Working
Element 2:
Cut patterns
of mica on 34 21 23 14 35 38 21 19 30 23 25.8
the part that
have been
marked

38.0 38.6 30.

Allowance 48.23 37.18 39.26 34.58 26 26 37.31 35.529
9 1 03

Material
6 6 8 7 7 5 4 6 5 6 6
Handling

Table 7 Data Recapitulation of Departement 2

Departeme
nt 2:
Ave
Souvenir
rage
Box 1 2 3 4 5 6 7 8 9 10
Assembling
Waiting 445.7 208.3 214.5 213.9 219.9 152.7 395.1 176.1 244.
162.6 224
Time 6 2 3 2 2 4 4 1 83
Operation 4: Fold the patterns of souvenir box

6
Departeme
nt 2:
Ave
Souvenir
rage
Box 1 2 3 4 5 6 7 8 9 10
Assembling
Working
element 1:
Fold the top
of the 27.7
souvenir box 21.74 15.3 43.42 31.11 42.17 12.77 15.09 8.69 19.83 15.44 5
pattern that
have been
marked
Working
element 2:
Fold the side
part of 19.1
souvenir box 22.56 26.92 25.36 22.17 9.86 8.19 6.01 7.04 9.73 15.89 8
patterns that
have been
marked
Operation 5: Stick the souvenir box with glue
Working
element 1:
Stick the top 25.3
20.58 27.86 34.08 28.69 24.15 16.77 18.89 18.52 19.63 18.36
of right and 6
left side of
the patterns

Working
element 2:
Fold the top
of the patters
6.62 7.8 7.98 9.69 7.6 6.42 18.89 18.52 19.63 18.36 7.69
that longer
than the
others part
to the inside
Working
element 3:
Stick the top 19.4
14.26 21.02 27.97 20.61 19.37 13.22 11.72 18.05 10.96 18.83
of fastening 1
part to the
inside

7
Departeme
nt 2:
Ave
Souvenir
rage
Box 1 2 3 4 5 6 7 8 9 10
Assembling
11.14 12.85 18.04 14.59 13.40 7.458 9.206 10.37 11.29 11.7
Allowance 9.178
88 7 53 51 95 1 6 14 44 6
Material
2.69 3.72 3.74 3.29 3.78 2.76 2.37 2.37 2.37 2.37 3.33
Handling

Table 8 Data Recapitulation of Departement 3

Departemen
Ave
t 3 : Pen
rage
Assembling 1 2 3 4 5 6 7 8 9 10
Waiting 464 378 452 419 416 345 285 278 417 336 379
Operation 6: Put Assembling
Working
Element 1 :
Assembly 5.21
2.6 6 4.4 10.8 5.1 4.3 4.07 4.1 4 6.8
the lower 7
part and
body part
Working
Element 2 :
Put the 4.74
2.3 11 4.9 3.3 3.3 3.5 3.2 3.1 3.9 8.97
content of 7
pen into the
body part
Working
Element 3
5.90
:Close the 2.2 3.4 17.1 6.01 3.6 3.5 3.9 2.9 3.9 12.56
7
upper part of
the pen
Working
Element 4 :
3.49
Close the 2.4 3.9 3.5 2.4 2.8 1.27 1.9 2.1 3.9 10.8
7
lower part of
the pen
2.926 1.634 1.699 5.086 2.51
Allowance 1.235 3.159 3.887 1.924 1.586 2.041
3 1 1 9 784

8
Departemen
Ave
t 3 : Pen
Assembling 1 2 3 4 5 6 7 8 9 10 rage
Material
5.2 8 6.5 3.5 6 4.5 3.4 4.8 3.6 5.6 5.11
Handling

Table 9 Data Recapitulation of Departement 4

Departement 4
: Pen and
Average
Souvenir Box 1 2 3 4 5 6 7 8 9 10
Assembling
Waiting 481 500 506 449 446 369 307 300 444 474 498.92
Operation 7 : Put pen inside the souvenir box
Operation 8 : Cover souvenir box with mica
Working
Element 1 :
Adjust mica
with souvenir
box 6.32 4.54 2.23 5.19 8.11 8.31 5.23 4.5 5.46 9.07 5.568
Working
Element 2 :
Fold the
patterns of mica
on the part that
have been
marked 19.6 29.1 22.3 15.5 21.2 20.2 23.4 21 15.3 12 24.596
Working
Element 3 : Cut
the part of mica
that isn’t
appropriate with
souvenir box 0 26 19 0 0 0 0 0 0 0 3.4615
Working
Element 4 :
Stick the mica
with souvenir
box using glue 29.7 29.3 31.4 35.2 37.9 27.2 29.2 18 19.1 27.1 28.279
Allowance 7.23 11.6 9.74 7.26 8.74 7.24 7.52 5.6 5.18 6.26 8.0477
Material
Handling 2.24 0.67 3.56 1.2 0.89 0.89 1.24 1.4 3.21 2.17 1.75

9
Table 10 Data Recapitulation of Departement 5

Departeme
Avera
nt 5 :
ge
Finishing 2 3 4 1 5 6 7 8 9 10
526.3 513.9 526.9 432.6 375.3 352,7 493. 552.6
Waiting 557 595.7 35,734
1 1 4 8 7 71 04 6
Operation 9 : Inspect the Souvenir Box
Inspection 7.52 8.23 8.46 7.44 6.91 6.41 5.49 5.84 4.86 11.9 7.306
0.977 1.069 1.099 0.967 0.898 0.833 0.713 0.75 0.631
Allowance 1.547 0.9498
6 9 8 2 3 3 7 92 8
Material
0.78 1.73 1.25 1.23 0.81 0.55 1.11 1.14 0.51 0.85 0.996
Handling

1.2.3 Data Uniformity Test of Initial Method

In this sub-sub chapter will be displayed the result of data uniformity test using
Minitab. In this uniformity test the iteration is done 2 times to eliminate the outlier
data.

Departement 1: Pattern Drawing 125

I Chart of Operation 1 Work Element 2

UCL=115,2

and Cutting 100

75
Individual Value

50
_
X=37,8

Operation 1 Work Element 1 25

-25

I Chart of Operation 1 Work Element 1 LCL=-39,6

160 -50
1 2 3 4 5 6 7 8 9 10
UCL=143,6 Observation

120
Individual Value

80
_
X=62,9

40

LCL=-17,8

1 2 3 4 5 6
Observation
7 8 9 10 Operation 2 Work Element 1
I Chart of Operation 2 Work Element 1
200

Operation 1 Work Element 2 UCL=177,0

150
Individual Value

100

_
X=66,5
50

LCL=-44,0
-50
1 2 3 4 5 6 7 8 9 10
Observation

10
 Operation 2 Work Element 2 Operation Work Element 2

I Chart of Operation 2 Work Element 2 I Chart of Operation 3 Work Element 2

70 50
UCL=47,96
UCL=63,49
60

40
50

40

Individual Value
Individual Value

30
30 _
_ X=25,8
X=23,3
20
20
10

0
10

-10
LCL=3,64
LCL=-16,89
-20 0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Observation Observation

Operation 3 Work Element 1 Material Handling

I Chart of Operation 3 Work Element 1 I Chart of Material Handling

10
UCL=81,23
80
UCL=9,251
9

70 8

Individual Value
Individual Value

7
60 _ _
X=57 6 X=6

50 5

4
40
3
LCL=2,749
LCL=32,77
30 2
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Observation Observation

Departement 2: Souvenir Box Operation 5 Work Element 1

Assembly

Operation 4 Work Element 1

Operation 5 Work Element 2

Operation 4 Work Element 2

Operation 5 Work Element 3

11
Matetrial Handling
Figure 0.2 1st Iteration of Work
Element 1

Departement 3 : Pen Assembling

Figure 0.3 1st Iteration of Work
Operation 6 : Pen Assembling Element 2

Figure 0. 1 1st Iteration of Waiting

Time Figure 0.4 1st Iteration of Work
Element 3

12
Figure 0.5 1st Iteration of Material Figure 0.6 1st Iteration of Working
Handling Element 4

Departement 4 : Pen and Souvenir

Box Assembling

Operation 8 : Cover Souvenir Box

with Mica

Figure 0.7 1st Iteration of Waiting Time Figure 0.8 2nd Iteration of Waiting
Time

Figure 0.9 1st Iteration of Work

Element 1

13
Figure 0.10 1st Iteration of Work Figure 0.13 1st Iteration of Working
Element 2 Element 4

Figure 0.11 1st Iteration of Working Figure 0.14 1st Iteration of Material
Element 3 Handling

Figure 0.12 2nd Iteration of Working

Element 3

14
Departement 5 : Finishing
Operation 9 : Inspect the souvenir
box

Figure 3. Chart of Working Element

2 Iteration 2

Figure 1. Chart of Working Element

1 Iteration 1

Figure 4. Chart of Working Element

3 Iteration

Figure 2. Chart of Working Element

2 Iteration 1

Figure 5. Chart of Material Handling

Iteration

1.2.4 Uniformity Test Data Recapitulation of Initial Method

15
After the data has been tested by Minitab software, outlier data in first iteration is
highlited with yellow color and in second iteration is highlighted with green color.

Departement 1: Pattern Drawing

Table 11 Uniformity Test Data Recapitulation of Departement 1

Departement 1 :
Pattern Drawing Average
1 2 3 4 5 6 7 8 9 10
and Cutting

Operation 1: Draw pattern of the souvenir box

Working Element 1
: Draw basic pattern
87 67 70 35 41 66 22 109 76 56 62,9
of souvenir box in
paperboard

Working Element 2
: Mark part of the
39 94 59 4 2 33 32 51 17 47 37,8
pattern that will be
folded

Operation 2: Draw pattern of the mica that will cover the souvenir box

Working Element 1
: Draw basic pattern
of the mica that will 75 35 84 128 33 22 62 80 101 45 66,5
cover the souvenir
box

Working Element 2
: Mark part of the
17 17 11 12 57 15 30 29 16 29 23,3
pattern that will be
folded

Operation 3: Patterns Cutting

16
Departement 1 :
Pattern Drawing Average
1 2 3 4 5 6 7 8 9 10
and Cutting

Working Element 1
: Cut pattern of
54 61 48 49 46 45 62 68 57 80 57
souvenir box that
has been marked

Working Element 2
: Cut pattern of
mica cover on the 21 23 14 38 21 19 23 34 35 30 25,8
part that have been
marked

Allowance

Material Handling 6 8 7 5 4 6 6 6 7 5 6

Departement 2: Souvenir Box Assembling

Table 12 Uniformity Test Data Recapitulation of Departement 2

Departem
ent 2:
Ave
Souvenir
rag
Box
1 2 3 4 5 6 7 8 9 10 e
Assemblin
g
44 21
208 162. 213. 223. 219. 152. 395. 176.
Waiting 5.7 4.
Time .32 6 92 83 92 74 14 11
6 53

Operation 4: Fold the patterns of souvenir box

17
 Departem
ent 2:
Ave
Souvenir
rag
Box
1 2 3 4 5 6 7 8 9 10 e
Assemblin
g
Working
element 1:
Fold the 43
top of the 21. 15. 31.1 42.1 12.7 15.0 19.8 15.4 22.6
souvenir .4 8.69
74 3 1 7 7 9 3 4 02
box pattern 2
that have
been
marked
Working
element 2:
Fold the
side part of 25
22. 26. 22.1 15.8 10.1
souvenir .3 9.86 8.19 6.01 7.04 9.73
box 56 92 7 9 45
6
patterns
that have
been
marked
Operation 5: Stick the souvenir box with glue
Working
element 1: 34
Stick the 20. 27. 28.6 24.1 16.7 18.8 18.5 19.6 18.3 22.7
top of right .0
58 86 9 5 7 9 2 3 6 53
and left 8
side of the
patterns
Working
element 2:
Fold the
top of the 6.6 7. 7.42
patters that 7.8 9.69 7.6 6.42 6.9 8.79 7.25 5.2
2 98 5
longer than
the others
part to the
inside

18
 Departem
ent 2:
Ave
Souvenir
rag
Box
1 2 3 4 5 6 7 8 9 10 e
Assemblin
g
Working
element 3: 27
Stick the 14. 21. 20.6 19.3 13.2 11.7 18.0 10.9 18.8 17.6
.9
top of 26 02 1 7 2 2 5 6 3 01
fastening 7
part to the
inside

Allowance
2.6 3.7 3.
Material 3.29 3.78 2.76 2.37 2.29 3.21 2.45
Handling 9 2 74

Departement 3: Pen Assembling

Table 13 Uniformity Test Data Recapitulation of Departement 3

Departeme
nt 3 : Pen Averag
Assemblin e
g 1 2 3 4 5 6 7 8 9 10
27
Waiting 464 378 452 419 416 345 285 417 336 379
8
Operation 6: Put Assembling
Working
Element 1
: Assembly 10. 4.0
2.6 6 4.4 5.1 4.3 4.1 4 6.8 5.217
the lower 8 7
part and
body part
Working
Element 2
: Put the
content of 2.3 11 4.9 3.3 3.3 3.5 3.2 3.1 3.9 8.97 4.747
pen into
the body
part

19
Departeme
nt 3 : Pen Averag
Assemblin e
g 1 2 3 4 5 6 7 8 9 10

Working
Element 3
17. 6.0 12.5
:Close the 2.2 3.4 3.6 3.5 3.9 2.9 3.9 5.907
1 1 6
upper part
of the pen

Working
Element 4
1.2
: Close the 2.4 3.9 3.5 2.4 2.8 1.9 2.1 3.9 10.8 3.497
7
lower part
of the pen

Allowance 7.2 11. 9.7 7.2 8.7 7.2 7.5 5.1

3 6 4 6 4 4 2 5.6 8 6.26 8.0477
Material
5.2 8 6.5 3.5 6 4.5 3.4 4.8 3.6 5.6 5.11
Handling

Departement 4: Pen and Souvenir Box Assembling

Table 14 Uniformity Test Data Recapitulation of Departement 4

Departe
ment 4 :
Pen and
Aver
Souveni
age
r Box
Assemb
1 2 3 4 5 6 7 8 9 10
ling
50 30 335.
Waiting 481 500 449 446 369 307 444 474
6 0 8
Operation 7: Put pen inside the souvenir box
Operation 8: Cover souvenir box with mica
Working
Element
1:
Adjust 2.2 5.89
6.32 4.54 5.19 8.11 8.31 5.23 4.5 5.46 9.07
mica 3 6
with
souvenir
box

20
Departe
ment 4 :
Pen and
Aver
Souveni
age
r Box
Assemb
1 2 3 4 5 6 7 8 9 10
ling
Working
Element
2 : Fold
that
patterns
22. 19.9
of mica 19.6 29.1 15.5 21.2 20.2 23.4 21 15.3 12
3 6
on the
part that
have
been
market
Working
Element
3 : Cut
the par
of mica
that is 0 26 19 0 0 0 0 0 0 0 4.5
not
appropri
ate with
souvenir
box
Working
Element
4 : Stick
the mica
31. 28.3
with 29.7 29.3 35.2 37.9 27.2 29.2 18 19.1 27.1
4 4
souvenir
box
using
glue
Allowan 7.23 11.5 11. 7.26 8.73 7.24 7.51 5.6 5.18 6.26 7.861
ce 06 622 96 57 73 23 79 55 18 21 49
Material
3.5
Handlin 2.24 0.67 1.2 0.89 0.89 1.24 1.4 3.21 2.17 1.658
6
g

21
Departement 5: Finishing

Table 15 Uniformity Test Data Recapitulation of Departement 5

Departem
Aver
ent 5 :
age
Finishing 1 2 3 4 5 6 7 8 9 10
35
526, 595 513 526 432 375 493 552 492.
Waiting 557 2,7
31 ,70 ,91 ,94 ,68 ,37 ,04 ,66 638
71
Operation 9 : Inspect the Souvenir Box

8,4 7,4 6,9 6,4 5,4 5,8 4,8 11, 7,03

Inspection 7,52 8,23
6 4 1 1 9 4 6 9 75

Allowanc
e

Material 1,2 1,2 0,8 0,5 1,1 1,1 0,5 0,8 0,99
0,78 1,73
Handling 5 3 1 5 1 4 1 5 6

1.2.5 Adequacy Test of the Initial Method

In this sub-chapter, is used to test whether the taken work samples are enough. If
the result of data adequacy test (N’) is smaller than data amount taken (N), then
the data taken are enough. the formula for N’ is shown below:

𝑍.𝑆 2
N′ = [ ] (1.1)
𝑋.𝑘

Description :

N’ = The amount of observation that should be done

Z = Level of confidence index (level of confidence 95% ≈ index 1,96)

s = Standard deviation of data

x̅ = The data average after doing the uniformity of data test

k = Error Level (5%)

22
Here is the example of calculating the N’ using the edequacy test formula for
working element 1 in Departement 1 (Finishing) :

′
1,96 . 25,675 2
N =[ ]
62,9 . 0,05

N′ = 256,0326

The test result from the calculation shows that the value of N’ is bigger than value
of N which is 256,0326 > 10, it means that the data taken for work sample is not
enough.

1.2.6 Adequacy Test Data Recapitulation of Initial Method

Here are the data recapitulation after doing data adequacy test for making
souvenir box by each Departement, respectively.

Departement 1: Pattern Drawing and Cutting

Table 11 Adequacy Test Data Recapitulation of Departement 1
Departement
1 : Pattern Standard
N N' Conclusion Average Z(95%) k(5%)
Drawing and Deviation
Cutting
Operation 1: Draw pattern of the souvenir box
Working
Element 1 :
Draw basic 256.0 Not 25.6751068
10 62.9 1.96 0.05
pattern of 32656 Adequate 4
souvenir box
in paperboard
Working
Element 2 :
Mark part of 810.3 Not 27.4501568
10 37.8 1.96 0.05
the pattern 60372 Adequate 5
that will be
folded
Operation 2: Draw pattern of the mica that will cover the souvenir box
Working
Element 1 :
390.3 Not
Draw basic 10 66.5 33.51699403 1.96 0.05
543 Adequate
pattern of the
mica that will

23
Departement
1 : Pattern Standard
N N' Conclusion Average Z(95%) k(5%)
Drawing and Deviation
Cutting
cover the
souvenir box
Working
Element 2 :
Mark part of 542.8 Not
10 23.3 13.84878655 1.96 0.05
the pattern 54866 Adequate
that will be
folded
Operation 3: Patterns Cutting
Working
Element 1 :
Cut pattern
58.331 Not
of souvenir 10 57 11.10555417 1.96 0.05
4661 Adequate
box that has
been
marked
Working
Element 2 :
Cut pattern
of mica 145.07 Not
10 25.8 7.927448798 1.96 0.05
cover on the 735 Adequate
part that
have been
marked
Allowance
Material 81.954 Not
10 5 1.154700538 1.96 0.05
Handling 1333 Adequate

Departement 2 : Souvenir Box Assembling

Table 12 Adequacy Test Data Recapitulation of Departement 2
Departement 2
Standard
: Souvenir Box N N' Conclusion Average Z(95%) k(5%)
Deviation
Assembling
230.
Not 98.360571
Waiting 10 1454 254.15923 1.96 0.05
Adequate 49
78
Opeartion 4 : Fold the patterns of souvenir box
Working 528.
Not 12.2399311
Element 1 : Fold 10 4320 20.872308 1.96 0.05
Adequate 9
the top side of 5

24
Departement 2 N N' Conclusion Average Standard Z(95%) k(5%)
: Souvenir Box Deviation
the souvenir box
Assembling
pattern that have
been marked
Working
Element 2 : Fold
the side part of 440.
Not 8.17944313
souvenir box 10 0143 15.285385 1.96 0.05
Adequate 5
patterns that 77
have been
marked
Operation 5 : Stick souvenir box with glue
Working
Element 1 :
92.5
Stick the top of Not 5.71540617
10 5177 23.288462 1.96 0.05
right and left Adequate 8
13
side of the
patterns
Working
Element 2 : Fold
the top of the 48.4
Not 1.26436852
patterns that 10 0502 7.1238462 1.96 0.05
Adequate 9
longer than the 24
others part to the
inside
Working 124.
Element 3 : Not 5.18701037
Stick the top of 10 3721 18.232308 1.96 0.05
Adequate 8
fastening part to 34
the inside
Allowance
61.0
Material Not 0.59168309
10 5027 2.9684615 1.96 0.05
Handling Adequate 8
28

25
Departement 3: Pen Assembling
Table 13 Adequacy Test Data Recapitulation of Departement 3
Departement 3
Standard
: Pen N N' Conclusion Average Z(95%) k(5%)
Deviation
Assembling
42.97 Not 393.6923 65.836497
Waiting 10 1.96 0.05
26085 Adequate 08 81
Operation 6 : Pen Assembling
Working
Element 1 :
295.9 Not 5.190769 2.2780110
Assembly the 10 1.96 0.05
51368 Adequate 23 72
lower part and
body part
Working
Element 2 : Put
532.0 Not 2.8773214
the content of 10 4.89 1.96 0.05
23959 Adequate 78
pen into the
body part
Working
Element 3 : 919.5 Not 6.359230 4.9193180
10 1.96 0.05
Close the upper 44532 Adequate 77 42
part of the pen
Working
Element 4 : 1174. Not 3.097692 2.7082755
10 1.96 0.05
Close the lower 57645 Adequate 31 89
part of the pen
Allowance
Material 154.9 Not 4.646153 1.4753154
10 1.96 0.05
Handling 36849 Adequate 85 09

Departement 4: Pen and Souvenir Box Assembling

Table 14 Adequacy Test Data Recapitulation of Departement 4
Departement
4 : Pen and
Conclusio Standard Z(95%
Souvenir N N' Average k(5%)
n Deviation )
Box
Assembling
35.47 Not 498.9230
Waiting 10 75.80559932 1.96 0.05
37843 Adequate 77
Operation 7 : Put pen inside the souvenir box
Operation 8 : Cover souvenir box with mica
Working
217.2 Not 5.568461
Element 1 : 10 2.093788698 1.96 0.05
53803 Adequate 54
Adjust mica

26
Departement N N' Conclusio Average Standard Z(95% k(5%)
4 : Pen and n Deviation )
with souvenir
Souvenir
box
Box
Assembling
Working
Element 2 :
Fold the
58.99 Not 24.59615
patterns of 10 4.819285447 1.96 0.05
33465 Adequate 39
mica on the
part that have
been marked
Working
Element 3 :
Cut the part
of mica that 11890 Not 3.461538
10 9.629237884 1.96 0.05
isn’t .9798 Adequate 46
appropriate
with souvenir
box
Working
Element 4 :
Stick the 73.54 Not 28.27923
10 6.186888376 1.96 0.05
mica with 98026 Adequate 08
souvenir box
using glue
Allowance
Material 509.6 Not
10 1.75 1.007818877 1.96 0.05
Handling 37074 Adequate

Departement 5: Pen Assembling

Table 15 Adequacy Test Data Recapitulation of Departement 5

Departement 5 Standard
N N' Conclusion Average Z(95%) k(5%)
: Finishing Deviation

43.8
Not 171.77648
Waiting 10 96 492.64 1.96 0.05
Adequate 28
Operation 9 : Inspect the Souvenir Box
26.0 Not 1.9928661
Inspection 10 7.0375 1.96 0.05
54 Adequate 66
Allowance
44.7
Material Not 0.3696003
10 39 0.996 1.96 0.05
Handling Adequate 85

27
 Considering the results for all Departements, none of the results
from the experiment are adequate to represent the data. But, due to time and
resource limitation, the data currently available are assumed to be sufficient.

1.2.7 Performance Rating Determination of Initial Method

This performance rating assessment is done by using the Westinghouse
Rating System Method. This Performance rating is used to asses the skill and
effort of the operator in doing the work by matching the parameter with the real
condition of the operator.

Table 16 Westing House rating System Departement 1

Westinghouse Rating System
Skill C2 0.03
Effort B1 0.1

Condition C 0.02

Consistency B 0.03

Algebric sum 0.18

1.18
Performance Factor
118.00%
Performance Rating

Table 17 Westing House rating System Departement 2

Westinghouse Rating System
Skill D 0.00
Effort D 0.00
Condition F -0.07
Consistency D 0.00
Algebric sum -0,07
Performance Factor 0,93
Performance Rating 93%

Table 18 Westing House rating System Departement 3

Westinghouse Rating System
Skill E1 -0.05
Effort D 0.00
Condition F -0.07
Consistency D 0.00

28
 Algebric sum -0.12
Performance Factor 0,88
Performance Rating 88%

Table 19 Westing House rating Table 20 Westing House rating

System Departement 4 System Departement 5
Westinghouse Rating System Westinghouse Rating System
Skill C1 0.06 Skill D 0
Effort B2 0.08 Effort C1 +0.05
Condition A 0.06 Condition A +0.06
Consistency A 0.04 Consistency C +0.01
Algebric sum 0.24 Algebric sum 0.12
Performance Factor 1.24 Performance Factor 1.12
Performance Rating 124% Performance Rating 112 %
Note: Note:
Skill ̶ C = Good Skill ̶ D = Average
Effort ̶ B2 = Excellent Effort ̶ C1 = Good
Condition ̶ A = Ideal Condition ̶ A = Ideal
Consistency ̶ A = Ideal Consistency ̶ C = Good

1.2.8 Allowance Determination of Initial Method

Allowance determination is used to determine the allowance time that will
be used to determine the standard time. In this practium, the allowance time is
13% from thet total operation time for each deprtement. First, calculate the
allowance. Here is the formulation to determine the allowance:

∑Allowance = 7.306 × 13%

∑Allowance = 0.94978

Therefore, use the formula below to calculate allowance percentage for

each Departement. For instance is the calculation for Departement 5. In
which only consist of one work element that is inpection
.
% Allowance
∑Allowance
=
∑Allowance + ∑Operation + ∑Average Material Handling Time
× 100%

0.94978
= × 100%
0.94978 + 7.306 + 0.996
29
 = 10.26 %

The calculation above is done for all five Departements. Thus, the
data recapitulation is listed in table below.

Table 1 Data Recapitulation of Allowance

Departement Average Average Average Allowance

Number of Number of Number of (%)
Allowance Operation Material
Time Time Handling
Time
1 35.529 273.3 6 11
2 11,142 17,445 3,03 35
3 2.51784 4.842 5.11 20.19
4 7.63334 14.6795 1.749 11.47
5 0.94978 7.306 0.996 10.26

1.2.9 Normal Time Determination of Initial Method

Normal time is the time that operator takes to finish an activity under the normal
conditions which not include the allowances time. Here is the formula to calculate
the normal :

𝑇𝑛 = 𝑇𝑎 × 𝑃𝑅

Note:

Tn = normal time

Ta = the amount of actual time (has been uniformed)

PR = performance rating %

Below is the calculation for Departement 5 which the data already showed in the
previous sub chapter.

𝑇𝑛 = 8,0335 × 112 %

𝑇𝑛 = 8,99752

Thus , the normal time for Departement 5 is 9,298 seconds. Meanwhile, the result
of normal time calculation for all Departements are:

Departement Actual Time Performance Normal Normal

Rating Time Time (hour)

30
 (seconds)
1 279.3 118% 329.574 0.091548
2 126,77 93% 117,89 0,0327
3 24.478 88% 21.54064 0.005983511
4 63.6554 124% 78.9327 0.021926
5 8,302 112 % 8,99752 0,002499

1.2.10 Standard Time Determination of Initial Method

Standard time is the time required for an operator to finish the activity which
already includes the alowances time. Standard time can be used as the basis for
production scheduling, determining wages and number of employee, determining
the number of material to be purchased, etc. Here is the formulation for
calculating the standard time for Departement 5

Standard time = 𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑖𝑚𝑒 + (𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑖𝑚𝑒 𝑥 % 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒)

Standard time = 0,002499 + (0,002499 𝑥 10,26 % )

Standard time = 0,002499 + (0,002499 𝑥 10,26 % )

Standard time = 0,002756 ℎ𝑜𝑢𝑟/𝑢𝑛𝑖𝑡

Below is the result of standard time calculation for all Departements

Departement Normal Allowance Standard Standard

Time (hour) (%) Time Time (hour)
(seconds)
1 0.091548 11.21 365.825 0,1016
2 0,0327 35 227.33352 0,06314
3 0.005983511 20.19 456.4771349 0.126799204
4 0.021926 11.47 87.98628 0.00273417
5 0,002499 10,26 9.920666 0,002756

1.2.11 Line Standard Time and Line Standard Output of Initial Method

Line standard time is the amount time required from maximum time in the parallel
Departements and the series Departements. Therefore, Line standard time is
calculated by using this formula:

Line Standard Time = {Max time of parallel dept} + standard time in series

Line Standard Time = 0 + 1147.542601

Line Standard Time = 1147.542601

31
Meanwhile line standard time output is the number of products that can be
produced during line standard time. It also can be used to determine the level of
work productivity. The formula of line standard time output is

1
Standard Line Output =
1147.542601
Standard Line Output = 0.000871427

1.2.12 Flow Diagram of Initial Method

The flow diagram of the initial method containing the operation of each
Departement will be shown below.

Notes:
D1: Draw pattern of souvenir box
D2: Draw pattern of mica
D3: Patterns cutting
D4: Fold the pattern of souvenir box
D5: Stick souvenir box with glue
D6: Pen assembling
D7: Put pen inside souvenir box
D8: Cover souvenir box with mica

1.2.13 Flow Process Chart of Initial Method

The table below shows the flow process chart of the initial method. The
productive process and the non-productive process will be listed in this chart.

Table 1. Flow Process Chart Departement 1

Activity
No Symbol Duration (s)
Description

32
 Activity
No Symbol Duration (s)
Description
Draw basic pattern
1. of souvenir box on
paperboard
Mark part of the
2. pattern that will be
folded
Draw basic pattern
3.
of mica
Mark part of the
4. pattern that will be
folded
Cut pattern of
5. souvenir box that
have been marked
Cut pattern of mica
6. that have been
marked
Handling the
souvenir box and
7.
mica to next
Departement
Fold top side of
8.
souvenir box

Fold side part of

9.
souvenir box
Glue top of right
10. and left side of the
pattern

33
 Activity
No Symbol Duration (s)
Description
Fold top of the
11. pattern that longer
than other parts
Glue top of
12.
fastening part inside
Handling the
souvenir box and
13.
mica to next
Departement
Assembly lower
14. and body part of
pen
Put the content of
15. pen into the body
part
Close upper part of
16.
pen

Close lower part of

17.
pen
Handling souvenir
box, mica, and pen
18.
to next
Departement
Adjust mica with
19.
souvenir box

Fold marked part of

20.
the mica

34
 Activity
No Symbol Duration (s)
Description
Cut inappropriate
21.
part of mica

Glue mica and

22.
souvenir box
Handling the
finished souvenir
23.
box to next
Departement
Inspect the finished
24.
souvenir box
Handling the
25. finished souvenir to
storage
Store the finished
26.
souvenir box

1.2.14 Operation Process Chart of Initial Method

This figure below shows the overall view of the entire process for the initial
method. The chart below shows the material and every operations and
inspection which done in the whole process.

35
36
1.3 Line Balancing

1.3.1 Precedence Diagram

The diagram below showed the sequences work in the practicum. This
precedence diagram is the first step to develop line balancing operation in the
assembly line or production system. This diagram will be very useful to avoid the
line balancing iteration to violate the precedence constrains in the assembly or
production processes.

1.3.2 Cycle Time

The Cycle time were developed as the second step to conduct line
balancing operation. The cycle time itself defined as the highest amount of time in
one departement amongts others. Related to the alghoritm of Largest Candidate
Rules (LCR) method, the cycle time can be called as upper limit time in one
departement. Hence, one departement operation time cannot exceeds the cycle
time.

Statio Station Cycle

Work Element Tek
n Time Time
69.07
1 Draw mica pattern 69.076 69.076
6
2 Draw basic patterns of souvenir box 67.07 67.076 69.076

37
Statio Station Cycle
Work Element Tek
n Time Time
6
Assembly lower and body 5.19
Put the content of the pen 4.89
3 19.52 69.076
Fasten Upper 6.35
Fasten lower 3.09
Mark part of the paper that will be
43.53
4 folded 66.45 69.076
Draw folded mica pattern 22.92
Cut mica 25.53
5 Fold mica pattern that have been 50.12 69.076
24.59
marked
59.07
6 Cut souvenir box 59.076 69.076
6
Fold top souvenir box 20.87
Fold side souvenir box 15.28
7 66.55 69.076
Stick top of right and left side 23.28
Fold top part 7.12
Stick the fastening top part 18.23
8 Insert pen into box 4.64 28.43 69.076
Adjust mica to box 5.56
Cut inappropriate mica 3.461
9 31.74 69.076
Stick mica to the box 28.28
10 inspection 7.77 7.77 69.076

1.4 Calculation of Line Balancing

After conduction the basic steps of conducting line balancing operation,

the illustration of precedence diagram and calculating cycle time, the iteration in
line balancing using Largest Candidate Rules were developed to find more

38
effective and efficient way to conduct the assembly process. The main purposes
are to minimize the lead time and decrease the overall assembly or production
time.

1.4.1 Precedence diagram after line balancing treatment based on each of the
departement

The diagram below showed the design of new departement and sequence
of production processes. This new diagram generated after followed the alghoritm
and iteration of Large Candidate Rules (LCR) method. The main system
engineering in this case were the use of the third departement to conducting
assembly process of pen thus generate smaller lead time and increase effectivity
and efficiency.

Efficiency Balancing :

329.092
Eb = = 22.73 %
10 𝑥 69.076

Delay Balancing :

Db = 1- 0.2273

39
= 72 %

40
1.5 Improvement Method
In this sub-chapter, all the data of the improved work method will
be displayed and interpreted, starting from data recapitulation, uniformity and
adequacy test, performance rating recapitulation, normal time, allowance,
standard time, line standard time and line standard output, flow diagram, flow
process chart, and operation process chart.

1.5.1 Departmentalization and Work Flow of Improvement Method

Below are displayed the table of initial method’s
departmentalization that shows the operations and activities in each department.
Department 1
Working Element 1 : Draw mica pattern
Allowance
Material Handling

Department 2
Working Element 2 : Draw basic patterns of souvenir box
Allowance
Material Handling

Department 3 : Pen Assembling

Working Element 3 : Assembly lower and body
Working Element 4 : Put the content of the pen
Working Element 5 : Fasten upper
Working Element 6 : Fasten lower
Allowance
Material Handling

Department 4
Waiting
Working Element 7 : Mark part of the paper that will be folded

41
Working Element 8 : Draw folded mica pattern
Allowance
Material Handling

Department 5
Waiting
Working Element 9 : Cut mica
Working Element 10 : Fold mica pattern that have been marked
Allowance
Material Handling

Department 6
Waiting
Working Element 11 : Cut souvenir box
Allowance
Material Handling

Department 7
Waiting
Working Element 12 : Fold top souvenir box
Working Element 13 : Fold side souvenir box
Working Element 14 : Stick top of right and left side
Allowance
Material Handling

Department 8
Waiting
Working Element 15 : Stick the fastening top part
Working Element 16 : Insert pen into box
Allowance

42
Material Handling

Department 9
Waiting
Working Element 17 : Adjust mica to the box
Working Element 18 : Glue the mica
Allowance
Material Handling

Department 10 : Inspection
Waiting
Working Element 19 : Inspection
Allowance
Material Handling

And below is the workflow process of souvenir box department

based on the departmentalization above:

Figure 15 Workflow Process of Departmentalization After Improvement

43
1.5.2 Data Recapitulation of Improvement Method
Here is the data recapitulation of operation time for each department after
improvement:

 Department 1

Working AVERA
1 2 3 4 5 6 7 8 9 10
Element GE
Draw
Basic
Pattern 122.7 111.2 131.2 84.1 192.9 108. 97.3 110. 103. 118.564
123
of 6 4 5 6 8 4 6 7 79
Souvenir
Box
Material 3.248
2.66 3.78 2.88 3.5 1.92 1.36 1.99 3.87 5.8 4.72
Handling
10.6707
11.04 10.01 11.81 7.57 17.36 9.75 8.76 11.0 9.96 9.34
Allowan 6
84 16 25 44 82 6 24 7 3 11
ce
AVERA 67.06 43.8 54.8 49.6 63.4 58.2 54.2 44.1609
62.71 57.51 97.45
GE 5 3 8 75 35 5 55 2

 Department 2

AVERA
6 7 8 9 10
Working 1 2 3 4 5 GE
Element
Draw 67.8 149.0 150.7 101. 107.
65.9 89.8 104. 136.0 135.4 110.852
Mica 5 2 3 28 87
8 3 47 5 4
Pattern
Material
2.52 1.96 19.99 2.08 1.7 3.497
Handlin 0.36 1.62 1.72 1.3 1.72
g
6.10 13.41 13.56 9.11 9.70
5.93 8.08 9.40 12.24 12.18 9.97668
Allowan 65 18 57 52 83
82 47 23 45 96
ce
35.1 51.6 54.7 41.44189
33.1 45.7 53.0 68.67 75.49 85.36
AVERA 68.58 85 8 85 333
7 25 95 5
GE

 Department 3

44
Worki
ng AVER
Eleme 6 7 8 9 10 AGE
nt 1 2 3 4 5
Assem
bly 5.7 11.
7.2 4.8 11. 5.35 6.48 5.88 8.173
Lower 5.56 17.29 1 98
8 1 39
and
Body
Put the
Conte 4.9 3.1
3.1 4.3 6.0 2.2 5.49 8.1 4.63
nt of 2.81 6.07 6 4
6 4 3
the
Pen
3.9
4.9 3.4 3.8 3.6 2.81 2.2 3.17 3.828
Fasten 5.96 4.33 2
8 6 5
Upper
2,8 3.5244
2.2 4.3 6.0 1.8 2.13 3.4 6.77
Fasten 2.42 2.56 5 44444
7 1 6
Lower
11. 15.
12. 11. 19. 9.065 11.837 16.744 14.052
Allow 11.725 21.175 389 323
283 844 131
ance
Materi
2.2 2.7
al 0.0 2.7 0.0 0.00 0.00 1.73 0.94
0.00 0.00 0 7
Handli 0 3 0
ng
3.6691 4.7911 4.9 7.0656 7.4 5.8583
4.7458 4.9 5.2 8.5708 7.7
AVER
33333 955 49 33333 435 66667 66667 765 66667 266 40741
AGE

 Department 4

Workin
AVERA
g 1 2 3 4 5 6 7 8 9 10
GE
Element
Mark
part of
the
68.71 66.70 51.1 44.51 53.7 52.73 45.6 50.2 38.78
paper 50.5 52.2727
that will 9 4 79 2 36 7 51 05 4
be
folded
Draw
folded 131.4 53.14 51.4 34.7 30.78 19.9 28.07 36.5 22.69
mica
38.7 44.7451
2 1 5 07 4 09 6 67 7
pattern

45
Allowan 18.01 10.78 9.23 7.80
7.489 7.96 7.517 5.9 7.072 5.533 8.7316
ce 3 6 7 9
Material
1.29 3.46 3.99 3.94
Handlin 2.571 2.252 3.064 3.987 3.759 3.811 3.2134
g 2 3 4 1
AVERA 55.18 33.22 28.28 23.44 24.96 23.75 18.86 22.35 24.63 17.70
27.2407
GE 075 075 95 125 65 625 35 175 05 625

 Department 5

AVERA
7 8 9 10
Working GE
Element 1 2 3 4 5 6
Waiting 199.7 42.6 25.7 19.3 0 6.705 7.72 0 33.0245
0 28.33
time 2 6 4 7
39.6
67.3 45. 34.2 42.5 44.15 45.59 45.37 46.892
Cut 40.79 63.32 3
3 87 9 8
mica
Fold
mica
pattern 25.8
59.0 29. 35.6 28.8 28.37 40.48 36.81 37.258
that 46.95 40.86 5
6 63 8 9
have
been
marked
Material
5.87 7.47 6.79 3.08 5.422
Handlin 6.97 4.67 3.3 4.54 5.77 5.76
g
6.141 8.84 5.2 7.292 4.89 5.00 5.076 5.752 4.58
6.0249 5.8905
Allowan 8 73 85 6 79 29 4 6 36
ce
73.60 43.4 19. 34.26 25.3 24.1 19.59 25.061 24.17 17.1 30.6491
AVERA 75 3 7 25 7 5 75 25 25 4 25
GE

 Department 6

Working AVERA
1 2 3 4 5 6 7 8 9 10
Element GE
Cut
88,4 77,8 83,6 67,2 63,7 60,6 75,1 77,7 73,5
souvenir 69,57 74,218
04 21 83 37 49 23 58 34 57
box
Allowan 285,9 41,2 20,6 26,3 32,1 30,8 21,8 28,0 35,9
0 52,301
ce 68 49 75 64 46 07 11 51 41

46
Material 4,30 6,07 6,74 9,29 9,94 12,1 8,95 6,24 8,41
- 8,016
Handling 8 6 5 4 4 58 2 8 7
AVERA 285,9 44,6 34,8 30,1 34,2 35,2 34,5 35,3 37,3 39,3
44,845
GE 68 54 57 43 98 80 29 07 44 05

 Department 7

Work
AVE
ing
1 2 3 4 5 6 7 8 9 10 RAG
Elem
E
ent
Waiti 375.4 76.3 72.4 93.35
39.62 31.16 31.48 65 86.88 78.1 77.02
ng 9 2 8 5
Fold
top
11.79
souve 24.22 26.67 3.1 19.34 6.31 4.49 4.64 18.22 5.89 5.06
4
nir
box
Fold
side
souve 2.3 8.88 5.57 14.87 13.8 7.9 6.7 2.8 14.8 7.57 8.519
nir
box
Stick
top of
right
16.24 15.12 7.09 2.21 6.83 8.58 9.3 6.13 2.12 4.74 7.836
and
left
side
Allo
2.993 3.546 1.103 2.549 1.885 1.46 1.444 1.900 1.596 1.21 1.970
wanc
2 9 2 4 8 79 8 5 7 59 43
e
Mate
rial
1.57 0.77 0.78 2.28 1.11 0.42 0.26 3.03 0.76 3.24 1.422
Hand
ling
AVE 70.46 15.76 8.133 12.12 15.82 16.5 18.20 18.36 17.03 15.7 20.81
RAG 88666 78166 86666 15666 26333 296 41333 34166 11166 176 60716
E 7 7 7 7 3 5 3 7 7 5 7

47
  Department 8

Worki
ng AVER
1 2 3 4 5 6 7 8 9 10
Eleme AGE
nt
Waitin 106.0
96.86 24.55 37.74 75.06 64.98 97.87 87.85 70.64 0 66.163
g 8
Stick
the
23.1
fasteni 25.46 61.5 24.21 16.84 22.72 20.19 18.64 21.49 24.48 25.872
9
ng top
part
Insert
pen
0.6 0.59 2.13 1.52 1.46 1.85 2.14 2.05 1.83 1.29 1.546
into
box
Allowa 1.824 4.346 1.843 1.285 1.692 1.542 1.454 1.647 1.841 1.71 1.9192
nce 2 3 8 2 6 8 6 8 7 36 6
Materi
al
1.06 0.73 1.17 0.87 0.69 0.77 0.8 0.67 1.02 0.85 0.863
Handli
ng
AVER 25.16 18.34 13.41 19.11 18.30 26.08 24.18 22.74 19.96 5.40 19.272
AGE 084 326 876 504 852 656 092 156 234 872 652

 Department 9

Work
ing AVER
1 2 3 4 5 6 7 8 9 10
Elem AGE
ent

123. 65. 89. 128. 119 112.0 97. 94.444

Waiti 87.37 94.29 25.33
98 25 85 89 .45 6 97
ng
Adjus
t mica 58. 100 41. 38.556
76.7 30.65 0 10 0 42.08 25.08
to the 67 .57 81
box

Glue 29. 35. 23.0 28. 35. 34.047

the 39 32.86 33.67 41.05 40.87
52 71 9 91 79
mica

48
 2.0 5.0822
8.09 4.445 3.056 6.6 1.61 5.819 9.0 4.616 5.4
Allow 66 1
9 7 9 066 63 1 636 5 32
ance 4
Mater
1.6844
ial 0.4 1,1 2.8 1.4
2 3.4 1.5 0.95 1.12 1.46 44444
Handl 4 5 7 2
ing

AVE 31.4 8.0 33. 6.41 35. 21. 19.842

17.83 12.05 22.51 18.00
RAG 497 06 662 407 353 11 41361
8925 6725 7275 6625
E 5 6 2 5 4 3

 Department 10

Wor
AVE
king
1 2 3 4 5 6 7 8 9 10 RAG
Elem
E
ent
15 13 17 17
241.6 184.2 152.9 109.5 168.5
Waiti 4.2 95.21 9.4 251.8 9.4 6.9
8 3 3 8 63
ng 8 6 7 9

10. 3.3 5.9

Inspe 14.2 8.4 7.8 5.59 8.8 4.95 4.31 7.366
3 5 6
ction

Allo 0.2 0.4

0.7 0.5 0.391 0.346 0.301 0.515
wanc 0.994 0.588 0.616 34 17
21 46 3 5 7 62
e 5 2
Mate
rial 2.7 1.0
3 2.77 3 1.25 1.65 2.05 1.9 0.5 1.993
Hand 4 7
ling

AVE 6.064 3.919 2.410 3.688 2.448 2.170 1.3 2.4

4.5 3.7 3.291
RAG 6666 3333 4333 6666 8333 5666 61 82
87 82 54
E 67 33 33 67 33 67 5 4

49
1.5.3 Uniformity Test Data of Improvement Method

In this sub-sub chapter will be displayed the result of data uniformity test
using Minitab. In this uniformity test the iteration is done 2 times to eliminate the
outlier data.
Department 1:

Figure 16 Iteration 1 of Work Figure 17 Iteration 1 of Material

Element 1 Handling Department 1
Department 2:

I Chart of Material Handling

3,0

UCL=2,675
2,5
Individual Value

2,0
_
X=1,664
1,5

1,0

LCL=0,654
0,5
1
1 2 3 4 5 6 7 8 9
Observation

Figure 18 Iteration 1 of Work Figure 20 Iteration 2 of Material

Element 2 Handling

Figure 19 Iteration 1 of Material

Handling
Department 3:

50
Figure 21 Iteration 1 of Work Figure 24 Iteration 1 of Work
Element 3 Element 5
I Chart of Assembly Lower and Body I Chart of Fasten Upper
14 6
UCL=13,25
UCL=5,606
12
5
10
Individual Value

Individual Value
4
8 _ _
X=7,16 X=3,591
6
3

4
2
2
LCL=1,576
LCL=1,07
0 1
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Observation Observation

Figure 22 Iteration 2 of Work Figure 25 Iteration 2 of Work

Element 3 Element 5

Figure 23 Iteration 1 of Work Figure 26 Iteration 1 of Work

Element 4 Element 6

51
 Figure 27 Iteration 1 of Material
Handling

Department 4:

I Chart of Draw folded mica pattern

60
UCL=56,31

50

Individual Value
40
_
X=35,11

30

20

LCL=13,92
10
1 2 3 4 5 6 7 8 9
Observation

Figure 28 Iteration 1 of Work Figure 30 Iteration 2 of Work

Element 7 Element 8

Figure 29 Iteration 1 of Work Figure 31 Iteration 1 of Material

Element 8 Handling

52
 I Chart of Material Handling_1 Figure 32 Iteration 2 of Material
4,5
UCL=4,294 Handling
4,0
Individual Value

3,5 _
X=3,427

3,0

2,5 LCL=2,560

1
2,0
1 2 3 4 5 6 7 8 9
Observation

Department 5:

Figure 33 Iteration 1 of Work Figure 35 Iteration 1 of Material

Element 9 Handling

Figure 34 Iteration 1 of Work

Element 10
Department 6:

53
 I Chart of Cut souvenir box I Chart of Material Handling
100 UCL=99,26 14 UCL=13,94

90 12
Individual Value

Individual Value
10
80
_ _
X=73,75 X=8,39
8
70

6
60
4
50 LCL=2,83
LCL=48,25
2
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Observation Observation

Figure 36 Iteration 1 of Work Figure 37 Iteration 1 of Material

Element 11 Handling
Department 7:

Figure 38 Iteration 1 of Work Figure 40 Iteration 1 of Work

Element 12 Element 14

Figure 39 Iteration 1 of Work Figure 41 Iteration 1 of Material

Element 13 Handling
Department 8:

54
Figure 42 Iteration 1 of Work Figure 44 Iteration 1 of Work
Element 15 Element 16
I Chart of Stick the fastening top part

30 UCL=30,46

25
Individual Value

_
X=21,91

20

15
LCL=13,37

1 2 3 4 5 6 7 8 9
Observation

Figure 43 Iteration 2 of Work Figure 45 Iteration 1 of Material

Element 15 Handling
Department 9:

Figure 46 Iteration 1 of Work Figure 47 Iteration 1 of Work

Element 17 Element 18

55
 Figure 48 Iteration 1 of Material
Handling

Department 10:

Figure 49 Iteration 1 of Work Element 19

I Chart of Inspection

12 UCL=12,25

10
Individual Value

8
_
X=6,61
6

2
LCL=0,96
0
1 2 3 4 5 6 7 8 9
Observation

Figure 50 Iteration 2 Work Element 19

1.5.4 Uniformity Test Data Recapitulation of Improvement Method

After the data has been tested by minitab software, outlier data in first
iteration is high lighted with yellow color and in second iteration is highlighted
with red color.

Table 1 Uniformity Test Data Recapitulation of Department 1

Depart Avera
ment 1 Operation Time ge

56
Workin
g
element 1 2 3 4 5 6 7 8 9 10
Draw
basic
pattern
of
souveni 122.7 111.2 131.2 84.1 192.9 103. 97.3 110 108 118.5
r box 6 4 5 6 8 79 6 123 .7 .4 64
Materia
l
handlin 3.8 1.3
g 2.66 3.78 2.88 3.5 1.92 4.72 1.99 7 5.8 6 3.248
Allowa 11.04 10.01 11.81 7.57 17.36 9.34 8.76 11. 9.9 9.7 10.67
nce 84 16 25 44 82 11 24 07 63 56 076

Table 2 Uniformity Test Data Recapitulation of Department 2

Depart
ment 2 Operation Time
Workin
g Aver
element 1 2 3 4 5 6 7 8 9 10 age
Draw
mica 65.9 89.8 104. 136. 135. 107. 149. 150. 101. 67.8 110.8
pattern 8 3 47 05 44 87 02 73 28 5 52
Materia
l
handlin 19.9 1.827
g 0.36 1.62 1.72 1.3 1.72 1.7 1.96 9 2.08 2.52 5
Allowa 5.93 8.08 9.40 12.2 12.1 9.70 13.4 13.5 9.11 6.10 10.42
nce 82 47 23 445 896 83 118 657 52 65 54

Table 3Uniformity Test Data Recapitulation of Department 3

Departm
ent 3 Operation Time
Working Averag
element 1 2 3 4 5 6 7 8 9 10 e
Assembl
y lower 17.2 11.3 11.9
and body 5.56 7.28 4.81 9 9 8 6.48 5.71 5.88 5.35 7.16

Put the
content
of the 2.81 3.16 4.34 6.07 6.03 3.14 5.49 4.96 8.1 2.2 4.63

57
Departm
ent 3 Operation Time
Working Averag
element 1 2 3 4 5 6 7 8 9 10 e
pen

Fasten 3.5911
upper 5.96 4.98 3.46 4.33 3.85 3.92 2.81 2.2 3.17 3.6 11
Fasten 3.5244
lower 2.42 2.27 4.31 2.56 6.06 2,85 2.13 3.4 6.77 1.8 44
Allowan 1.17 1.23 1.18 2.11 1.91 1.33 1.18 1.13 1.67 0.90
ce 3 8 4 8 3 3 4 9 4 7 1.3863
Material
handling 0 0 2.73 0 0 2.77 0 2.2 1.73 0 0.943

Table 4Uniformity Test Data Recapitulation of Department 4

Depart
ment 4 Operation Time
Workin
g Avera
element 1 2 3 4 5 6 7 8 9 10 ge
Mark
part of
the
paper
that will
be 68.7 66.7 51.1 44.5 53.7 52.7 45.6 50.2 38.7 52.27
folded 19 04 79 12 36 37 51 50.5 05 84 27
Draw
folded
mica 131. 53.1 51.4 34.7 30.7 19.9 28.0 36.5 22.6 35.11
pattern 42 41 5 38.7 07 84 09 76 67 97 456
Allowa 18.0 10.7 9.23 7.48 7.51 7.07 7.80 5.53 8.731
nce 13 86 7 9 7.96 7 5.9 2 9 3 6
Materia
l
handlin 2.57 2.25 1.29 3.06 3.46 3.98 3.99 3.75 3.94 3.81 3.573
g 1 2 2 4 3 7 4 9 1 1 75

Table 5Uniformity Test Data Recapitulation of Department 5

Depart Aver
ment 5 Operation Time age

58
Workin
g
element 1 2 3 4 5 6 7 8 9 10
Waiting 199. 42.6 28.3 25.7 19.3 6.70 33.02
time 72 6 0 3 4 7 0 5 7.72 0 45
Cut 40.7 67.3 45. 63.3 34.2 42.5 44.1 45.5 45.3 39.6 46.89
mica 9 3 87 2 9 8 5 9 7 3 2
Fold
mica
pattern
that
have
been 46.9 59.0 29. 40.8 35.6 28.8 28.3 40.4 36.8 25.8 37.25
marked 5 6 63 6 8 9 7 8 1 5 8
Material
handlin
g 6.97 4.67 3.3 4.54 5.77 5.76 5.87 7.47 6.79 3.08 5.422
Allowa 6.14 8.84 5.2 7.29 4.89 5.00 5.07 6.02 5.75 4.58 5.890
nce 18 73 85 26 79 29 64 49 26 36 5

Table 6Uniformity Test Data Recapitulation of Department 6

Departmen
t6 Operation Time
Working Avera
element 1 2 3 4 5 6 7 8 10 11 ge
Cut
souvenir 69.5 88.4 77.8 83.6 67.2 63.7 75.1 77.7 73.5 60.6 73.75
box 70 04 21 83 37 49 58 34 57 23 36
28.5 41.2 20.6 0.00 26.3 32.1 21.8 28.0 35.9 30.8 26.56
Allowance 97 49 75 0 64 46 11 51 41 07 408
Material 0.00 4.30 6.07 6.74 9.29 9.94 8.95 6.24 8.41 12.1 7.214
handling 0 8 6 5 4 4 2 8 7 58 2

Table 7Uniformity Test Data Recapitulation of Department 7

Depart
ment 7
Workin
g Aver
element 1 2 3 4 5 6 7 8 9 10 age
375. 39.6 31.1 31.4 76.3 86.8 77.0 72.4 93.35
Waiting 49 2 6 8 65 2 8 78.1 2 8 5

Fold 24.2 26.6 19.3 18.2 11.79

top 2 7 3.1 4 6.31 4.49 4.64 2 5.89 5.06 4

59
Depart
ment 7
Workin
g Aver
element 1 2 3 4 5 6 7 8 9 10 age
souveni
r box

Fold
side
souveni 14.8
r box 2.3 8.88 5.57 7 13.8 7.9 6.7 2.8 14.8 7.57 8.519
Stick
top of
right
and left 16.2 15.1
side 4 2 7.09 2.21 6.83 8.58 9.3 6.13 2.12 4.74 7.836
Allowa 2.99 3.54 1.10 2.54 1.88 1.46 1.44 1.90 1.59 1.21 1.970
nce 32 69 32 94 58 79 48 05 67 59 43
Materia
l
handlin
g 1.57 0.77 0.78 2.28 1.11 0.42 0.26 3.03 0.76 3.24 1.422

Table 8Uniformity Test Data Recapitulation of Department 8

Depart
ment 8 Operation Time
Workin
g Avera
element 1 2 3 4 5 6 7 8 9 10 ge
96.8 24.5 37.7 75.0 64.9 106. 97.8 87.8 70.6 66.16
Waiting 6 5 4 6 8 08 7 5 4 0 3
Stick
the
fastenin
g top 25.4 24.2 16.8 22.7 20.1 18.6 21.4 24.4 23.1 21.91
part 6 61.5 1 4 2 9 4 9 8 9 333
Insert
pen into
box 0.6 0.59 2.13 1.52 1.46 1.85 2.14 2.05 1.83 1.29 1.546
Allowa 1.82 4.34 1.84 1.28 1.69 1.54 1.45 1.64 1.84 1.71 1.919
nce 42 63 38 52 26 28 46 78 17 36 26
Materia
l 1.06 0.73 1.17 0.87 0.69 0.77 0.8 0.67 1.02 0.85 0.863

60
Depart
ment 8 Operation Time
Workin
g Avera
element 1 2 3 4 5 6 7 8 9 10 ge
handlin
g

Table 9Uniformity Test Data Recapitulation of Department 9

Depart
ment 9 Operation Time
Workin
g Avera
element 1 2 3 4 5 6 7 8 9 10 ge
Adjust
mica to 76. 30.6 58.6 100. 25.0 41. 42.0 38.55
the box 7 5 0 10 7 0 57 8 81 8 6
Glue the 32.8 29.5 33.6 35.7 23.0 28.9 40.8 35. 41.0 34.04
mica 39 6 2 7 1 9 1 7 79 5 7
Allowa 8.0 4.44 2.06 3.05 6.60 1.61 9.06 4.61 5.4 5.81 5.082
nce 99 57 64 69 66 63 36 65 32 91 21
Material
handlin 1.4 1.684
g 2 3.4 0.44 1.5 1,15 0.95 2.87 1.46 2 1.12 444

Table 10Uniformity Test Data Recapitulation of Department 10

Departm
ent 10 Operation Time
Working Avera
element 1 2 3 4 5 6 7 8 9 10 ge
Inspecti 14. 10. 6.6066
on 2 3 8.4 7.8 5.59 8.8 4.31 3.35 5.96 4.95 67
Allowan 0.9 0.7 0.5 0.5 0.39 0.6 0.30 0.23 0.41 0.34 0.5156
ce 94 21 88 46 13 16 17 45 72 65 2
Material 2.7 2.7 1.6
handling 3 4 7 3 1.25 5 1.9 0.5 1.07 2.05 1.993

61
1.5.5 Adequacy Test of Improvement Method
In this sub-chapter, is used to test whether the taken work samples are
enough. If the result of data adequacy test (N’) is smaller than data amount taken
(N), then the data taken are enough. the formula for N’ is shown below:

𝑍.𝑆 2
N′ = [ ] (1.1)
𝑋.𝑘

Description :

N’ = The amount of observation that should be done

Z = Level of confidence index (level of confidence 95% ≈ index 1,96)

s = Standard deviation of data

x̅ = The data average after doing the uniformity of data test

k = Error Level (5%)

Here is the example of calculating the N’ using the edequacy test formula for
working element 1 in Departement 1 (Draw basic patern) :

′
1,96 . 27,94 2
N =[ ]
118,564 . 0,05

N′ = 85,331586

The test result from the calculation shows that the value of N’ is bigger than value
of N which is 85,331586 > 11, it means that the data taken for work sample is not
enough.

1.5.6 Adequacy Test Data Recapitulation of Improvement Method

Below is the data recapitulation of adequacy test base on the observation
of the improved method respectively

N N’ Conclusio Averag Standar Z K

Stati n e d (9 (5
Work Element
on Deviati 5 %)
on %)
10 85. Not 118.564 27.9396 1.9 0.0
33 Adequate 97 6 5
1 Draw mica pattern 15
86

62
 N N’ Conclusio Averag Standar Z K
Stati n e d (9 (5
Work Element
on Deviati 5 %)
on %)
10 10 Not 110.852 29.5506 1.9 0.0
9.1 Adequate 32 6 5
Draw basic patterns
2 98
of souvenir box
99

10 34 Not 1.9 0.0

Assembly lower 2.8 Adequate 3.86078 6 5
8.173
and body 94 76
85
10 21 Not 1.9 0.0
Put the content of 9.3 Adequate 1.74943 6 5
4.63
the pen 85 99
65
3
10 10 Not 1.9 0.0
9.4 Adequate 1.02179 6 5
Fasten Upper 3.828
84 06
36
10 36 Not 1.9 0.0
0.6 Adequate 3.52444 1.70740 6 5
Fasten lower
30 44 29
81
10 43. Not 1.9 0.0
Mark part of the
62 Adequate 8.80757 6 5
paper that will be 52.2727
49 8873
folded 9
4
10 72 Not 1.9 0.0
Draw folded mica 2.0 Adequate 30.6722 6 5
44.7451
pattern 60 9189
6
10 67. Not 1.9 0.0
61 Adequate 9.83636 6 5
Cut mica 46.892
51 3962
2
5
10 10 Not 1.9 0.0
Fold mica pattern
3.2 Adequate 9.65741 6 5
that have been 37.258
41 8703
marked
7
10 19. Not 73.7536 8.24681 1.9 0.0
21 Adequate 0198 6 5
6 Cut souvenir box 22
3

7 Fold top souvenir 10 84 Not 11.794 8.74258 1.9 0.0

63
 N N’ Conclusio Averag Standar Z K
Stati n e d (9 (5
Work Element
on Deviati 5 %)
on %)
box 4.3 Adequate 79 6 5
64
39
10 40 Not 1.9 0.0
Fold side souvenir 7.5 Adequate 4.38722 6 5
8.519
box 44 57
32
10 51 Not 1.9 0.0
Stick top of right 2.4 Adequate 4.52514 6 5
7.836
and left side 46 57
37
10 33 Not 1.9 0.0
9.0 Adequate 6 5
Stick the fastening 25.872 12.1520
Top Part 07 29
84
8
10 19 Not 1.9 0.0
3.0 Adequate 0.54803 6 5
Insert pen into box 1.546
95 65
48
10 10 Not 1.9 0.0
Cut inappropriate 08. Adequate 31.2425 6 5
38.556
mica 97 41
9 61
10 39. Not 1.9 0.0
02 Adequate 5.42605 6 5
Stick mica to box 34.047
85 39
7
10 23 Not 7.516 2.95148 1.9 0.0
6.9 Adequate 68 6 5
10 Inspection 62
86

1.5.7 Performance Rating Determination of Improvement Method

Just like sub-chapter 1.2.7, this performance rating assessment is done by
using the Westinghouse Rating System Method. This Performance rating is used
to asses the skill and effort of the operator in doing the work by matching the
parameter with the real condition of the operator. The performance rating tables
below are the performance rating of the improvement methods:

64
Table 11 Westing House rating System Department 1
Westinghouse Rating System
Skill C2 0.03
Effort C1 0.05
Condition D 0
Consistency B 0.03
Algebraic Sum 0.11
Performance Factor 1.11
Performance Rating 111%

Table 12 Westing House rating System Department 2

Westinghouse Rating System

Skill C1 0.06
Effort D 0
Condition C 0.02
Consistency D 0
Algebraic Sum 0.08
Performance
Factor 1.08
Performance
Rating 108%

Table 13 Westing House rating System Department 3

Westinghouse Rating
System
Skill C1 0.06
Effort B2 0.08
Condition C 0.02
Consistency B 0.03
Algebraic Sum 0.19
Performance
Factor 1.19

65
 Performance
Rating 119%

Table 14 Westing House rating System Department 4

Westinghouse Rating
System
Skill C2 0.03
Effort C1 0.05
Condition B 0.04
Consistency C 0.01
Algebraic Sum 0.13
Performance
Factor 1.13
Performance
Rating 113%

Table 15 Westing House rating System Department 5

Westinghouse Rating
System
Skill C1 0.06
Effort C2 0.02
Condition B 0.04
Consistency C 0.01
Algebraic Sum 0.13
Performance
Factor 1.13
Performance
Rating 113%

Table 16 Westing House rating System Department 6

Westinghouse Rating
System
Skill B1 0,11

66
 Effort C1 0.05
Condition A 0.06
Consistency C 0.01
Algebraic Sum 0.12
Performance
Factor 1.12
Performance
Rating 112%

Table 17 Westing House rating System Department 7

Westinghouse Rating
System
Skill C1 0.06
Effort C1 0.05
Condition C 0.02
Consistency C 0.01
Algebraic Sum 0.14
Performance
Factor 1.14
Performance
Rating 114%

Table 18 Westing House rating System Department 8

Westinghouse Rating
System
Skill C2 0.03
Effort E1 -0.04
Condition C 0.02
Consistency D 0
Algebraic Sum 0.01
Performance
Factor 1.01
Performance
Rating 101%

67
 Table 19 Westing House rating System Department 9
Westinghouse Rating
System
Skill A2 0.13
Effort A2 0.12
Condition A 0.06
Consistency A 0.04
Algebraic Sum 0.35
Performance
Factor 1.35
Performance
Rating 135%

Table 20 Westing House rating System Department 10

Westinghouse Rating
System
Skill B2 0.08
Effort A2 0.12
Condition A 0.06
Consistency A 0.04
Algebraic Sum 0.3
Performance
Factor 1.3
Performance
Rating 130%

1.5.8 Allowance Determination of Improvement Method

The allowance percentage must be calculated at the first place in order to

calculate the normal time. In this practium, the allowance time is 7% from the
overall time of departement 3,5,7,8,9,10 and 9% from the overall time of
departement 1,2,4,6. The formula to calculate allowance percentage require
the time allowance for each of the product, the calculation below giving the
example for departement 1 allowance time determination:

68
 ∑Allowance = 122.76 × 0.09%
∑Allowance = 11.048

The next step is to use the formula below to calculate allowance

percentage for each Departement. For instance is the calculation for
Departement 1. In which only consist of one work element that is inpection
.
∑Allowance
% Allowance =
∑Allowance + ∑Operation + ∑ Material Handling Time
× 100%

106.70
= × 100%
106.70 + 1185.64 + 3.24
= 8.054 %

The calculation above is done for all five Departements. Thus, the
data recapitulation is listed in table below.

Table 1 Data Recapitulation of Allowance

Departement Average Average Average Allowance

Number of Number of Number of (%)
Allowance Operation Material
Time Time Handling
Time
1 10.670 118.564 3.248 8.054
2 9.595 106.61 3.667 8.004
3 1.409 20.535 1.05 6.126
4 8.731 97.017 3.213 2.949
5 5.98 85.44 5.372 6.17
6 51.635 74.464 8.016 5.976
7 1.97 28.149 1.422 6.247
8 1.970 28.155 0.87 6.358
9 5.082 72.603 1.684 6.403
10 0.407 5.822 1.631 5.184

1.5.9 Normal Time Determination of Improvement Method

In the improvement of the production line, the new production line have 10
departements with rearranged work element deployment for each of the
departement. This case resulting the calculation of allowance includes for 10

69
departement and also impact the calculation of normal time. Below is the
calculation for Departement 5 which the data already showed in the previous sub
chapter.

𝑇𝑛 = 89.572 × 115 %

𝑇𝑛 = 103.0078

Thus , the normal time for Departement 5 is 9,298 seconds. Meanwhile, the result
of normal time calculation for all Departements are:

Actual Performance Normal Time Normal Time

Departement
Time Rating (seconds) (hour)

1 121.812 111% 135.2113 0.037559

2 114.39 108% 123.5412 0.034317
3 21.098 119% 25.10662 0.006974
4 100.231 113% 113.261 0.031461
5 89.572 115% 103.0078 0.028613
6 82.234 113% 92.92442 0.025812
7 29.571 114% 33.71094 0.009364
8 28.281 101% 28.56381 0.007934
9 74.287 135% 100.2875 0.027858
10 9.473 130% 12.3149 0.003421

1.5.10 Standard Time Determination of Improvement Method

As already mentioned in the previous subchapter, the new production line
of the improvement method has 10 departments. This change causes the change in
work elements performed by each department, and thus resulting change in the
allowance, normal time, and standard time as well. The formula of standard time
calculation is same with the formula used to calculate standard time in the initial
method. However, the example of standard time calculation of improvement
method will be provided below.

Standard time = 𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑖𝑚𝑒 + (𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑖𝑚𝑒 𝑥 % 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒)

Standard time = 0,0375587 + (0,0375587 𝑥 8,05 % )

Standard time = 0,0375587 + (0,003024978)

Standard time = 0,040583678 ℎ𝑜𝑢𝑟/𝑢𝑛𝑖𝑡

70
 Meanwhile, below is the recapitulation table of the standard time for each
department.

Departement Normal Allowance Standard Standard

time(hour) (%) time time (hour)
(seconds)
1 0,0375587 8,05 146,1012397 0,040583678
2 0,034317 8,00 133,4294376 0,037063733
3 0,006974061 6,13 26,64465154 0,007401292
4 0,031461397 2,95 116,6010978 0,032389194
5 0,028115656 6,17 107,4614094 0,029850392
6 0,025583911 5,98 97,6061003 0,027112806
7 0,00936415 6,25 35,81686242 0,009949128
8 0,007934392 6,36 30,37989704 0,00843886
9 0,002785763 6,40 10,67088554 0,002964135
10 0,003420806 5,18 12,95330442 0,00359814

1.5.11 Line Standard Time and Line Standard Output of Improvement Method
As already explained in the previous subchapter, line standard time is the amount
time required from maximum time in the parallel departments and the series departments.
Because there are changes in departments and production line, the line standard time will
also be changed. In the initial method, there was no parallel departments, while in the
improvement method, there are five parallel departments with two different sequence.
Those are Department 1, 2, and 3 in the first sequence, in which Department 1 has longest
standard time. The second parallel departments are Department 5 and 6 in the third
sequence, in which Department 5 has longest standard time. The line standard time
formula and calculation will be shown below.

Line Standard Time = {Max time of parallel dept} + standard time in series

Line Standard Time = 146,1012397 + 313,8834094

Line Standard Time = 459,9846963 seconds

Meanwhile, for line standard time of the improvement method can be calculated
using the formula below. The calculation is also provided after the formula.

71
 1
Standard Line Output =
459,9846963

Standard Line Output (seconds) = 0,002173985

Standard Line Output (hours) = 7.826347331

1.5.12 Flow Diagram of Improvement Method

1.5.13 Flow Process Chart of Improvement Method

No Symbol Description Time
Draw mica pattern
118.564

Material Handling to
3.248
department 4

Tabel 1.66 Flow Process Chart Department 2

No Symbol Description Time
Draw basic pattern of
souvenir box 110.852

Material Handling to
3.497
department 4

Tabel 1.67 Flow Process Chart Department 3

No symbol description time
`
Assembly lower and
8.173
body

`
Put the content of the
4.63
pen

`
Fasten the upper 3.828

72
 No symbol description time
`
Fasten the upper 3.524

Material Handling to
0.94
department 8

Tabel 1.68 Flow Process Chart Department 4

No Symbol Description Time
Waiting

`
Mark part of the paper
52.2727
that will be folded

`
Draw folded mica
44.7451
pattern

`
Material Handling to
3.2134
deprtment 5 and 6

Tabel 1.69 Flow Process Chart Department 5

No Symbol Description Time
Waiting

Cut mica
46.892

Fold mica pattern that

have been marked 37.258

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 No Symbol Description Time

Material Handling to
5.422
department 9

Flow Process Chart Department 6

No Symbol Description Time
Waiting

`
Cut souvenir box
74,464

Material Handling to
8,016
department 7

Flow Process Chart Department 7

No Symbol Description Time
Waiting

`
Fold top souvenir box 11.794

`
Fold side souvenir box 8.519

`
Stick top of right and
7.836
left side

Material Handling to
1.422
department 8

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Flow Process Chart Department 8
No Symbol Description Time
Waiting

`
Stick the fastening top
25.872
part

Insert pen into the

1.546
souvenir box

Material Handling to
0.863
department 9

Flow Process Chart Department 9

No Symbol Description Time

Waiting

`
Cut inappropriate
39.364
mica

`
Stick mica to the box
33.936
with glue

Material Handling to
1.628
department 10

Flow Process Chart Department 10

No Symbol Description Time

Waiting

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 No Symbol Description Time
`
Inspection
7.282

Storage 1.965

1.5.14 Operation Process Chart of Improvement Method

In this subchapter, the diagram that shows the overall operation process of
the operation of making souvenir is given below. It shows the material that is used
and the processes that needed to process the material.

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1.6 Percentage of Improvement Between Initial and Improvment Condition
This percentage shows the productivity ratio in initial and improvement
method consists of ratio between each output.

Standard Line Output Initial Condition = 0,0008714273

Standard Line Output Improved Condition = 0,002173985

Standard Line Output Initial Condition
Improvement percentage = Standard Line Output Improved Condition

0,0008714273
=
0,002173985

= 0,40084331

This means that the initial is only 40% compared to the improvement. This
means that the improvement is 60% better than the initial.

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 2 CHAPTER II
DATA ANALYSIS AND INTERPRETER
2.1 Comparison Analysis of Stopwatch Time Study between Initial and
Improvement Method
Stopwatch time study is one of the measurement that is done directly on a
short and repetitive work (Wingjosoebroto, 2000). This measurement is used to
identify the average time of assembling process of 10 souvenir box. In the initial
process, there are 5 department of assembly, which are; pattern drawing ad
cutting, souvenir box assembling, pen assembling, pen and souvenir box
assembling, and inspection. the average number of operation time of department
one is 273.3 s, department two is 80.53, department three is 19.4 s, department
four is 58.64 s, and department five is 7.04 s.
Then the line balancing is done. The result shows that with 21 work
element are groups into 10 department for the whole process to produce smaller
lead time and increase effectivity and efficiency. Thus, this result is used for
making further improvement. Before in the initial condition, the third department
which is the pen assembly takes a big operation time because of the operator
found difficulties in matching the cap color of the pen. Therefore in the
improvement condition, extra lamps are added to increase the brightness of the
work station.
In the improvement condition, the average number of operation time of
department one is 118.56 s, department two is 106.61 s, department three is 20.54
s, department four is 97.02 s, department four 97.02 s, department five is 85.44 s,
department six is 74.46 s, department seven is 28.15 s, department eight is 28.155
s, department nine is 72.60, and department ten is 55.822. The decrease of
operation time are caused by a smaller number of elements that is done by one
department and because of the operator that is already used to the work element
therefore they can produce the product faster.

2.2 Analysis of Line Balancing

The line balancing was done by using Largest Candidate Rule (LCR)
method. The calculation sequence started by defining all of the working element
and also their ‘Te’ or time needed for doing certain element. After assigned, all
the elements are sorted according to the biggest Te to the least Te. The station
arrangement are arranged by assigning element starting from the top of the list
that not violate their predecessor. After found one, these element are assigned to
first station, and then start again from the top to find the next element to be
assigned to the first station. If the total Te in one station exceed the cycle time,
then it is time to move to the next station. It was done for all the elements.

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 The result is there are 10 station in total, which depicted in the chapter
before. Some of them are parallel, some are sequence to each other. According to
the LCR method, the improvement apply around 45 seconds of average time from
the longest element operation time needed.
Based on the efficiency balancing calculation, the result is 22.73%. This
value means that the efficiency ratio is 22.73 out of 100. The gap is happened
because of the accumulation of waiting and idle time on entire line. However, the
delay balancing is around 78%. This value obtained by subtracting 1 to the
efficiency value. This is because delay is the opposite attribute of the efficiency.
In this case, the delay is covering up to more than 70% which is not so efficient.
In application, the delay comes from the waiting and idle time of the operator.
Even though the waiting or idle time is short, however almost all ten department
are having an idle time so that it covering so much time. In the real application,
the improvement have reduced the cycle time more than more than 20 seconds so
it is faster after all.

2.3 Comparison Analysis of Standard Time and Standard Output between

Initial and Improvement Method
Standard time is the time required by an average skilled operator, working
at a normal place, to perform a specific task (Zandin & Maynard, 2001). The
value of standard time for each department depends on the normal time that has
been calculated previously. The standard time represents the normal time added
with an allowance relative to that normal time. In line balancing, the line standard
time is the time required to finish one product in that assembly line. From the
result of line standard time, line standard output is also calculated. Standard
output refers to the number of products than can be produced within 1 time period
(second, hour, etc), under the assumption that the operator is average-skilled and
is working under normal condition. It is calculated by dividing 1 by the standard
time.
In this practicum, the initial assembly line consisted of 5 departments. However
the workload of the departments were uneven so bottleneck occured. From the
calculated normal time, department 1 and 2 took up to 80% of the total time of the
entire assembly line. Department 1 took approximately 329.5 seconds and
department 2 took 117.9 seconds meanwhile department 5 only took 8.5 seconds.
Because of this, improvements were made for the assembly line and 5 new
departments were created. Department 1 and 2 were split according to their work
elements so that the delay for the departments can be reduced. For the initial
method, department 1 was in charge of drawing the pattern for the mica as well as
the souvenir box carton. In the improved assembly line, these jobs were split into
departments so that the next departments don’t have to wait for both of the mica
and carton pattern to be drawn.

79
For comparing the initial and improved methods, the line standard time and
standarrd output are analyzed. The initial method produced a standard time of
1,147.54 seconds or about 19.12 minutes. Whereas for the standard output, it is
calculated by dividing 1 by the normal time in seconds. The calculations yielded a
value of 0.000871. For the improved method, the line standard time decreased by
59.91% or becoming 459.984 seconds. Meanwhile the standard line output is
boosted to 0.00217.

2.4 Analysis of Percentage of Improvement between Initial and

Improvement Method
Productivity is commonly defined as a ratio between the output volume
and the volume of inputs. In other words, it measures how efficiently production
inputs, such as labor and capital, are being used to produce a given level of output
(Krugman, 1994). Productivity is considered a key source of economic growth
and competitiveness and, as such, is basic statistical information for comparisons
and performance assessments.

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 3 CHAPTER III
CONCLUSION AND SUGGESTON

3.1 Conclusion
Stopwatch time study that is applied for repetitive and short-in-time jobs. It
can be implemented for assembly line that produces the same products
repetitively. By using stopwatch time study, the standard time and standard output
of the assembly line can be measured. Because of this, sources of problems that
cause time inefficiency can be identified. Thus, improvements can be made and
the time efficiency can be increased.

3.2 Suggestion
- Repair the station/department facility such as lamp, so that it would operate
properly
- Provides a choice of station tables to be able to improve the condition rating
- Give a brief 5-10 minutes explanation before the trial process in initial
conditioned started, to confirm that all students understand and ready

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 4 REFERENCES

Krugman, P., 1994. The Age of Deminishing Expectations. In: Defining and
Measuring Productivity. s.l.:s.n.
Wingjosoebroto, S., 2000. Ergonomi: Studi Gerak dan Waktu. Surabaya: Jurusan
Teknik Industri-ITS.
Zandin, K. B. & Maynard, H. B., 2001. Maynard's Industrial Engineering
Handbook. 5 ed. New York: McGraw-Hill.

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