Case Study

School of Mechanical and Industrial Engineering,
Department: production Engineering and management

(PG)
Case study on method study and ergonomics
Title: Improvement in process industries by using work study
method: A case Hawi flour and macaroni factory
Name: Zewude Hirpesa
ID No. DDU1300743
Submitted to: Dr. K. Balasundaram
Assistant Professor
Submission date: 15/07/2021

Improvement in process industries by using work study method: A case Hawi flour and macaroni factory
Acknowledgement
First of all, I would like to thanks to the creator of heaven and earth. Next, to God I would like
to thanks to Dr. K. Balasundaram (ass. Professor) how’s give this semester term paper as I
develop my ability to think how to solve the problem and initiate me by teaching every aspect of
finding problem and finding the solution for that problem. Secondly, I would like to thanks Mr.
Jima Megersa and Mr. Daniel how’s give for me the key of their office as I use internet to at
their office to complete this semester term paper. The last not least thanks to all of my friend,
teachers, Dire Dawa university staff and supporting staff who directly or indirectly stand with
me.
II
Abstract
In world industrial there is a great challenging on quality product, cost of manufacture, delivery of
both finished and raw material at a time. To achieve success in the global market it is required
fundamental improvement in the way of utilization of available recourse in proper manner for
increase the productivity. The purpose of this paper is to develops the systematic improvement on
Hawi flour and macaroni factory.
This case study applying a method of work study principles to reducing unwanted movement of
worker, machine and all equipment in Hawi flour and macaroni factory, for reduction of
manufacturing cost simultaneously while productivity of the company is increased.
A key factor when developing work study and work measurement at hawi flour and macaroni
factory formulate the standard time of operation, improve unwanted movement of worker,
utilization of available recourse without changing the amount of recourse and training the worker
at standard time for farther improvement of the organization productivity.
This paper provides an insight to judge the work study method and work measurement concept for
Hawi flour and macaroni factor context and offers framework for the company.
Key term: Hawi flour factory, work study, industrial systematic improvement, time study, work
measurement, flour and macaroni Industrial flow process.
III
Contents
Abstract ........................................................................................................................................................ III
Acknowledgement ........................................................................................................................................ II
1 Introduction ........................................................................................................................................... 1
1.1 Basic procedure of Work Measurement ....................................................................................... 2
1.2 TIME STUDY................................................................................................................................... 3
1.1.1 PROCEDURE OF TIME STUDY. ....................................................................................... 4
2 Case study ............................................................................................................................................. 5
1.3 Observation................................................................................................................................... 5
1.4 Problems faced in existing process ............................................................................................... 7
1.5 Improvement in process ............................................................................................................. 13
3 Calculation and numerical analysis..................................................................................................... 19
4 Conclusion .......................................................................................................................................... 22
5 References ........................................................................................................................................... 23
table 1 Flow chart of existing process ........................................................................................................... 8

Table 2Flow chart of improved process ...................................................................................................... 13
Figure 1 work study ...................................................................................................................................... 2

Figure 2 work measurement dominiques ...................................................................................................... 3
Figure 3 Fig step of time study ..................................................................................................................... 4
Figure 4 over all flow process of macaroni production ................................................................................ 7
IV
1 Introduction
In today’s challenging market, every organization is looking to achieve higher quality and
productivity. Productivity improvement is an everlasting continuous activity in manufacturing.
Industries need to develop capability of coping up with customer demands to deliver quality
products on time. Hawi flour factory is one of Ethiopian factory which is established August
26/2005 in Dire dawa town to produce and marketing macaroni. Macaroni is a universally enjoyed
food, and almost every country serves a type of noodle. It is made from a mixture of water and
semolina flour. Semolina is a coarse-ground flour from the heart, or endosperm, of durum wheat,
an amber-colored high protein hard wheat that is grown specifically for the manufacture of
macaroni. With a lower starch content and a higher protein content than all-purpose flours,
semolina flour is easily digested. Farina, rougher granulations of other high-quality hard wheat, is
also used to make some macaroni’s.
Nevertheless, the great deal of effort is required in factory for effective production that includes
less production time and higher efficiency, are to measure the work content of the job by measuring
the time required to do the job for a qualified worker, to establish the standard time and train the
worker at that standard time. To set standard time for the worker and every flow process required
for production of flour and macaroni at Hawi flour factory every worker and management have to
know the concept of work study to developing a new working method by using some Engineering
Techniques.
Work study highly concerned with increasing the productivity by utilizing of resource without
adding the quantity of the resource but by changing the method of doing job. Work study is a
generic term for those techniques, particularly method study and work measurement, which are
used in the examination of human work in all its contexts, and which lead systematically to the
investigation of all the factors which affect the efficiency and economy of the situation being
reviewed, in order to effect improvement.
The amount of work in a given job is referred to as work content. The work study consists of two
techniques. The first is Method Study: Method study is the systematic recording and critical
examination of existing and proposed ways of doing work. It is concerned with the reduction of
work content of a job or operation and the second techniques Work Measurement: Work
Measurement is the application of techniques designed to establish the time for a qualified worker
to carry out a specified job at defined level of performance. It is concerned with the investigation
and reduction of any ineffective time associated with it.
The amount of work in a given job is referred to as work content. The work study consists of two
techniques. The first is Method Study: Method study is the systematic recording and critical
examination of existing and proposed ways of doing work. It is concerned with the reduction of
work content of a job or operation and the second techniques Work Measurement: Work
1
Measurement is the application of techniques designed to establish the time for a qualified worker
to carry out a specified job at defined level of performance. It is concerned with the investigation
and reduction of any ineffective time associated with it.
work study
work method
mesurement study
motion
time study
study
Figure 1 work study
1.1 Basic procedure of Work Measurement

The basic procedure needs to be understood to apply modified technique of work measurement.
The basic procedure is divided into six steps namely selection, recording, examining, measuring,
compiling and precisely defining methods. Full steps need to be performed only when standard
time is to be calculate.
2
selection, recording, examining,

measuring, compiling and
precisely defining methods
work stop watch predetermined

sampling time study time standards
with allowence to get

to get standard standard time
time of of operation
operation
to establish
standard data
bank
Figure 2 work measurement dominiques
1.2 TIME STUDY

Time study is the technique of work measurement to establish time for a qualified worker to
carry out specified task under specified conditions and at defined level of performance. Basic
time study equipment consists of a stopwatch, a study board and time study forms. The time
study procedure consists of steps such:
3
Figure 3 Fig step of time study
Time study can be performed depending on the accuracy of stopwatch method, time recording
machine and motion picture camera
1.1.1 PROCEDURE OF TIME STUDY.

• Identifying the job to be timed and operations to be timed
• Obtaining an improved procedure from method study department
• Select worker for study
• Collecting the equipment and arrange machinery required to conduct time study and ensure
accuracy in recording time
• Explaining to the worker the improved working procedure and use of tools and fixtures
• Breaking the job into operations and operations into elements and writing them in a proper
format
• Conducting the observations and recording them on the time study form
• Rating the performance of the worker
4
2 Case study
1.3 Observation
After deep observation and collecting information about the flow process and work study of Hawi
flour factory. I discussed with engineer, managers, labour force, guard and all stakeholder of Hawi
flour factor to improve the problem I was seen in the factory. Hawi flour factor produce macaroni
and the production flow process starting from wheat cultivating to supplies macaroni for its
customer are as follow. Hawi flour factory transport hard wheat from different part of our country
like Asella, Jijjiga, Adama and some amount of flour from India, Turkey, and Egypt depend on
the requirement of the product. The flour imported is the finished product it is directly used for
making macaroni. The wheat transported from our country to Hawi flour factory are inter to flour
mill. First the wheat is stored in silos with wheat of the same grade until needed for milling. Before
wheat can be ground into flour it must be free of foreign matter. This requires several different
cleanings processes. By using a device known as a separator wheat and other small particles pass
through the screen while large objects such as sticks and rocks are removed. Then the wheat next
passes through an aspirator. This device works like a vacuum cleaner. The aspirator sucks up
foreign matter which is lighter than the wheat and removes it. A disk separator, moves the wheat
over a series of disks with indentations that collect objects the size of a grain of wheat. Smaller or
larger objects pass over the disks and are removed. After disk separator other ingredient like wheat
include magnets to remove small pieces of metal, scourers to scrape off dirt and hair, and electronic
color sorting machines to remove material which is not the same color as wheat. After purification
wheat is washed in warm water and placed in a centrifuge to be spun dry. During this process any
remaining foreign matter is washed away. The moisture content of the wheat must now be
controlled to allow the outer layer of bran to be removed efficiently during grinding. Wheat of
different grades and moistures is blended together to obtain a batch of wheat with the
characteristics necessary to make the kind of flour being manufactured. At this point, the wheat
may be processed in an Entoleter, a trade name for a device with rapidly spinning disks which hurl
the grains of wheat against small metal pins. Those grains which crack are considered to be
unsuitable for grinding and are removed. Finally, the wheat inters into rollers of two different sizes
and move at different speeds. By this roller known as breaker roller the desired final product is
produced. At the end flour is obtained and small amounts of bleaching agents and oxidizing agents
are usually added to the flour after milling. Vitamins and minerals are added as required by law to
produce enriched flour. The flour is packed into cloth bags according to the necessity of flour.
Now the flour is produced and the production of macaroni’s started. At first stage of macaroni
production flour is stored in giant silos. Then Pipes move the flour to a mixing machine equipped
with rotating blades in pre mixer. Pre mixer is mix flour with water at first stage and transport the
mixture to main mixer for mixing flour and water at the same proportion. Main mixture is
connected to vacuum mixer and in vacuum mixer the powder of wheat left without mixed with
water are sucked and removed from the mixture. The main purpose of vacuum mixer is for color
5
making, for humidification and removing unmixed powder by sucking. Pure mixture is interring
to compression screw. Compression screw using high pressure around 140 bar. At this pressure a
vacuum mixer-machine further flattens the dough while pressing air bubbles and excess water
from the dough to reach the optimum water content of 12%.
The next is die. Depend on the size and shape of macaroni ordered from customer Hawi flour
factor are produce macaroni for customer. There are around four types of die are used in Hawi
flour factory. They are small elbow die for producing small size macaroni, medium elbow die for
medium product of macaroni, big elbow die for big sized macaroni and spiral elbow die for
manufacturing spiral type macaroni. After the shape and size of macaroni are identified depending
on its size the macaroni is inter into cutter and cuter are cut according to the order given from die
and transported to trebato for drying. In trebato macaroni are somewhat wet and by using packet
elevator it is transported to main dryer. Main dryer is classified in to pre dryer and dryer. In pre
dryer by using high temperature around 94℃ and at this temperature macaroni gate elasticity form
and humidification at this temperature. In this stage the wet in macaroni are evaporated as
humidification form and inter to dryer. The main purpose of dryer is for stabilization of macaroni.
The drying time is critical because if the macaroni is dried too quickly it will break and if it is dried
too slowly, the chance for spoilage increases. The macaroni is placed in a drying tank in which
heat, moisture, and drying time are strictly regulated. The drying period differs for the various
types of macaroni. After dryer the macaroni transported to cooler in addition to cooling the
macaroni the main advantage of cooler is make macaroni is sensitive with environmental air
condition. Depending on the outside atmosphere cooler are cooling for farther attractive color and
good surface finishing. Macaroni is ready now and check the quality of the macaroni and
depending on the weight ordered from customer macaroni are packing in bag. Macaroni is
transported to warehouse by human some amounts are transported to selling center found in dire
dawa city. Finally, the customer purchases the product from the company or some selling center
at dire dawa city.
6
Wheat is Remove Aspirator

Separator
Wheat stored in foreign vacuum
screen
silos matter clenaner
Magnets, scourers
Conditioning Washar Spiral seed Disc
and electronic
or tempering stoner separator separator
color sorting
Breaker Enriched
Entoleter Middlings Bleaching
rolls. flour
Flour is
Main mixer Pre mixer stored in Dispatch Packaging
giant silos
Vacuum Compresso
Die Cutter Trebato
mixer r screw
Dispatch Packaging Cooler Dryer Pre dryer
Warehouse Customer
Figure 4 over all flow process of macaroni production
1.4 Problems faced in existing process

1. Some amounts of flour are transported from foreign country this required much money for
import to overcome this problem Hawi flour factory must increase the amount of wheat
transported in our country by cultivating wheat by itself.
2. It is producing 10 𝑘𝑢 per hour and 24 × 10 = 240 𝑘𝑢⁄𝑑𝑎𝑦 the car which transport
macaroni at Hawi flour factory carrying capacity is 300 𝐾𝑢 to fill the order the car stop for
more than a day. This makes customer dissatisfaction.
3. The flour is transported to giant silos by human it takes more time and less productivity.
7
4. The finished product is transported to ware house by manual it consumes labour force and
money.
table 1 Flow chart of existing process
Process flow chart 1 Type: material
Chart No 1 Summary of the activity

Sheet No 1 of 1
Subjected chart: Activity Symbol Existing Proposed Saving
Hawi flour factory work
study analysis
Method: existing Operation 18
Location: Dire Dawa Inspection 6

Charted by: Zewude H.
Date: 17/06/2021
Approved by: Bal Date:
Distance In Transportati 6
meter on
Operation Time In min Delay 1
Storage 5
Description quantit Distance Time Symbol Remark

y
(QYT)
Wheat 79000meter 48 hr
transported to
Hawi flour *
factory
Wheat is stored 24hr 5
in silos until
needed for * laboure
rs
milling
8
Removing 5hr 10
foreign mater
from wheat for * laboure
rs
milling
wheat is 20min 2
inspected and
purified again if * laboure
rs
necessary
Depending on 20min 2
the properties of
material, size of * laboure
rs
material
separate wheat
from extra
gradient
Purified wheat 1hr 3
is washed in
warm water and * laboure
rs
placed in a
centrifuge to be
spun dry
Removing the 30min 1labour
moisture
content of *
wheat for
efficient for
grinding
Wheat of 2
different grades
and moistures is * laboure
rs
blended
together
wheat moves 2 meters 1min 1labour
between two
large metal
rollers known
as breaker
rolls to make *
the kind of flour
being
manufactured
and middiling is
formed
The middlings 5min 1
purifier moves
the middlings * labour
9
over a vibrating
screen
By sifting, 1hr 4labour
separating, and
regrinding the * ers
flour, several
different grades
of flour are
produced at the
same time.
Adding small 3min 1
amounts of
bleaching * labour
agents and
oxidizing
agents
Enriching flour 2min 1
by adding
Vitamins and * labour
minerals
Packaging by 1min 2
bag
* laboure
rs
Dispatch flour
*
Store flour by 100 meter 1hour 30 5
worker in
company
min
* laboure
rs
warehouse
Transport flour 50 meter 40 min 4
in giant silos by
worker * laboure
rs
Pipes move the 3 meter 30sec
flour to a mixing
machine *
equipped with
rotating blades
in pre mixer
Mix flour with 1 min 1labour
warm water at
pre mixer *
Managing the 4min 1
proportion of
water with flour * labour
in main mixture
10
Vacuum mixing 3 min 1

* labour
Identifying the 2
color
powder
and
left * laboure
rs
without mix
with water
A vacuum 3min 1labour
mixer-machine
further flattens
the dough while
pressing air
bubbles and *
excess water
from the dough
to reach the
optimum water
content of 12%.
Depending on 24rpm 2
the size and
shape of * laboure
rs
macaroni
ordered from
costumer check
the die
appropriate fit
for customer
need
Using different 1min 1labour
die shaping and
sizing macaroni *
Cutting 54rpm 1labour
macaroni
depending on *
sized and
shaped
Store macaroni 10min
in trebato
*
Transport 3 meters 1hr and 1
macaroni by
bucket elevator
10min
* labour
to pre dryer for
11
making
elasticity form
elasticity form 1labour
of macaroni is
interring to *
dryer for drying
strictly 2hr 50
The oxygen min 1labour
level in the tank
is regulated,
and lab
technicians test
frequently for *
salmonella and
other bacteria.
Cooling 2 min 1labour

macaroni with
relative to
environmental
atmospheric
condition *
Quality control 30 min 1
technicians
constantly test * labour
the macaroni
for elasticity,
texture, taste,
and tolerance to
overcooking
Packing 1min 2
depends on the
kg ordered from * laboure
rs
customer
Waiting to fill 24 hr
the order since
the car transport
300𝑘𝑢 per day
and Hawi flour
factory produce *
240 𝑘𝑢 𝑝𝑎𝑟 𝑑𝑎𝑦
Transport 20 meters 2hr 5
finished product
to company * laboure
rs
12
warehouse and
selling center
Store and 1
selling
macaroni to end * labour
user
1.5 Improvement in process

Importing flour from other country is very cost and required much time for delivering for customer
after it cultivated by itself and fill the customer by internal transported wheat the manufacturing
cost is highly reduced and productivity of the company automatically increased. The second major
improvement is previously it use worker, it minimizes productivity and discomfort to worker it is
batter to use belt conveyer system for moving macaroni to warehouse and transport flour from
warehouse to giant silos. In addition to this Hawi flour factory uses old machine which production
capacity of 10𝐾𝑢 𝑝𝑒𝑟 𝑑𝑎𝑦 after improvement Hawi flour factory use modern machine for high
production rate.
Table 2Flow chart of improved process
Process flow chart 2 Type: material
Chart No 2 Summary of the activity

Sheet No 1 of 1
Subjected chart: Activity Symbol Existing Proposed Saving
Hawi flour factory work
study analysis
Method: Proposed Operation 18 18 0
Location: Dire Dawa Inspection 6 6 0

Charted by: Zewude H.
Date: 17/06/2021
Approved by: Bal Date:
Distance In meter Transportati 6 6 0
on
Operation In min Delay 1 0 1

Time
13
Storage 5 5 0
Location In meters 79178 30178 meters 49000

meters meters
Operation In minute 6807min 3845 min 2962 min
clock’s
Worker force Number of labourers 67 62 labourers 5
labourers labourers
Description QYT Distance Time Symbol Remark
Use wheat 30000meter 24 hr

nearest to
company like *
Adama and
Jigjig as well
as cultivate
by itself
Wheat is 24hr 5
stored in
silos until * labourers
needed for
milling
Removing 5hr 10
foreign mater
from wheat * labourers
for milling
wheat is 20min 2
inspected
and purified * labourers
again if
necessary
Depending 20min 2
on the
properties of * labourers
material, size
of material
separate
wheat from
extra
gradient
14
Purified 1hr 3
wheat is
washed in * labourers
warm water
and placed in
a centrifuge
to be spun
dry
Removing g 30min 1labour
the moisture
content of *
wheat for
efficient for
grinding
Wheat of 2
different
grades and * labourers
moistures is
blended
together
wheat moves 2 meters 1min 1labour
between two
large metal
rollers
known
as breaker *
rolls to make
the kind of
flour being
manufacture
d and
middiling is
formed
The 5min 1 labour
middlings
purifier *
moves the
middlings
over a
vibrating
screen
By sifting, 1hr 4labourer
separating,
and * s
regrinding
the flour,
15
several
different
grades of
flour are
produced at
the same
time.
Adding small 3min 1 labour
amounts of
bleaching *
agents and
oxidizing
agents
Enriching 2min 1 labour
flour by
adding *
Vitamins and
minerals
Packaging by 1min 2
bag
* labourers
Dispatch
flour
*
By belt 100 meter 30 min 2
conveyer
transport to * labourers
flour
warehouse
Transport 50 meter 20 min 2
flour in giant
silos by belt * labourers
conveyer
Pipes move 3 meter 30sec
the flour to a
mixing *
machine
equipped
with rotating
blades in pre
mixer
Mix flour 1 min 1labour
with warm
water at pre *
mixer
16
Managing 4min 1 labour

the
proportion of *
water with
flour in main
mixture
Vacuum 3 min 1 labour
mixing
*
Identifying 2
the color and
powder left * labourers
without mix
with water
A vacuum 3min 1labour
mixer-
machine
further
flattens the
dough while *
pressing air
bubbles and
excess water
from the
dough to
reach the
optimum
water content
of 12%.
Depending 24rpm 2
on the size
and shape of * labourers
macaroni
ordered from
costumer
check the die
appropriate
fit for
customer
need
Using 1min 1labour
different die
shaping and *
17
sizing
macaroni
Cutting 54rpm 1labour
macaroni
depending on *
sized and
shaped
Store 10min
macaroni in
trebato *
Transport 3 meters 1hr and 1 labour
macaroni by 10min
bucket
elevator to
pre dryer for
making *
elasticity
form
elasticity 1labour
form of
macaroni is *
interring to
dryer for 2hr 50 min
drying
strictly
The oxygen 1labour
level in the
tank is
regulated,
and lab
technicians *
test
frequently
for
salmonella
and other
bacteria.
Cooling 2 min 1labour

macaroni
with relative
to
environment
al *
18
atmospheric
condition
Quality 30 min 1 labour
control
technicians *
constantly
test the
macaroni for
elasticity,
texture, taste,
and tolerance
to
overcooking
Packing 1min 2
depends on
the kg * labourers
ordered from
customer
Transport 20 meters 2hr 5
finished labourers
product to
warehouse
and selling
center *
Store and 1 labour
selling
macaroni to *
end user
3 Calculation and numerical analysis

𝑜𝑢𝑡𝑝𝑢𝑡
𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑎𝑏𝑜𝑢𝑟 𝑖𝑛𝑝𝑢𝑡
In existing method, the productivity of Hawi flour factory is
𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑑𝑖𝑟𝑖𝑛𝑔 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑 𝑝𝑒𝑟 𝑑𝑎𝑦

𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑎𝑏𝑜𝑢𝑟𝑒𝑟𝑠
240 𝑘𝑢
67 𝑙𝑎𝑏𝑜𝑢𝑟𝑒𝑟𝑠
𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = 3.58 𝑘𝑢⁄𝑙𝑎𝑏𝑜𝑢𝑟
19
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 ℎ𝑜𝑢𝑟
In Hawi flour and macaroni factory machine is working every day for 24 hours to produce 10ku
of macaroni per hour.
The productivity of machine in this factory in existing method is
𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑖𝑛 𝑎 𝑑𝑎𝑦𝑠

24ℎ𝑟
240
24ℎ𝑟
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = 10 𝑘𝑢⁄ℎ𝑟
In proposed method the productivity of hawi flour and macaron I factory is:
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 ℎ𝑜𝑢𝑟
𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑖𝑛 𝑎 𝑑𝑎𝑦
24
300 𝑘𝑢
24 ℎ𝑟
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = 12.5 𝑘𝑢⁄ℎ𝑟
𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑑𝑖𝑟𝑖𝑛𝑔 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑

𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑 =
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑎𝑏𝑜𝑢𝑟𝑒𝑟𝑠
300
62 𝑙𝑎𝑏𝑜𝑢𝑟𝑒𝑟𝑠
𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = 4.84 𝑘𝑢⁄𝑙𝑎𝑏𝑜𝑢𝑟
Productivity change can be calculated as
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑 − 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 12.5 − 10
𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 2.5%
𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑 − 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑
20
𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑 − 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑
𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 4.84 − 3.58
𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 1.26 𝑘𝑢⁄𝑙𝑎𝑏𝑜𝑢𝑟𝑒𝑠
21
4 Conclusion
During my supervision of Hawi flour and macaroni factory the existing processes consume the
numbers of worker as well as low in productivity because the un wanted movement of the worker,
machine, equipment and transporting raw material from a far distance. Using conveyer system for
transporting finished goods and raw material inside the company improve the unwanted movement
of worker and transport the product safely. By Appling, the principle I addressed to hawi flour and
macaroni factor the company increase the productivity of machine and labour by 2.5% and 1.26%
within the hour respectively. In generally in addition to increase the machine and labourers
productivity the company improve the quality of product, increase the satisfaction of customer,
moral of workers, utilization of recourse like machine, man, method, money, material and
simultaneously increase the wall productivity of the company.
22
5 References
[1] Singh, M. P., and Hemant Yadav. (2016). "Improvement in process industries by using work study
methods: a case study.". Int. J. Mech. Eng. Technol 7, no. 3, 426-436.
[2] Karger, D.W. and Bayha, F.H., 1987. Engineered work measurement: the principles, techniques,
and data of methods-time measurement background and foundations of work measurement and
methods-time measurement, plus other related material. Industrial Press Inc..
[3] Singh, M. P., and Hemant Yadav. (2016). Singh, M. P., and Hemant Yadav. Singh, M. P., and
Hemant Yadav., 436-450.
[4] Singh, M. P., and Hemant Yadav. "Improvement in process industries by using work study
methods: a case study." Int. J. Mech. Eng. Technol 7, no. 3 (2016): 426-436.
[5] Karger, Delmar W., and Franklin H. Bayha. Engineered work measurement: the principles,
techniques, and data of methods-time measurement background and foundations of work
measurement and methods-time measurement, plus other related material. Industrial Press Inc.,
1987.
[6] Finkler, Steven A., James R. Knickman, Gerry Hendrickson, Mack Lipkin Jr, and Warren G.
Thompson. "A comparison of work-sampling and time-and-motion techniques for studies in
health services research." Health services research 28, no. 5 (1993): 577.
[7] Ampt, A., Westbrook, J., Creswick, N. and Mallock, N., 2007. A comparison of self-reported and
observational work sampling techniques for measuring time in nursing tasks. Journal of health
services research & policy, 12(1), pp.18-24.
[8] Aft, L.S., 2000. Work measurement and methods improvement (Vol. 9). John Wiley & Sons.
[9] Zandin, Kjell B. MOST work measurement systems. CRC press, 2002.
23

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School of Mechanical and Industrial Engineering,

Department: production Engineering and management

Submitted to: Dr. K. Balasundaram

Submission date: 15/07/2021

table 1 Flow chart of existing process ........................................................................................................... 8

Figure 1 work study ...................................................................................................................................... 2

Figure 1 work study

1.1 Basic procedure of Work Measurement

selection, recording, examining,

work stop watch predetermined

with allowence to get

Figure 2 work measurement dominiques

1.2 TIME STUDY

Figure 3 Fig step of time study

1.1.1 PROCEDURE OF TIME STUDY.

Wheat is Remove Aspirator

Dispatch Packaging Cooler Dryer Pre dryer

Figure 4 over all flow process of macaroni production

1.4 Problems faced in existing process

table 1 Flow chart of existing process

Process flow chart 1 Type: material

Chart No 1 Summary of the activity

Method: existing Operation 18

Location: Dire Dawa Inspection 6

Operation Time In min Delay 1

Description quantit Distance Time Symbol Remark

Vacuum mixing 3 min 1

to pre dryer for

Cooling 2 min 1labour

1.5 Improvement in process

Process flow chart 2 Type: material

Chart No 2 Summary of the activity

Method: Proposed Operation 18 18 0

Location: Dire Dawa Inspection 6 6 0

Operation In min Delay 1 0 1

Location In meters 79178 30178 meters 49000

Use wheat 30000meter 24 hr

Managing 4min 1 labour

Cooling 2 min 1labour

3 Calculation and numerical analysis

In existing method, the productivity of Hawi flour factory is

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑑𝑖𝑟𝑖𝑛𝑔 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑 𝑝𝑒𝑟 𝑑𝑎𝑦

𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = 3.58 𝑘𝑢⁄𝑙𝑎𝑏𝑜𝑢𝑟

The productivity of machine in this factory in existing method is

𝑡𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑖𝑛 𝑎 𝑑𝑎𝑦𝑠

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑑𝑖𝑟𝑖𝑛𝑔 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑

Productivity change can be calculated as

𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑 − 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑

𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 12.5 − 10

𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 2.5%

𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑 − 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑

𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 𝑝𝑟𝑜𝑝𝑜𝑠𝑒𝑑 𝑚𝑒𝑡ℎ𝑜𝑑 − 𝑒𝑥𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑒𝑡ℎ𝑜𝑑

𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 4.84 − 3.58

𝑙𝑎𝑏𝑜𝑢𝑟 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐ℎ𝑎𝑛𝑔𝑒 = 1.26 𝑘𝑢⁄𝑙𝑎𝑏𝑜𝑢𝑟𝑒𝑠

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