"YEAR OF STRENGTHENING AND NATIONAL SOVEREIGNTY"

INDEX

INTRODUCTION

1. COMPANY DESCRIPTION

1.1 Business name

1.2 Category
1.3 Brief historical overview of the company
1.4 Product chosen for diagnosis
1.5 Production process description

2. EVALUATION OF THE CURRENT SITUATION OF THE COMPANY

2.1 Current productivity indicators

2.2 Process operations diagram (DOP).

A brief description of the activity being diagrammed must be included.

2.3 Process activity diagram (DAP).

A brief description of the activity being planned must be included.

2.4 Stroke diagram.

It should be diagrammed based on the DAP made in the previous point.

2.5 Man – machine diagram.

A man-machine diagram must be made.
A brief description of the activities being planned must be included.

2.6 Study of times.

The time study must be carried out with the timing method (choose between
return to zero or continuous method)

2.6.1 Information gathering.

2.6.2 Division of the process into elements.
2.6.3 Making times.
2.6.4 Record and analyze timed times.
2.6.5 Apply valuation system and calculate normal time.
2.6.6 Establish supplements and calculate the standard time.

3. IMPROVEMENT PROPOSAL

3.1 Improvement proposal: Process operations diagram (DOP).

A description of the improvement being proposed must be included.

3.2 Improvement proposal: Process activities diagram (DAP). A description of the

improvement being proposed must be included.

3.3 Improvement proposal: Route diagram.

 A description of the improvement being proposed must be included.

3.4 Improvement proposal: man-machine diagram.

A brief description of the improvements being proposed must be included.

3.5 Improvement proposal: Time study

A brief description of the improvements being proposed must be included.

3.6 Production line

Carry out the analysis of the production line. Determine the indicators of the
production line:

3.6.1 Determine the times for each station

3.6.2 Graph the production line
3.6.3 Determine production indicator
3.6.4 Time-out
3.6.5 Efficiency
3.6.6 Base times

3.7 Simple line balance for new demand twice the current production.
Perform a simple line balance assuming a scenario in which the company must
cover a new demand that doubles the current demand.

4. ECONOMIC IMPACT OF THE IMPROVEMENT PROPOSAL

An analysis must be carried out of how the proposed improvement proposals can
generate greater income and/or savings.

5. CONCLUSIONS AND RECOMMENDATIONS

6. BIBLIOGRAPHIC REFERENCES
 INTRODUCTION

1. Description. - Peruvian capital company, dedicated to the production and

processing of practical, high quality and exquisite value food solutions.

1.1 Company name RAM INDUSTRIES SAC

RAM INDUSTRIES

1.2 Category: 5th range foods (canned goods)

1.3 Brief historical overview of the company

We are a company with 100% Peruvian capital with 14 years of experience in the
production and marketing of foods developed in order to satisfy the needs of our
customers through practicality, quality and good taste. To achieve this, we use
cutting-edge technology, which is reflected in innovative products.

1.4 Product chosen for diagnosis

Yellow Base Packaging Process

Product: Made from

yellow chili pepper

Product brand: HORECA

HORECA

RAN,
Presentation: Polyethylene bag per 1 kg

1.5 Description of the Current Packaging

Process
 Current Process Line

Current Dispenser Current Sealer

2. EVALUATION OF THE CURRENT SITUATION OF THE COMPANY

Currently, a low-performance manual dispenser and a semi-automatic vertical sealer are used for
the product packaging and sealing process. The constant unforeseen failures and weight variations
of the dosing machine would be affecting production, generating delays and loss of product at the
time of dosing.
FIG: Operation carried out when sealing
2.1 Current productivity indicators

2.1.1 EFFICIENCY

Dosing process losses

- Machine Calibration
- Unforeseen failures of the dosing machine that cause constant changes in weight
- Small capacity dispenser.

2.1.2 PRODUCTIVITY

• Dosing machine:
capacity: 12 bags per minute

• Vertical sealer:
Capacity: 12 bags per minute
• Number of workers: 10 people
• Total packaging process time: 6 hours
• Production of day 4320 bags
2.1.3 DEFECT RATE

Stained bags at the time of dosing

Bag loss due to poor sealing
Product reprocessing due to low weight
2.2 Process operations diagram (DOP). You must record a
brief description of the activity being diagrammed.

PROCESS OPERATIONS DIAGRAM

Activity: Yellow Base packaging process Part: Process area Date: 09-25-22
Department: Production Sheet N°01of01
Preparation: María palomino Operator
Method: Current
Type: Operator

TO
RAW MATERIAL______

\ } Feed the hopper

1 Dosing machine weight calibration

(2)
\ / Delay

(31
\ J Dosed 12 bags per min

/\ Weight control
Bag per Ikg

(4)
\y Cleaning the edges of the bag

(5) Delay in cleaning

(Sealing/Verification T =180-

(6 ) Plating

_______________________________________________ (7) Transfer to thermal treatment area

SUMMARY______ N
Activity Number to
EITHER 10 (s) Heat treatmentT= 100°, t = 40min
1
•
• 2 (9 Warehouse fairy transfer
Total__________13 and J.

(10) Stored T= 25°

 2.3 Process operations diagram (DOP). You must record a
brief description of the activity being diagrammed.

PROCESS ANALYSIS DIAGRAM

ACTIVITY Yellow Base Packaging Process DIAGRAM NO. 1
METHOD Current DATE: 26/09/2022

( I OPERATION INSPECTION 1 TRANSPORT

DELAY STORE

Di st
DESCRIPTION OF THE ACTIVITY SYMBOLS OBSERVATIONS
TIME (min) (Meters)

Feed hopper
Q_VDE 2min 1.5 Buckets for a 30 Lt hopper
calibration of the dispenser only once, before starting

Weight calibration OIVD or 5min packaging

Delay
ODDE 5min
Delay in regulating the dosage and calibrating the
scales

Dosed
_YOU lmin Semi-manual dispenser, 12 bags per min

Weight control 0 ■VD Ó 1 min Weighing 6 bags per minute with 2 operators

Cleaning bag edges

(3 vDc lmin Cleaning for every 6 bags with 2 operators

Delay
OLV2—V 2min Delay due to excessive stained bags

Sealing and verification

OlVb • lmin Continuous caller , 12 bags per minute.

Plating
@VD E> 30 min Considering the filling of S carts

Transfer to the heat treatment area

OLVB= 6 min 2.5 The transfer is considered in the minute for each car.

Heat treatment
G<VD —> Or min 720 bags per batsh with two Autod birds

Transfer to the warehouse

OVD •2 20 min 10.13 It is done with a forklift

Stored

NUMBER OF ACTIVITIES
OvD—
5 3 12 2
10 minutes

124 12.63
Room temperature

SUMMARY
Activity Number
Time (min) Distance (m)
Operation 5 74
Inspection 3 7

Transport 2 26 12.63
Delay 2 5
Storage 1 7
Total 13 119 12.63

Hour time in the packaging stage 4320 1kg bags in 360 min = 6h.
Stopped time in the dosing machine calibration process, delay in the weighing process and
cleaning the edges of the bags, there we see that a bottleneck is generated at the time of
sealing.

2.4 Stroke diagram. It should be diagrammed based on the DAP made in the
previous point.

2.5 Man – machine diagram. A man-machine diagram must be made. A brief

description of the activities being planned must be included.
 MAN-MACHINE DIAGRAM
OPERATION. PACKAGING OF DRESSINGS
DEPARTMENT- PRODUCTION
DIAGRAMMER. JORGE SALAS
DESCRIPTION OF THE ACTIVITY TIME(MIN) TIME(MIN) OPERATOR 1 TIME(MIN) OPERATOR 2 TIME(MIN) OPERATOR 3 TIME(MIN) OPERATOR 4 TIME(MIN) OPERATOR 5

FEED HOPPER 1 2 —
2
3
4
WEIGHT CALIBRATION 5 5
5
7
DOSAGE Y 1
WEIGHT CONTROL es 9 1 1
BAG EDGE CLEANING 10
SEALED 11
12
13
14
15
15
17
1S
19
2D
21
77
23
24
25
26
PLATED
27
28
29
3D
31
32
33
34
35
36
37
38
39
4D
41
42
43
44
TRANSFER TO THERMAL TREATMENT
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
6D
61
62
63
64
65
66
67
TREAT Ml IN TOTAL T ERMI CO
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
TRANSFER TO WAREHOUSE
98
99
100
1O1
102
103
104
105
106
107
k EN u MENU T.C. % SATURATION 96 SATURATION % SATURATION % SATURATION % SATURATION
Sop 1-2/107 • GONE Sop2-5/107*100 Sop3—1/107*100 So p4-1/107*100 Sop 5—1/107*100
Sop1-1.87% Sop2—4.67% Sop 3-0.93% Sop4-0.93% Sop 5-0.93%
107 CYCLE PRODUCTION
107 million-1284 units. 4320 units - 6h.-36Omln.
12 units x min.
 MAN - MACHINE DIAGRAM
DATE: 09/30/2022
PAGE 1 OF 2
CURRENT METHOD
TIME(MIN) OPERATOR 6 TIME(MIN) OPERATOR 7 TIME(MIN) OPERATOR 8 TIME(MIN) OPERATOR 9 TIME(MIN) OPERATOR 10 TIME(MIN) RA DOSAGE

1 1
1

30

40

20

9 SATURATION 9 SATURATION 9 SATURATION 9 SATURATION 9 SATURATION % SATURATION

So p6= 1/107*100 Sop7 =1/107*100 Sop8=1/107*100 Sop9=36/107*100 So p 10=60/107* 1OO Sdo yes fi cher=1/107*100
Sop6=0.939 Sop 7=0.939 Sop8=0.939 Sop9=33,659 Sop 10=56.075% Dispenser=0.93%
 MAN - MACHINE DIAGRAM
OPERATION: PACKAGING OF DRESSINGS DATE: 09/30/2022
DEPARTMENT. PRODUCTION PAGE 2 OF 2
DI AGRAMADOR: JORGE SALAS CURRENT METHOD
DESCRIPTION OF THE ACTIVITY TIME(MIN) SCALE 1 TIME(MIN) SCALE 2 TIME(MIN) SEALER 1 TIME(MIN) SEALING TIME(MIN) AUTOCLAVE TIME(MIN) FORKLIFT
MACHINE 2
HOPPER INCREASE

WEIGHT CALIBRATION

DOSAGE
WEIGHT CONTROL 1 1
BAG EDGE CLEANING
SEALED 1 1

PLATED

TRANSFER TO THERMAL TREATMENT

HEAT TREATMENT 40

TRANSFER TO WAREHOUSE 20

% SATURATION 96 SATURATION % SATURATION % SATURATION % SATURATION % SATURATION

SUMMARY Sbalanzal-1/107*100 Scale2-1/107*100 Sselladoral-1/107*100 Sealer2-1/107*100 Sautoclave-40/107*100 Smontacarga-20/107*100
sbalanzal-0.9396 sbalanzaz-o. 93% Sse 11 ad or ra 1-0.93% Ssealeraz-0.9396 Sautoclave-37.3896 Smontacarga-18,699
 2.6 Study of times. The time study must be carried out with the timing method
(choose between return to zero or continuous method)

To calculate the standard time, the measurements made will first be taken. From this, we
will calculate whether the number of observations corresponds to the correct sample size
that allows us to have an acceptable level of confidence. For them, the following formula
will be used with a confidence level of 95.45%.

40
n 2x2 -z(x)2
n =(
Zx
Confidence level of 95.45% with a margin of error of ± 5%
Where:
• n: is the sample size.
• n': is the number of observations from the preliminary study.
• ⅀ : is the sum of the values.
• x: is the value of the observations.
• 40: is the constant for a confidence level of 95.45%.
Calculation of the number of observations with a confidence level of 95.45%.

Number of observations
Observations T1 T2 T3 T4 T5 T6 T7 T8

2 1.59 2.1 2 2.2 1.58 1.59 2.1

Feed hopper

Weight 5 4.59 5.1 5.2 4.58 5 4.55 5.55

calibration

Delay 5.55 4.55 5 4.58 5.2 4.59 5 5.1

Dosed 1 1.5 0.55 1.2 0.58 1.3 0.57 1

1 0.57 1.3 0.58 0.55 1.2 1 1.5

Weight control

Cleaning 1.3 0.57 1.2 0.58 1 1.3 0.57 1

Delay 2 1.56 2.4 2 2.2 1.58 2.1 1.59

Sealing and 0.57 1.3 0.58 1.2 1 0.56 1.4 0.59

verification

Plating 30 29.5 30.5 29 31 29.6 3.4 30

 6 6.2 5.8 5.9 6.1 6 6.3 5.7
Transfer to heat
treatment

40 40.2 39.8 41 39 39.6 40.4 40

Heat treatment

Transfer to the 20 20.1 19.9 20.4 19.6 20.2 19.8 20

warehouse

Stored 10 10.2 9.8 10.5 9.5 10 10.1 9.9

NUMBER OF OBSERVATIONS BY STATISTICAL METHOD

Observation T1 T2 T3 T4 T5 T6 T7 T8 ⅀x _ 2 2x

2 1.59 2.1 2 2.2 1.58 1.59 2.1 15.16 230

Feed hopper

Weight 5 4.59 5.1 5.2 4.58 5 4.55 5.55 39.57 1566

calibration

Delay 5.55 4.55 5 4.58 5.2 4.59 5 5.1 39.57 1566

Dosed 1 1.5 0.55 1.2 0.58 1.3 0.57 1 7.7 59.29

Weight 1 0.57 1.3 0.58 0.55 1.2 1 1.5 7.7 59.29

control

Cleaning 1.3 0.57 1.2 0.58 1 1.3 0.57 1 7.52 57

Delay 2 1.56 2.4 2 2.2 1.58 2.1 1.59 15.43 238

Sealing and 0.57 1.3 0.58 1.2 1 0.56 1.4 0.59 7.2 52
verification

Plating 30 29.5 30.5 29 31 29.6 3.4 30 213 45369

Transfer to 6 6.2 5.8 5.9 6.1 6 6.3 5.7 48 2304

heat
treatment

Heat 40 40.2 39.8 41 39 39.6 40.4 40 320 102400

treatment

Transfer to 20 20.1 19.9 20.4 19.6 20.2 19.8 20 160 25600

the
warehouse

Stored 10 10.2 9.8 10.5 9.5 10 10.1 9.9 80 6400

2 _____________________
n=8 ⅀x = 59518 1 x 2 =713767684

Typical paced rating scales (the British Standard scale)

 0-100 Performance Description
(British
standard)

0 Null activity

50 Very slow, clumsy, unsure movements, the operator seems

asleep and therefore uninterested in the work.

75 Without rushing, but well directed and monitored; It seems

slow, but it doesn't waste time.

100 (type Active, capable, he calmly achieves the set level of quality
rhythm) and precision.

125 Very fast, the operator acts with great safety, dexterity and
coordination of movements, far above the average qualified
operator.

150 Exceptionally fast, intense concentration and effort, unlikely

to last for several periods, only achieved by outstanding
workers.

No. Observation Observed time Assessment

1 Feed hopper 15.16 110

2 Weight calibration 39.57 90

3 Delay 39.57 95

4 Dosed 7.7 115

5 Weight control 7.7 90

6 Cleaning 7.52 100

7 Delay 15.43 85

8 Sealing and verification 7.2 95

9 Plating 213 120

10 Transfer to heat treatment 48 80

11 Heat treatment 320 105

12 Transfer to the warehouse 160 110

13 Stored 80 90
 With this information, the assessment is applied to each observed time:
No. Observation Observed Assessment tn
time

1 Feed hopper 15.16 110 15.16× 111000 = 16.676

2 Weight calibration 39.57 90 39.57× 19000 = 35.613

3 Delay 39.57 95 39.57× 19050 = 37.5915

4 Dosed 7.7 115 7.7× 111050= 8.855

5 Weight control 7.7 90 7.7× 19000 = 6.93

6 Cleaning 7.52 100 7.52× 110000= 7.52

7 Delay 15.43 85 15.43× 18050 = 13.1155

8 Sealing and verification 7.2 95 7.2× 19050 = 6.84

9 Plating 213 120 213× 112000= 255.6

10 Transfer to heat treatment 48 80 48× 18000 = 38.4

11 Heat treatment 320 105 320× 110050 = 336

12 Transfer to the warehouse 160 110 160× 111000= 176

13 Stored 80 90 80× 19000 = 72

TOTAL 1011.141

Average time
Ex
tp = 8

⅀x
No. Observation
Average time

1 Feed hopper 15.16 15.16/8= 1.8

2 Weight calibration 39.57 39.57/8= 4.9

3 Delay 39.57 39.57/8= 4.9

4 Dosed 7.7 7.7/8= 0.9

5 Weight control 7.7 7.7/8= 0.9

6 Cleaning 7.52 7.52/8= 0.94

7 Delay 15.43 15.43/8= 1.92

 8 Sealing and verification 7.2 7.2/8= 0.9

9 Plating 213 213/8= 26.6

10 Transfer to heat treatment 48 48/8= 6

11 Heat treatment 320 320/8= 40

12 Transfer to the warehouse 160 160/8= 20

13 Stored 80 80/8= 10

Now if we get the normal time:

No. Observation tn=
⅀x normal time

1 Feed hopper 15.16 15.16/8= 1.8

2 Weight calibration 39.57 39.57/8= 4.9

3 Delay 39.57 39.57/8= 4.9

4 Dosed 7.7 7.7/8= 0.9

5 Weight control 7.7 7.7/8= 0.9

6 Cleaning 7.52 7.52/8= 0.94

7 Delay 15.43 15.43/8= 1.92

8 Sealing and verification 7.2 7.2/8= 0.9

9 Plating 213 213/8= 26.6

10 Transfer to heat treatment 48 48/8= 6

11 Heat treatment 320 320/8= 40

12 Transfer to the warehouse 160 160/8= 20

13 Stored 80 80/8= 10
For
me
r
no .
Rest supplement in percentages

Due to constant fatigue (man)

personal need 5%

Fatigue 4%

Due to variable fatigue (man)

 Concentration 2%

standing state 2%

TOTAL 13%
Below is the table with the calculation of the average time, normal time and standard time for the
packaging process. To do this, he calculated the standard time
for the proposed packaging process.

No. Items Average time Assessment normal time Supplement Standard time

1 Feed 15.16/8= 1.8 110 15.16/8= 1.8 2.034

(1+ 13%) = 1.13
hopper

2 Weight 39.57/8= 4.9 90 39.57/8= 4.9 5.537

(1+ 13%) = 1.13
calibration

3 Delay 39.57/8= 4.9 95 39.57/8= 4.9 5.537

(1+ 13%) = 1.13

4 Dosed 7.7/8= 0.9 115 7.7/8= 0.9 1.017

(1+ 13%) = 1.13

5 Weight 7.7/8= 0.9 90 7.7/8= 0.9 1.017

(1+ 13%) = 1.13
control

6 Cleaning 7.52/8= 0.94 100 7.52/8= 0.94 1.06

(1+ 13%) = 1.13

7 Delay 15.43/8= 85 15.43/8= 2.16

(1+ 13%) = 1.13
1.92 1.92
Sealing (1+ 13%) = 1.13 1.017
8 7.2/8= 0.9 95 7.2/8= 0.9
and
verification
n
9 Plating 213/8= 26.6 120 213/8= 26.6 30.05
(1+ 13%) = 1.13

10 Transfer to 48/8= 6 80 48/8= 6 (1+ 13%) = 1.13 6.78

heat
treatment

11 Heat 320/8= 40 105 320/8= 40 45.2

(1+ 13%) = 1.13
treatment

12 Transfer to 160/8= 20 110 160/8= 20 (1+ 13%) = 1.13 22.6

the
warehouse

13 80/8= 10 90 80/8= 10 11.3

Stored (1+ 13%) = 1.13

TOTAL 135.309
In the graph we can see that the total cycle time for the stations is
135,309 min.
 IMPROVEMENT
PROPOSAL
3.1 Improvement proposal: Process operations diagram (DOP). A description of
the improvement being proposed must be included.
 3.2 Improvement proposal: Process activities diagram (DAP). A description of the
improvement being proposed must be included.

PROCESS ANALYSIS DIAGRAM

ACTIVITY Base Amar 3 Packaging Process DAGRAMANS 1
Current METHOD________________________ DATE:______________________

: ) OPERATION Inspection
1 TRANSPORT

STORE
) DELAY

ACTIVITY DESCRIPTION SYMBOLS TIME OBSERVATIONE5

Dist (Meters)
|min|

All mint rhopper

0VDE 2min 15 30
Q ibration of the dispenser only once,
Calibrate where weight
O1VDB 2mm
before packaging

Wrapped and sealed

@•VD5 imin 30 bags25 min 144 min

P a uado ® 7DQ 30 min Considering the swim of 6 credits

The transfer was considered to take
Fairy milling 3 heat treatment zone

O•VDu> 40
5 25
1 minute per
ada
720 expensive
bo Isaspo r batsh c: nd os Airtoc
Heat treatment
O0D • thousand ares

ODV©
20
Traelado had 3 3 3 warehouse 10.13 It is done with a forklift
thousand
Stored
FORGOT•>
32102
10
minutes
124 126
Room temperature
____________NDEACTIVIDADE5_______________

With the implementation of the improvement, 3 processes that will be carried out by the packaging
machine will be eliminated (weight control, edge cleaning and product sealing), reducing a total of
216 min.
30 bags per minute will be packaged and the execution time in the 4320 kg stage will be 2.4
hours. Productivity will improve by taking advantage of the hours to package other products.
ri
3.3 Improvement proposal: Record diagram. A description of the improvement being
proposed must be included.

The route diagram will have some variations, where three processes will be eliminated to
optimize the route and achieve an efficient result.
3 3.4 Improvement proposal: man-machine diagram.
 3.5 Improvement proposal: Time study A brief description of the improvements being
proposed must be included.

In the improvement proposal, it is considered to eliminate some activities from the

process, which would reduce production costs. Currently, there is a semi-manual
machine which processes 12 bags per minute. With the new machine, which is
automated, it would process 30 bags per minute. It should be noted that in the current
process the participation of 10 operators is necessary; with the improvement we would
only have to employ 2 operators.

The cost of the machine is S/91,093.40

Observations T1 T2 T3 T4 T5 T6 T7 T8

2 1.59 2.1 2 2.2 1.58 1.59 2.1

Feed hopper

Weight 5 4.59 5.1 5.2 4.58 5 4.55 5.55

calibration

Sealing and 0.57 1.3 0.58 1.2 1 0.56 1.4 0.59

verification

Plating 30 29.5 30.5 29 31 29.6 3.4 30

6 6.2 5.8 5.9 6.1 6 6.3 5.7

Transfer to heat
treatment

40 40.2 39.8 41 39 39.6 40.4 40

Heat treatment

Transfer to the 20 20.1 19.9 20.4 19.6 20.2 19.8 20

warehouse

Stored 10 10.2 9.8 10.5 9.5 10 10.1 9.9

3.6 Production line Perform the analysis of the production line. Determine the indicators
of the production line:

The production line will be modified by replacing the dosing machine with the automatic
packaging machine that will be managed by two operators.
The objective is to reduce the packaging time of the product so that this line can be
used for the packaging of other products.
This improvement also allows increasing production, which leads to modifying some
workstations, increasing operators or machinery, such as having another Autoclave that
supports the quantity produced by the packaging machine.

Packaging machine to be implemented to improve production

 Technical specification

MODEL: VM1
TECHNICAL SPECIFICATIONS 23 OT-PLUS
DATA

DIMENSIONS OF THE MIN.(mm) SO x SO mm

BAG MAX.(mm) 230 x 385mm
VOLUME f with background} MAX.(CC.) 4 000 It
SPEED (envelopes/min) Until 30
MATERIAL OF CONTAINER Sealable thermos
MAX DIAM. 500MM
SAY AM. COIL (mm.) MAX WIDTH 625
CORE DIAM. 70/72 -90/92

ELECTRICAL DATA 4.5KW 87.5Hz

AIR CONSUMPTION 4.51t min
SOUND LEVEL Less than 70 dB

(mm : LxWxH)
MEASUREMENTS OF THE 120x365 x 1175.
MACHINE
NET WEIGHT Kg. (approx) 2500KG

1 EFFICIENCY

By changing the semi-manual dosing machine for an automatic packaging machine

for liquids and semi-liquids, greater efficiency is projected since problems in the procedures
that the previous machine produced would be avoided, such as problems in calibration and in
the dosage of the product in the containers. , dirt in the containers and poor sealing. This
caused the need for operators for manual work, which would be replaced by more effective and
faster automatic work.

2 PRODUCTIVITY

Vertical packaging machine for liquids and semi-liquids: Capacity: 30 bags per minute.
This machine doses the product, calibrates the desired weight and seals.
Number of workers: 2 people.
Total packaging process time: 2.4 hours.
 Production of the day: 4320 bags.

3.- DEFECT RATE

The defect rate decreases drastically, since:

Avoids stained bags.
The loss of bags due to poor sealing is reduced.
Manual work and rework caused by defects are avoided.

2.7.1 Determine the times for each station

Where:
ti= Operation time at workstation “i” (Li + mi)
Li = Preparation time at workstation “i” (loading and unloading) mi = Machining time at
workstation “i”

ti = (Li+min)
my (min)
Workstation Li (min) manual
machining

Feed hopper 2 0 2

Weight 2 0 2
calibration

Packaging and 0 1 1
sealing
Plating 5 25 30

2 4 6
Transfer to heat
treatment

5 35 40
Heat treatment

Transfer to the 2 18 20
warehouse

TOTAL(OPERATIO 101
N TIME)

2.7.2 Graph the production line

2.7.3 Determine production indicator p

=tB
 Where:
P = Production
c = Cycle = Bottleneck = Production speed
tB = Base time
480-min
d aia
40 min
und
P = 12u
n.d.
day

2.7.4 Time-out

Total lost or idle time of each workstation.

δ = Σ(ct 1)
Where:
δ = Dead time
c = Cycle = Bottleneck = Production speed
ti= Operation time at workstation “i” (Li + mi)
δ = Σ(ct 1)
δ = (40 - 2) + (40 - 2) + (40 - 1) + (40 - 30) + (40 - 6) + (40 - 40) + (40 - 20)
δ = 38 + 38 + 39 + 10 + 34 + 0 + 20 = 179

2.7.5 Efficiency

E =Tx 100
nc
E = -101- x 100
4(40)
E = -101 x 100
4(40)
E = 63%
Where:
E = Line efficiency
c = Cycle = Bottleneck = Production speed
T = Total time of the
2.7.6 Production line base times n = Number of resources (machines)

The initial base time was 6 hours for the packaging line.
It is expected that with the improvement the base time will be reduced to 2.4 hours. This is
what is sought since this line will be used in the packaging of other products.
Tb = 2. 4h = 144 min.
1. 7 Simple line balance for a new demand twice the current production. Perform a simple
line balance assuming a scenario in which the company must cover a new demand that
doubles the current demand.
P = 4320x2 = 8640 Tb = 2.4 h = 144 min
144m 0.016-
___________ais

8640 umds
day

Workstati
you #ma qu¡ñas /#operarios Time
on

Feed hopper
2 2/(0.016* 30) =4.16~4 2/4=0.5min/und

Weight
2 2/(0.016*30)=4. 16k4 2/4=0.5min/und
Calibration
Packaging
1 1/(0.016*30)=2.0882 l/2=0.5min/und
and sealing
30/(0.016*720)=2.60~ 30/3=10min/720 units
Plating 30 3
Transfer to
heat 6 6/(0.016*720)=0.52~1 6/l=6min/720 units
treatment
Heat
40
treatment 40/(0.016*720)=3.47® 4 40/4=10min/720 units
Transfer to
the 20 20/(0.016*720)=l. 74® 2 20/2=10min/720 units
warehouse
101
 4. ECONOMIC IMPACT OF THE IMPROVEMENT PROPOSAL An analysis must be
carried out on how the proposed improvement proposals can generate greater income
and/or savings.

This table presents the cost of the automatic machine (vertical packaging machine) for
implementation in the packaging area, with the required quantities and the respective
prices.

DESCRIPTION AMOUNT COST (S/)

Vertical packaging 1 69.865.00
machine
Heated hopper 1 12,288.00

Width former 1 4,723.20

bag

Photoelectric cell 1 3,763.20

Mobility 400.00

Total cost 91,093.40

4.1 Technical and economic evaluation of the improvement

Benefit per man-hour cost

DETAILS CURRENT IMPROVED SAVING SAVING
OPERATORS 9 2 7 78%
TIME (Man Hour) 6 2 4 67%
TIME (Hours - months) 1404 104 1300 93%
COST(Man-Hour) 4.9 4.9 0 0%
TOTAL COST S/.6,879.6 509.6 6370 93%
With the improved benefit we will save s/6370 per month (26 business days)

Profit from the cost of production materials

DETAILS CURRENT IMPROVED SAVING SAVING
OPERATORS 9 2 7 78%
MASK (Day) 2 2 0 0%
COFIA (Day) 1 1 0 0%
GLOVES (Day) 6 2 0 0%
CONSUMPTION (One-Month) 468 104 364 78%
Mask
CONSUMPTION (One-Month) Cap 234 52 182 78%
CONSUMPTION (One-Month) 1.404 104 1.300 93%
Gloves
TOTAL COST OF MASK (S/) 187 42 146 78%
TOTAL COFFEE COST (S/) 94 21 73 78%
TOTAL COST OF GLOVES (S/) 983 73 910 93%
TOTAL 1.076 94 983 91%
With the improved benefit we will save S/989 per month (26 business days)
Shrinkage reduction benefit
CURRENT
WEIGHT (KG) IMPROVED SAVING

lili weight 4400 4400 0

Weight Loss 80 3.7 80
Performance 4320
% Loss 1.82% 0.08% 1.73%
%Rend 98.18% 99.92% 0.00%
SHIFT
Day S/. 640 29.6 S/. 610
Week (6 days) S/. 51,200 177.6 S/. 51,022
Monthly (26 days) S/. 16,640 4617.6 S/. 12,022
COST
cost kg (S/.) S/. 8 0 0
TOTAL COST Q
S/. 16,640 0 S/. 12,022
Yo M ENSUALM EN SUAL
Interpretation: with the current process there is a loss of 80kg, which per month would be S/ 16,640.
With the improved process, there are losses in shrinkage of 0.08%, therefore losses in shrinkage will
be minimal.

Summary of cost per benefit obtained

SAVING MONTHLY ANNUAL

Labor benefit S/6,370 S/ 7

6,440
S/983 S/ 11,796
Materials benefit
Waste reduction benefit S/12,022 S/ 144,264

Total cost S/19,375 S/232,500

Benefit/cost ratio
S /232,500
Annual profit = = 2.6
Total investment S/ 91,093.4

Interpretation: The result indicates that the improvement is viable, for each sol invested the
company will have a return of 2.6, therefore a profit of 1.6.

Cost benefit relation

Interpretation: The return on investment will occur in 4 months and 7 days, starting the
following month there will be a monthly profit of 19,375.

5. CONCLUSIONS AND RECOMMENDATIONS

Conclusions regarding the improvement implementation objectives

1. According to the results obtained during the development of the work, it is possible to
conclude the following:
With the implementation of a vertical packaging machine, packaging time will be reduced
 from 360 min to 144, and it will no longer be a manual process, but will be a more
automated operation.

2. Labor will be reduced by 78% (man-hour), since we would only need 2 operators for the
packaging process

3. By reducing packaging operations, times will be optimized and the execution of other tasks
will be used.
4. It must be considered that idle times are generated, but these are limited since operations
are carried out constantly and in parallel.
5. The proposal seeks to improve production quality and reduce packaging times for this
specific product, since this line is used to package other products. This allows a greater
margin of time in the packaging of these other products of the company.

RECOMMENDATIONS

1. The new technological tools provide us with a notable improvement in production

processes but they are also a great challenge, which is why we have to have trained
personnel for their operation, which is why it is necessary to train personnel in the correct
use of the machines.

2. Preventive maintenance increases the useful life of machinery, which is why it is

recommended not to exceed the time of use recommended by the manufacturer and
always maintain the equipment.

3. It is recommended to have maintenance personnel who inspect the equipment at the

beginning and end of the work day in order to verify any anomalies that may arise.
 6. BIBLIOGRAPHICAL REFERENCES

http://www.simagindustrialperu.com/envasadoras-automaticas-verticales/envasadoras-d
e-liquidos-viscosos-polvos-granulados-granos-peru.html

https://ramperu.com/es

https://www.industriaalimentaria.org/blog/tipo/articulos