Work Process Assessment

Practical Presentation 4

Presented by :
Shubham Taware 3106
Dhanraj Yeole 3118
Bhavesh Patil 3103
Suyash Shinde 3136
Omkar Manapure 3133
Method Study :
• Method study is the study or analysis of existing, find out the
problem with that method and establishment of a
best method for smooth production, waste reduction and
increased profitability .
CASE STUDY :
• Production Of Battery In XYZ LTD COMPANY.
• Steps explained :
1. Select
2. Record
3. Examine
4. Define
5. Develop
6. Maintain
SELECTION OF WORK:
• PROBLEM STATEMENT :
XYZ Ltd is a battery production industry.
Manufacturing process of the XYZ Ltd is described as follows-
Brought up the lead alloy from supplier and store it to company
Warehouse. Also purchase container, packing cartoon, separator
and terminals from other suppliers. Now firstly mix water to lead
alloy by workers and then the mixture is enter to the casting
machine hopper and casting the plate by old casting machine.
Now the casting plates placed outside for two days for drying.
Then plates are taken away for pasting.
RECORD:
• Problem 1: In existing plant of XYZ Ltd casting machine is old
technology based. It has less production rate which is quite
not suitable in this competitive global market. The lower
production rate causes delay the product for next process.
• Problem 2: The second major problem faced in plant is that
plate finishing is done by labor manually. So the finishing rate
is very less and labor cost is high.
• Problem 3: Some components brought from sister industry
are not ready to use. So it consume some time to make it
suitable for use like battery container without hole.
EXAMINE:
• Assemble section total cycle time 30 min. Total plant working
time 8 hours.
• Total Cycle = 8*60/30=16
• one cycle save time by purchase container with hole = 1min.
one day =16 cycle
• Before implementation mold casting rates 24 plates per min.
DEFINE:
• After implementation XYZ Ltd is started use of advance casting
machine which has high production rate. It neglect the delay
time. Second major improvement is install automated plate
finishing machine. XYZ Ltd is now started purchasing the
battery container with hole and complete ready to use
condition which reduce the process time.
DEVELOP :
• Assemble section total cycle time 30 min. Total plant working time 8 hours.
• Total Cycle = 8*60/30=16
• one cycle save time by purchase container with hole = 1min
one day =16 cycle
• one day saving time =16*1=16 min
• one month time save = 16*30= 480 min.
• Before implementation mold casting rates 24 plates per min.
If we will use advance casting m/c casting rates 36 plates per min.
• Production rate increase per minute by advance casting m/c:
=(36-24/24)*100=50%.
• Time save in one hour approx =10 min. One day saving time = 10*8=80 min.
• One month saving time=80*30=2400min.
• Plate finishing 7 workers only 5400 plate finishing.
DEVELOP :
• If we will using automated finishing m/c we use only 2 workers
and around
• 12000 plate finishing one day.
• Finishing rate increases per day (12000-5400/5400)*100 =
6600 = 122%
• Therefore we use automated m/c our production rate increase
and save 5 labours.
COMPARISION:
Present:
• Molded casting machine production
rate 24 plates per min.
• Delay time for pasting machine is high.
• Plate finishing by worker and finishing
rate is low.  machine and finishing rate is high.
• 5400 plates finished in one day.
• 7 workers is working in finishing
process.
• Company create holes in container in 1
min.
• Create a hole in container by one
worker.
• Labor cost is high .
• Production cost is high.
• Production rate is low.
Proposed:
• Advance casting machine production
rate 36 plates per min.
• Delay time reduce for pasting machine.
• Plate finishing by automated finishing
• 12000 plates finished in one day.
• 2 workers will be working in finishing
process.
• Company purchase container with hole
and save 1 min .
• Already create hole and save one
worker.
• Labor cost is low.
• Production cost is low.
• Production rate is high.
CONCLUSION:
• During the study of the process of the battery manufacturing
plant, existing processes are examined critically with method
study & layout technique.
• It is observed that the battery plant is not using optimum
layout and there are chances for improvement.
• Various layout and method study tools are applied and flow
process charts, flow diagram and existing layout has been
prepared.
• New technologies are used to reduced production cost,
process time, cost and energy consumption.