UNIVERSITY TECHNOLOGY of MALAYSIA

FACULTY of MECHANICAL
ENGINEERING

SMN 3823 WORK DESGIN

LECTURER: MR JAFRI BIN MOHD ROHANI

DATE SUBMITTED : 21/10/2010

GROUP MEMBERS MATRIC CARD

1. AHMAD SULIMAN AM070398

2. AHMAD AIZUDDIN AM070008
3. EZAR MUGAHED AM080384

SMN 3823 Page 1

 Table of contents

1.0 Introduction…………………………………………………………………………
1.1 Background of the company ………………………………………………………………
1.2 History of the company ……………………………………………………………………
1.3 Objectives of the research
1.4 Product and services…………………………
2.0 Literature review…………………………………………………………………………………….
2.1 Method study…………………………………………………………………………
2.1.1 Two hand chart……………………………………………….
2.1.2 Multi activity chart or man machine chart ……….……………..
…………………………………………………..
2.1.3 Principles of motion economy …………………………
3.0 Work measurement …………………………………………………………………………
4.0 Existing method……………………………………………………………
5.0 Propose method…………………………………………………….
6.0 Conclusions …………………………………………………………………

Work schedule of the group

References………………………………………………………………………………

Appendices………………………………………………………………………………

SMN 3823 Page 2

 1.0 Introduction

1.1 BACKGROUND OF THE PROJECT

OPERATION CONTROL FOR CARTON

Process flow Chart

PAPER ROLL

RAW MATERIAL - Paper Rolls

1 IQC CHECK RING CRUSH, THICKNESS, MOISTURE,
GRAMMAGE & BURSTING
STARCH
PREPARATION

CORRUGATING
2 IPQC CHECK STARCH VISCOSITY & GEL POINT

3 IPQC CHECK VISUAL, SUBSTANCE, DIMENSION, FLUTE

TYPE & CONDITION, LAMINATING & WARPAGE
NO
Printing

INK PREPARATION
YES

PRINTING 4 IPQC CHECK INK VISCOSITY & COLOUR RANGE

CHECK COLOUR, PRINTING, SLOTTING, LETTERING,

5 IPQC
DIMENSION, CREASING & CUTTING LINE

NO
Cutting?

YES

CUTTING
(SLITTING/SLOTTING/UP &
DOWN DIE-CUT)

CHECK SUBSTANCE, FLUTE CONDITION,

6 IPQC LAMINATION, DIMENSION, CREASING, &
WARPAGE
NO
Finishing?

YES
GLUING / STITCHING /
ASSEMBLY CHECK STITCHING DISTANCE GAP, BONDING, &
FINISHING 7 IPQC
BOX ALIGNMENT

GLUING / STITCHING /
ASSEMBLY 8 IPQC CHECK COMPRESSION, BURSTING, ECT
NO
PACKING

YES CHECK PACKING CONDITION , SLOTTING, PRINTING,

9 IPQC FINAL SHAPE, STACKING & NO MIX PART
STORAGE

YES
10 OGQA
CHECK OVERALL APPEARANCE & AS PER CUSTOMER
DELIVERY REQUIREMENT

SMN 3823 Page 3

BACKGROUND OF CASE STUDY COMPANY

Company Name : UKB Packaging Malaysia (Johor) Sdn Bhd

Industry : Manufacturing / Production of Carton

Location : NO.5, Jln,Tahana,Tampoi industrial state, 81400 Senai

Company phone : 07-5995533

Company Fax : 07-5994515

No. of Employees : 120

1.2 HISTORY

 UKB Packaging is a European leading provider of customer-specific packaging

solutions with emphasis on state-of-the art design and local service close to customer
facilities.

 UKB Packaging is a leading provider of customer-specific packaging with emphasis

on state-of-the art packaging design and local service close to customer facilities. With
a product portfolio that includes transit packaging, consumer packaging, displays and
promotional packaging, customized protective packaging and industrial packaging,
UKB Packaging answers to each market requirement.

 Operate along the whole supply chain, from the raw materials to the high-quality
finished product. Their emphasis is on state-of-the-art design and local service close to
food, non food and industrial customer facilities in Europe.  Supported by a creative
design network, an extensive range of materials, an efficient paper mill system and an
internal recycled fiber supply, they provide the right packaging solution for your
products around the world. 

 Containerboard is a global product that is traded on world markets. Our paper division,
UKB Containerboard, is uniquely positioned to offer one of the widest ranges of kraft
liner, test liner and fluting grades on the market, with the service of a specialist in
logistics.

 Being an integrated company allows SCA Containerboard to constantly meet and

exceed new trends in corrugated board.  This results in their ability to meet the
increased demands for lightweight grades and presentation grades.

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1.2 Objectives

I. To improve method of doing work

II. To evaluate the effectiveness of work measurement

III. To do improvement to the existing method

1.3 PRODUCT AND SERVICES

 UKB Packaging product is customer packaging.  Depending on the functional

requirements, company has different product types that serve a variety of segments.

 Examples

COMPANY VISION

 "To be recognized as the leading provider of value for customers, shareholders and
employees in its field."

COMPANY MISSION

 "To provide essential products that improves the quality of everyday life."

QUALITY POLICY

 To provide Outstanding Product Quality, Services and Total Customer Satisfaction

SMN 3823 Page 5

2.0 LITERATURE REVIEW

In this project, we include few charts that we use to improve the method they do the work.
First of all, we want to introduce about the method we use in work study.

2.1 METHOD STUDY

WORK STUDY

METHOD STUDY WORK

MEASUREMENT

2.1.1 Two hand chart

This chart is use to record the activity of both hands of a worker. There are 4 symbols used in
this chart which is operation, transportation, delay and storage.

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 Operation – Grasp, position, use, release the component

Transportation – hand moving to or from workplace, equipment

or material

Delay – Hand idle

Storage – hold equipment or material.

2.1.2 Multi Activity Chart or Man Machine Chart

This chart is used to record and show more than one activities on the same time scale. It is
also use to show the relationship between these activities.

Example of man machine chart laundry process for one operator, 2 machines.

Time (min) Operator Machine 1 Machine 2

2 Load Being loaded Idle
4
6 Load Being loaded
8 Running
10
12 Idle Running
14 Idle
16 Unload Being unloaded
18 Unload Idle Being unloaded

Idle time = 6min

Working time = 12min

Cycle time = 18min

Working time
Utilization =
Cycle time

12
Utilization = x 100 = 66.7%
18

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2.1.3Principle of Motion Economy

This principle is divided into 3 categories.

1. The use of human body

2. The arrangement of workplace
3. The design of tools and equipment

This principle is good for the company to apply to their workplace layout because it can
reduce accidents, can improve the quality of the product, the employee feel more comfortable
while working.

1. The use of human bodies.

i) Both hands should begin as well as complete their motion.
ii) Both hands should not idle at the same time.
iii) Motions of the arms should be made in opposite and symmetrical directions.
iv) Motions should be confined to the lowest degree.
v) Momentum should be used when wherever possible but should be reduce
vi) Smooth continuous curved hand motions are better to straight line motions.
vii) Ballistic movements are faster, easier and more accurate.
viii) Work should be arranged to permit an easy and natural rhythm.
ix) Work should be arranged such that eye motion is limited to one comfortable area.

2. Work place layout

i) There should be definite and fixed place for tools and materials.
ii) Tools and materials should be placed first to reduce search activity.
iii) Gravity feed, box or container should be used to deliver material.
iv) Tool and material should be placed within the maximum working area.
v) Material and tools should be located to permit the best sequence of motions.
vi) Drop deliveries or ejectors should be used.
vii) Adequate illumination and good contrast.
viii) Ergonomically design and workplace should be used.

3. Design of tool and equipment.

i) Hands should be free from all work that may be done with fixture.
ii) Two or more tool should be combined.
iii) Load should be distributed in accordance to the inherent capacity of the fingers.
iv) Handles of tools should be design so as to allow as much surface area of the hands.

This is how principles of motions economy can give a good workplace area. By following this
method we can improve the productivity of our product.

SMN 3823 Page 8

3.0 WORK MEASUREMENT

Definition of work measurement is the application of techniques design to establish the time
for a qualified worker to carry out the task at a defined rate of working. This is specific
techniques used to determined time required for a qualified worker to do their job. In
conducting time measurement, we can identify the ineffective time and then we can propose
some improvement.

There are procedures for time measurement:

 Select
 Record
 Analyze
 Measure
 Compile
 Define

There are four techniques to measure work and time:

1. Stopwatch method
2. Predetermined time system
3. Standard time
4. Activity sampling

In this project, we use stopwatch time study and predetermined time system to analyze the
work done by the worker at gluing and stitching process.

1. Stopwatch method
We take event description done by the worker and we record the time using stopwatch.
Then, we record the time into the table to analyze the process. Repeat the process for
several times to get an average value of time. After that, we calculate the time with
multiply the average time with rating to get normal time. After that, we need to
multiply normal time to get standard time.
Normal time = average time x rating.
Standard time = normal time x (1 + allowance)

SMN 3823 Page 9

 Rating is process where the time study analyst compares the performances (speed or
tempo) of the operator under observation with the observers own concept of normal
time for the job. Rating is important to analyze the job.
Rating value:
 100 – if working at normal rate
 < 100 – if working below the normal rate
 > 100 – if working above the normal rate

Allowance consists of 3 types:

 Rest allowances
 Contingency allowances
 Special allowances

Predetermined time system

It is a time measurement techniques whereby time for basic human motion is determined. It is
use to built up standard time of the specific job. Predetermined time system has 8 categories,
but we only use Method time Measurement (MTM) in our work design analysis. MTM is the
system identifies the basic motion of an operation or manual method. A predetermined time is
then identified for each of these basic motion based on type of motion. Motions are divided to
5 main categories:

a) Release – RL
b) Reach – R
c) Grasp – G
d) Move – M
e) Position – P

We measure the work from the table of the categories. Firstly, we look at the motion of the
work done by the worker. Then, we refer to table to determine the time in unit tmu. After that,
we calculate the standard time by multiply the time in unit tmu with 0.036 seconds.

1 tmu = 0.036 seconds.

Example of MTM:

Description No LH TMU RH No Description

. .
At rest - - - - - At rest
At rest - - 15.6 R65A 1 Reach the body, 65 cm
At rest - - 2.0 G1A 1 Grasp the body
At rest - - 23.6 M65 1 Move body to left hand
A
At rest - - 2.0 RL1 1 Release to left hand

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 Total TMU = 15.6+2.0+23.6+2.0 = 43.2
Standard time = 43.2 x 0.036 = 1.6s

4.1 EXISTING METHOD

Stitching process is the process of combining two box pieces. The process is quite
similar to stapling paper, but rather than a stapler they use a stitching machine. The
layout of the stitching process consists of the stitching machine itself, 2 piles of box
piece, and a pile of completed product.

MACHINE

Operator Operator
1 2

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Stitching process

1. Take the box piece, fold it and bring it to the machine

 Operator 1 and operator 2 will move to the box piece pile. Operator 1 will go
to pile 1 and operator 2 will go to pile 2
 The operator will retrieve a box piece from the respective pile. 1.5m

1.5m The box piece is folded before being mounted to the machine.
 Then, the operator will bring the box piece to the machine.

2. Position the two box piece and stitch the far end
 The operator will hold the box piece on the machine to make sure the box
pieces are aligned with each other.
 Operator 1 then pushes the foot paddle to operate the machine.
 They stitch once at the far end for initial grip of the box pieces.
BOX PIECE PILE 1 BOX PIECE PILE 2

3. Reposition the two box piece and stitch all the way
 The operator will realign with the box pieces for further stitching.
 Operator 1 then pushes the foot paddle to operate the machine.
 They will stitch all the way along the3.0m
box.

4. Turn the box to the other end

 Dismount from the stitching machine.
 The operators will turn the box piece to the other end.
 Mount the box piece again.

5. Position the two box piece and stitch the far PRODUCT
FINISHED end PILE
 The operator will hold the box piece on the machine to make sure the box
pieces are aligned with each other.
 Operator 1 then pushes the foot paddle to operate the machine.
 They stitch once at the far end for initial grip of the box pieces.

6. Reposition the two box piece and stitch all the way
 The operator will realign with the box pieces for further stitching.
 Operator 1 then pushes the foot paddle to operate the machine.
 They will stitch all the way along the box.

7. Bring completed box to the stacked pile

 After finish stitching the box pieces, dismount the completed product from the
stitching machine
 Operator 2 will bring the completed product to the stacked pile.

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Existing method

Man Machine Chart (Stitching process)

Existing process

TIMES
OPERATOR 1 OPERATOR 2 MACHINE
(s)
2 Pull the box piece from the Pull the box piece from
4 pile the pile
6
Fold the box piece Fold the box piece
8 Idle
10
Bring the box piece to the Bring the box piece to
12
machine the machine
14
16 Fold the edge side of the box
Mount on the machine Being loaded 2
18 piece
20
Mount on the machine Being loaded 1
22
24 Hold the box piece while
stitch the right side once
26 Hold the box piece
(Press foot paddle)
28 Running
Stitch the box piece all the
30
way
32
34 Dismount box piece Dismount box piece Being unloaded
36 turn box piece to the other turn box piece to the
Idle
38 edge other edge
40
Mount on the machine Mount on the machine Being loaded (both)
42
44
stitch the right side once
46
48 Hold the box piece Running
Stitch the box piece all the
50
way
52
54 Dismount from machine Dismount from machine Being unloaded
56
58 Move the completed stack Move the completed
Idle
60 pile stack pile
62

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   OPERATOR 1 OPERATOR 2 MACHINE
Idle Time (s) = 0 0 26

Working Time (s) = 62 62 36

Idle Time (%) = 0.00 0.00 41.94

Working Time (%) = 100.00 100.00 58.06

SMN 3823 Page 14

Two hand chart for operator 1 (stitching process)
TWO-HANDED
PROCESS
      CHART      
                   
LEFT HAND O T D S S D T O RIGHT HAND
1. Pull the box piece down ●             ● 1. Pull the box piece down
2. Fold the box piece ●       ●       2. hold the box piece
3. Bring the box piece to the 3. Bring the box piece to the
machine   ●         ●   machine
4. Fold the edge side of the
box piece ●       ●       4. Hold of the box piece
5. Mount on the machine ●             ● 5. Mount on the machine
6. Hold the box piece with
6. Allign the box piece with the second box piece
the second box piece ●     ●       together
7. Hold the box piece while 7. Hold the box piece while
stitch the right side once stitch the right side once
(Press foot paddle)     ● ●       (Press foot paddle)
8. Slide box piece to the 8. Sliding box piece to the
right and stitch all the way right and stitch all the way
(Press foot paddle) ●           ● (Press foot paddle)
9. Dismount box piece and 9. Dismount box piece and
turn to the other edge ●             ● turn to the other edge
10. Mount on the machine ●             ● 10. Mount on the machine
11. Hold the box piece with
11. Allign the box piece with the second box piece
the second box piece ●     ●       together
12. Hold the box piece while           12. Hold the box piece while
stitch the right side once stitch the right side once
(Press foot paddle) ● ● (Press foot paddle)
13. Slide boxpiece to the           13. Sliding boxpiece to the
right and stitch all the way right and stitch all the way
(Press foot paddle) ● ● (Press foot paddle)
14. Dismount from machine ●             ● 14. Dismount from machine
15. Move the completed           15. Move the completed
stack pile   ● ● stack pile
                   
  Summar                
y
METHODS LH R              
H
Operations 11 7              
Transports 2 2              
Delays 0 3              
Holds 2 6              
Inspections - -              
Totals 15 15              

SMN 3823 Page 15

Two Hand Chart for operator 2 (stitching process)
TWO-HANDED
      PROCESS CHART      
                   
LEFT HAND O T D S S D T O RIGHT HAND
1. Pull the box piece down ●             ● 1. Pull the box piece down
2. Fold the box piece ●       ●       2. hold the box piece
3. Bring the box piece to the 3. Bring the box piece to the
machine   ●         ●   machine
4. Mount on the machine ●             ● 4. Mount on the machine
5. Hold the box piece (Wait 5. Hold the box piece (Wait
for operator 1)       ● ●       for operator 1)
6. Hold the box piece while 6. Hold the box piece while
it is being alligned     ● ●       it is being alligned
7. Hold the box piece while 7. Hold the box piece while
being stitched on the left being stitched on the left
side once     ● ●       side once
8. Slide boxpiece to the left 8. Slide boxpiece to the left
while being stitched all the while being stitched all the
way ●           ● way
9. Dismount box piece and 9. Dismount box piece and
turn to the other edge ●             ● turn to the other edge
10. Mount on the machine ●             ● 10. Mount on the machine
6. Hold the box piece while 6. Hold the box piece while
it is being alligned     ● ●       it is being alligned
12. Hold the box piece while           12. Hold the box piece while
stitch the left side once ● ● stitch the left side once
13. Slide boxpiece to the left           13. Slide boxpiece to the left
and stitch all the way ● ● and stitch all the way
14. Dismount from machine ●             ● 14. Dismount from machine
15. Move the completed           15. Move the completed
stack pile   ● ● stack pile
                   
  Summar                
y
METHODS LH RH              
Operations 8 7              
Transports 2 2              
Delays 0 0              
Holds 5 6              
Inspections - -              
Totals 15 15              

SMN 3823 Page 16

 Method Time Measurement (MTM)

1. Take the box piece, fold it and bring it to the machine

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
BOX PILE BOX PILE
EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 30CM TO THE R30B 12.8 R30B REACH 30CM TO THE

BOX PILE BOX PILE
GRASP THE BOX G4A 7.3 G4A GRASP THE BOX

MOVE THE BOX 20CM M20A 9.6 M20A MOVE THE BOX 20CM
BACKWARD BACKWARD

RELEASE THE BOX RL1 2.0 RL1 RELEASE THE BOX

EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 10CM TO A R10B 6.3 R10B REACH 10CM TO A BOX

BOX PIECE PIECE
GRASP THE BOX G1A 2.0 G1A GRASP THE BOX
HOLD THE BOX PIECE 3.4 AF APPLY PRESSURE TO
THE BOX
HOLD THE BOX PIECE 8.5 T90⁰ TURN THE BOX 90⁰
WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
MACHINE MACHINE

SMN 3823 Page 17

 OPERATOR 2:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
BOX PILE BOX PILE
EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 30CM TO THE R30B 12.8 R30B REACH 30CM TO THE

BOX PILE BOX PILE
GRASP THE BOX G4A 7.3 G4A GRASP THE BOX

MOVE THE BOX 20CM M20A 9.6 M20A MOVE THE BOX 20CM
BACKWARD BACKWARD

RELEASE THE BOX RL1 2.0 RL1 RELEASE THE BOX

EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 10CM TO A R10B 6.3 R10B REACH 10CM TO A BOX

BOX PIECE PIECE
GRASP THE BOX G1A 2.0 G1A GRASP THE BOX
WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
MACHINE MACHINE

Total TMU of Element 1 = 158.7

Convert into seconds = 5.71 s

Normal time = 5.71 s

Standard time = 5.71 (1+0.2)

= 6.85 s

SMN 3823 Page 18

 2. Position the two box piece and stitch the far end

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

MOVE THE BOX 80CM M80B 25.2 M80B MOVE THE BOX 70CM
SIDELINE SIDELINE
POSITION THE BOX TO P1S 5.6 P1S POSITION THE BOX TO
MACHINE MACHINE
STEP ON THE FMP 19.1
MACHINE

Total TMU of Element 2 = 77.2

Convert into seconds = 2.78 s

Normal time = 2.78 s

Standard time = 2.78 (1+0.2)

= 3.33 s

3. Reposition the two box piece and stitch all the way

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

MOVE THE BOX 4CM M4B 4 M4B MOVE THE BOX 4CM
SIDELINE SIDELINE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX TO
TO MACHINE MACHINE
STEP ON THE FMP 19.1
MACHINE
MOVE THE BOX M60B 20.4 M60B MOVE THE BOX 60CM
60CM SIDELINE SIDELINE

Total TMU of Element 3 = 49.1

SMN 3823 Page 19

 Convert into seconds = 1.77 s

Normal time = 1.77 s

Standard time = 1.77 (1+0.2)

= 2.12 s

4. Turn the box to the other end

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

MOVE THE FIXTURE M80B 26.9 M80B MOVE THE FIXTURE
80CM SIDELINE 80CM SIDELINE
RELEASE THE BOX RL1 2

REACH 50CM TO THE R50E 16.5 RL1 RELEASE THE BOX

BOTTOM BOX
GRASP BOTTOM BOX G1A 16.5 R50E REACH 50CM TO
BOTTOM BOX
2 G1A GRASP THE BOX

TURN THE BOX 180⁰ T180⁰ 14.8 T180⁰ TURN THE BOX 180⁰

MOVE THE FIXTURE M80B 26.9 M80B MOVE THE FIXTURE

80CM SIDELINE 80CM SIDELINE

OPERATOR 2:

SMN 3823 Page 20

 DESCRIPTION No. LH TMU RH No. DESCRIPTION
MOVE THE FIXTURE M80B 26.9 M80B MOVE THE FIXTURE
80CM SIDELINE 80CM SIDELINE
2 RL1 RELEASE THE BOX

RELEASE THE BOX RL1 16.5 R50E REACH 50CM TO THE

BOTTOM BOX
REACH 50CM TO THE R50E 16.5 G1A GRASP THE BOX
BOTTOM BOX
GRASP BOTTOM BOX G1A 2

TURN THE BOX 180⁰ T180⁰ 14.8 T180⁰ TURN THE BOX 180⁰

MOVE THE FIXTURE M80B 26.9 M80B MOVE THE FIXTURE

80CM SIDELINE 80CM SIDELINE

Total TMU of Element 3 = 105.6

Convert into seconds = 3.80 s

Normal time = 3.80 s

Standard time = 3.80 (1+0.2)

= 4.56 s

5. Position the two box piece and stitch the far end

OPERATOR 1:

SMN 3823 Page 21

 DESCRIPTION No. LH TMU RH No. DESCRIPTION
EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

MOVE THE BOX 70CM M70B 22.8 M70B MOVE THE BOX 70CM
SIDELINE SIDELINE
POSITION THE BOX TO P1S 5.6 P1S POSITION THE BOX TO
MACHINE MACHINE
STEP ON THE FMP 19.1
MACHINE

Total TMU of Element 3 = 74.8

Convert into seconds = 2.69 s

Normal time = 2.69 s

Standard time = 2.69 (1+0.2)

= 3.23 s

6. Reposition the two box piece and stitch all the way

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

MOVE THE BOX 4CM M4B 4 M4B MOVE THE BOX 4CM
SIDELINE SIDELINE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX TO
TO MACHINE MACHINE
STEP ON THE FMP 19.1
MACHINE
MOVE THE BOX M60B 20.4 M60B MOVE THE BOX 60CM
60CM SIDELINE SIDELINE

Total TMU of Element 3 = 49.1

Convert into seconds = 1.77 s

SMN 3823 Page 22

 Normal time = 1.77 s

Standard time = 1.77 (1+0.2)

= 2.12 s

7. Bring completed box to the stacked pile

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

MOVE THE BOX M20B 10.5 M20B MOVE THE BOX

SIDELINE FOR 20CM SIDELINE FOR 20CM
RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

29 B.S BEND

6.8 R10E REACH 10CM TO THE

BOX
REACH 10CM TO THE R10E 6.8 G1A GRASP THE BOX
BOX
GRASP THE BOX G1A 2

TURN THE BOX 90⁰ T90⁰ 8.5 T90⁰ TURN THE BOX 90⁰

WALK 3M TO THE W-M 52.2 W-M WALK 3M TO THE

STORAGE STORAGE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX

RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

OPERATOR 2:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

SMN 3823 Page 23

 MOVE THE BOX M20B 10.5 M20B MOVE THE BOX
SIDELINE FOR 20CM SIDELINE FOR 20CM
RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

29 B.S BEND

6.8 R10E REACH 10CM TO THE

BOX
REACH 10CM TO THE R10E 6.8 G1A GRASP THE BOX
BOX
GRASP THE BOX G1A 2

TURN THE BOX 90⁰ T90⁰ 8.5 T90⁰ TURN THE BOX 90⁰

WALK 3M TO THE W-M 52.2 W-M WALK 3M TO THE

STORAGE STORAGE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX

RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

Total TMU of Element 3 = 141.6

Convert into seconds = 5.09 s

Normal time = 5.09 s

Standard time = 5.09 (1+0.2)

= 6.11 s

Total standard time = 6.85 + 3.23 + 2.12 + 4.56 + 3.23 + 2.12 + 6.11

= 28.22 s

Weakness of the existing Process

1. Folding the box before mounting takes time

During element 1, before the box pieces are mounted on the machine, the operators will fold
the box piece at the folding edge for convenient purposes when stitching them together.

SMN 3823 Page 24

2. Too many holding process

From the two hand chart, it can be determined that there are many holding processes for
operator 2, especially when the stitching machine is running. This will waste time and energy
as the operator merely functions as a holder.

5.0 PROPOSE METHOD

For the process of assembling a 2 piece box, we have explored that there are many ways that
can be implemented to improve the productivity of the product such as tools or methods being
used. However, we only focus on the best solution which can reduce unnecessary actions in
doing the task.

In order to identify the best solution which can be used to reduce unnecessary actions, first of
all we observed the process and analyzed for weaknesses of the assembly. After that, we
identify the opportunities to improve from these weaknesses. (Choose the bottle neck
operation) Then we will analyze the chosen improvements and translated into diagrams and
charts to see whether the improvement is efficient. Comparison can do either in the term of
normal time, standard time, and the number of observation.

After the comparison, we discover that the process can be improved through various methods.
With this improvement, the proposed methods are more convenient to the operator

Work measurement is an essential part to the process of improving an existing method. I is

one of the most fundamental tools for the industrial engineers to achieve a variety of
objectives, including setting time standards for production scheduling and wage payment
plans. The industrial engineer will be constantly required to apply his work measurement
skill. We try to eliminate unnecessary actions by (state your suggestion)

Weakness of the existing Process

1. Folding the box before mounting takes time

During element 1, before the box pieces are mounted on the machine, the operators will fold
the box piece at the folding edge for convenient purposes when stitching them together.

2. Too many holding process

From the two hand chart, it can be determined that there are many holding processes for
operator 2, especially when the stitching machine is running. This will waste time and energy
as the operator merely functions as a holder.

SMN 3823 Page 25

Opportunities for improvement

1. Introduce holding device (fixture)

 Re-fixture ineffective activity can be reduce
 To guide work piece to be in the right position.
 Essential in effort to move to automation.
 Since stitching process uses steel wire as stapler bullets, the possibilities of the
fragment pieces flying off to operator is possible. So, with the holding device it
will reduce the exposure time to the second operator.

2. Explanations of proposed Method

The process reduces several factors and elements compared to the existing method. This
process reduces from 2 box pieces pile to 1 focusing the mounting process on operator 2. So,
operator 1 stay on the machine and just stitch. The only step that is the same with the existing
method is when both operator carry the completed product to the finished product pile.

F
I
MACHINE 1 X
T
U
R
E

1.5m

3.0m

BOX PIECE PILE

FINISHED PRODUCT PILE

SMN 3823 Page 26

Steps of propose method:

1. Take 2 box pieces and bring it to the machine and mount the box piece on the fixture and
stitch
 Operator 1 remain at the machine while operator 2 go to the box piece pile and
take 2 piece of boxes.
 Operator 1 and 2 will mount the box pieces on the fixture and setup.

2. Position the two box piece and stitch the far end
 The operator will hold the box piece on the machine to make sure the box pieces
are aligned with each other.
 Operator 1 then pushes the foot paddle to operate the machine.
 They stitch once at the far end for initial grip of the box pieces.

3. Reposition the two box piece and stitch all the way
 The operator will realign with the box pieces for further stitching.
 Operator 1 then pushes the foot paddle to operate the machine.
 They will stitch all the way along the box.

4. Extend fixture and turn the box to the other end and retract
 Fixture arm being extended in order to mount the box pieces using the clamp.
 One box piece is mounted on one side on fixture.
 Then, it is turn 180° for the other box piece to be mounted.
 The arm fixture is retracted back.

5. Position the two box piece and stitch the far end
 The operator will hold the box piece on the machine to make sure the box pieces
are aligned with each other.
 Operator 1 then pushes the foot paddle to operate the machine.
 They stitch once at the far end for initial grip of the box pieces.

6. Reposition the two box piece and stitch all the way
 The operator will realign with the box pieces for further stitching.
 Operator 1 then pushes the foot paddle to operate the machine.
 They will stitch all the way along the box.

7. Bring completed box to the stacked pile

 After finish stitching the box pieces, dismount the completed product from the
stitching machine
 Operator 1 and 2 will bring the completed product to the stacked pile.

Improved method
SMN 3823 Page 27
Two hand Chart for Operator 2 with fixture (Stitching process)

TWO-HANDED
      PROCESS CHART      
                   
LEFT HAND O T D S S D T O RIGHT HAND
1. Pull the box piece down ●             ● 1. Pull the box piece down
2. Fold the box piece ●       ●       2. hold the box piece
3. Bring the box piece to 3. Bring the box piece to
the machine   ●         ●   the machine
4. Mount on fixture ●             ● 4. Mount on the machine
5. Delay     ●   ●     5. Delay
6. Delay   ●   ●     6. Delay
7. Delay   ●   ●     7. Delay
8. Slide boxpiece to the left 8. Slide boxpiece to the left
while being stitched all the while being stitched all the
way ●           ● way
9. Dismount box piece and 9. Dismount box piece and
turn to the other edge ●             ● turn to the other edge
10. Mount on the machine ●             ● 10. Mount on the machine
6. Hold the box piece while 6. Hold the box piece while
it is being alligned     ● ●       it is being alligned
12. Hold the box piece           12. Hold the box piece
while stitch the left side while stitch the left side
once ● ● once
13. Slide boxpiece to the           13. Slide boxpiece to the
left and stitch all the way ● ● left and stitch all the way
14. Dismount from           14. Dismount from
machine ●   ● machine
15. Move the completed           15. Move the completed
stack pile   ● ● stack pile
                   
  Summar                
y
METHODS LH RH              
Operations 8 7              
Transports 2 2              
Delays 0 0              
Holds 5 6              
Inspections - -              
Totals 15 15              

Method Time Measurement (MTM)

1. Take 2 box pieces and bring it to the machine

SMN 3823 Page 28
 OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
BOX PILE BOX PILE
EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 30CM TO THE R30B 12.8 R30B REACH 30CM TO THE

BOX PILE BOX PILE
GRASP THE BOX G4A 7.3 G4A GRASP THE BOX

MOVE THE BOX 20CM M20A 9.6 M20A MOVE THE BOX 20CM
BACKWARD BACKWARD

RELEASE THE BOX RL1 2.0 RL1 RELEASE THE BOX

EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 10CM TO A R10B 6.3 R10B REACH 10CM TO A BOX

BOX PIECE PIECE
GRASP THE BOX G1A 2.0 G1A GRASP THE BOX
WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
MACHINE MACHINE

OPERATOR 2:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

SMN 3823 Page 29

WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
BOX PILE BOX PILE
EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 30CM TO THE R30B 12.8 R30B REACH 30CM TO THE

BOX PILE BOX PILE
GRASP THE BOX G4A 7.3 G4A GRASP THE BOX

MOVE THE BOX 20CM M20A 9.6 M20A MOVE THE BOX 20CM
BACKWARD BACKWARD

RELEASE THE BOX RL1 2.0 RL1 RELEASE THE BOX

EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

REACH 10CM TO A R10B 6.3 R10B REACH 10CM TO A BOX

BOX PIECE PIECE
GRASP THE BOX G1A 2.0 G1A GRASP THE BOX
WALK 1.5M TO THE W-M 26.1 W-M WALK 1.5M TO THE
MACHINE MACHINE

Total TMU of Element 1 = 146.8

Convert into seconds = 5.28 s

Normal time = 5.28 s

Standard time = 5.28 (1+0.2)

= 6.34 s

2. Mount the two box pieces on the fixture, position the two box piece and stitch the far end

SMN 3823 Page 30

 OPERATOR 1:
DESCRIPTION No. LH TMU RH No. DESCRIPTION
MOVE THE FIXTURE M80B 25.2 M80B MOVE THE FIXTURE
80CM SIDELINE 80CM SIDELINE
DISENGAGE THE D2 7.5 D2 DISENGAGE THE
CLAMP CLAMP
OPEN THE CLAMP OF RL1 2 RL1 OPEN THE CLAMP OF
THE FIXTURE THE FIXTURE
GRASP THE FIXTURE G1A 2 G1A GRASP THE FIXTURE

TURN 9O⁰ T9O⁰ 8.5 T9O⁰ TURN 9O⁰

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

TURN 9O⁰ T9O⁰ 8.5 T9O⁰ TURN 9O⁰

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

STEP ON THE FMP 19.1

MACHINE

OPERATOR 2:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

GRASP THE FIXTURE G1A 2 G1A GRASP THE FIXTURE

TURN 9O⁰ T9O⁰ 8.5 T9O⁰ TURN 9O⁰

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

TURN 9O⁰ T9O⁰ 8.5 T9O⁰ TURN 9O⁰

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

Total TMU of Element 2 = 105.2

Convert into seconds = 3.78 s

Normal time = 3.78 s

Standard time = 3.78 (1+0.2)

= 4.54 s

SMN 3823 Page 31

 3. Reposition the two box piece and stitch all the way

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

MOVE THE BOX 4CM M4A 3.1 M4A MOVE THE BOX 4CM
SIDELINE SIDELINE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX TO
TO MACHINE MACHINE
STEP ON THE FMP 19.1
MACHINE
MOVE THE BOX M60B 20.4 M60B MOVE THE BOX 60CM
60CM SIDELINE SIDELINE

Total TMU of Element 3 = 48.2

Convert into seconds = 1.73 s

Normal time = 1.73 s

Standard time = 1.73 (1+0.2)

= 2.08 s

4. Extend the fixture and turn the box to the other end

SMN 3823 Page 32

 OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

MOVE THE FIXTURE M80B 25.2 M80B MOVE THE FIXTURE
80CM SIDELINE 80CM SIDELINE
TURN 18O⁰ T18O⁰ 14.8 T18O⁰ TURN 18O⁰

MOVE THE FIXTURE M80B 25.2 M80B MOVE THE FIXTURE

80CM SIDELINE 80CM SIDELINE

OPERATOR 2:
DESCRIPTION No. LH TMU RH No. DESCRIPTION
- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

Total TMU of Element 4 = 65.2

Convert into seconds = 2.34 s

Normal time = 2.34 s

Standard time = 2.34 (1+0.2)

= 2.81 s

5. Position the two box piece and stitch the far end

SMN 3823 Page 33

 OPERATOR 1:
DESCRIPTION No. LH TMU RH No. DESCRIPTION
EYE TRAVEL ET 20 ET EYE TRAVEL

EYE FOCUS EF 7.3 EF EYE FOCUS

MOVE THE BOX 70CM M70B 22.8 M70B MOVE THE BOX 70CM
SIDELINE SIDELINE
POSITION THE BOX TO P1S 5.6 P1S POSITION THE BOX TO
MACHINE MACHINE
STEP ON THE FMP 19.1
MACHINE

Total TMU of Element 6 = 74.8

Convert into seconds = 2.69 s

Normal time = 2.69 s

Standard time = 2.69 (1+0.2)

= 3.23 s

6. Reposition the two box piece and stitch all the way

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

MOVE THE BOX 4CM M4A 3.1 M4A MOVE THE BOX 4CM
SIDELINE SIDELINE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX TO
TO MACHINE MACHINE
STEP ON THE FMP 19.1
MACHINE
MOVE THE BOX M60B 20.4 M60B MOVE THE BOX 60CM
60CM SIDELINE SIDELINE

Total TMU of Element 3 = 48.2

Convert into seconds = 1.73 s

SMN 3823 Page 34

 Normal time = 1.73 s

Standard time = 1.73 (1+0.2)

= 2.08 s

7. Bring completed box to the stacked pile

OPERATOR 1:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

MOVE THE BOX M20B 10.5 M20B MOVE THE BOX

SIDELINE FOR 20CM SIDELINE FOR 20CM
RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

29 B.S BEND

6.8 R10E REACH 10CM TO THE

BOX
REACH 10CM TO THE R10E 6.8 G1A GRASP THE BOX
BOX
GRASP THE BOX G1A 2

TURN THE BOX 90⁰ T90⁰ 8.5 T90⁰ TURN THE BOX 90⁰

WALK 3M TO THE W-M 52.2 W-M WALK 3M TO THE

STORAGE STORAGE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX

RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

OPERATOR 2:

DESCRIPTION No. LH TMU RH No. DESCRIPTION

SMN 3823 Page 35

POSITION THE BOX P2S 16.2 P2S POSITION THE BOX

MOVE THE BOX M20B 10.5 M20B MOVE THE BOX

SIDELINE FOR 20CM SIDELINE FOR 20CM
RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

29 B.S BEND

6.8 R10E REACH 10CM TO THE

BOX
REACH 10CM TO THE R10E 6.8 G1A GRASP THE BOX
BOX
GRASP THE BOX G1A 2

TURN THE BOX 90⁰ T90⁰ 8.5 T90⁰ TURN THE BOX 90⁰

WALK 3M TO THE W-M 52.2 W-M WALK 3M TO THE

STORAGE STORAGE
POSITION THE BOX P1S 5.6 P1S POSITION THE BOX

RELEASE THE BOX RL1 2 RL1 RELEASE THE BOX

Total TMU of Element 3 = 141.6

Convert into seconds = 5.09 s

Normal time = 5.09 s

Standard time = 5.09 (1+0.2)

= 6.11

Total standard time: = 6.34 + 4.54 + 2.08 + 2.81+ 3.23 +2.08 + 6.11

= 27.19 s

SMN 3823 Page 36

5.0 CONCLUSION

As the conclusion, we have determined that by designing a fixture on the stitching machine,
the effort of the second operator can be reduced and with the allocated time can a better use
can be given the operator to improve efficiency of the employee. So, by using Two Hand
Chart, Man machine Chart, Method Time Measurement (MTM) we can reduce cycle of the
stitching process.

Activities Wk2 Wk Wk4 Wk Wk6 Wk Wk8 Wk Wk11 Wk12 Wk1 Wk14

3 5 7 9 3

SMN 3823 Page 37

Identifying company and
the field of study

Spreads task between

member group

Discussing & designing

instruments

Collecting primary &

secondary data

Analyzing collected data

Drafting report

Group discussion

Last check for the report

Revising final report

Binding final report

Work schedule

7. Reference

[Link]

[Link]

SMN 3823 Page 38

SMN 3823 Page 39