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Article
Publication date: 14 December 2022

Priyabrata Mondal and Prabir Jana

Automation and the new buzzword, “Industry 4.0”, have dominated the media headlines in recent months. In this scenario, apparel manufacturers should not only install automatic…

Abstract

Purpose

Automation and the new buzzword, “Industry 4.0”, have dominated the media headlines in recent months. In this scenario, apparel manufacturers should not only install automatic machines but also standardise them based on specific industry requirements, and precise measures are required for daily target demands.

Design/methodology/approach

This study demonstrates the application of Predetermined Motion and Time System (PMTS) tools in various automatic and semiautomatic machines to obtain higher productivity and the highest utilisation percentage of operator and automats between the 1:1 and 1:2 man vs machine configuration models. In this study, timeSSD® was used to calculate the micro motions of humans. In addition, a video annotation and modelling software Tracker was used to calculate high-speed machine movements with loading frames of 30 FPS.

Findings

After the implementation of PMTS tools, it was found that for a 1:1 man vs machine configuration, the operator utilisation is 75% per shift and the operator idle time is 50% per cycle time, and the operator is sitting idle for 2 h per 8 h of shift. So, there is scope to improve the utilisation and idle time of operator.

Research limitations/implications

With the PMTS software, an industrial engineer professional with knowledge of the micromotion economy can only calculate micromotion.

Originality/value

Exploring the first time in the world to establish standard allowed minute (SAM) of a partly automated single-unit sewing machine with partial human intervention and a semiautomatic machine. Theoretical underpinnings indicate that manufacturers use the experience to determine the SAM of any operation over time, necessitating this work to calculate standard minutes automatically.

Article
Publication date: 1 April 1991

A. Rauof

Presents the results of some recent studies undertaken to discoverthe effect of various factors on basic motions by conducting laboratoryexperiments, and the models derived from…

Abstract

Presents the results of some recent studies undertaken to discover the effect of various factors on basic motions by conducting laboratory experiments, and the models derived from them. Argues that the PMTS in use since the 1920s do not take into consideration all the factors that affect time in basic motions. Argues that simultaneous motions, simultaneous symmetrical reach, asymmetrical motions, and cranking motion must all be studied and modelled.

Details

Work Study, vol. 40 no. 4
Type: Research Article
ISSN: 0043-8022

Keywords

Article
Publication date: 1 December 1968

INDUSTRIALLY the two ‘in’ words today seem to be participation and consensus, the first leading to the second. How these can become a reality in modern business was discussed…

Abstract

INDUSTRIALLY the two ‘in’ words today seem to be participation and consensus, the first leading to the second. How these can become a reality in modern business was discussed recently by the London Region of the Institute of Work Study Practitioners.

Details

Work Study, vol. 17 no. 12
Type: Research Article
ISSN: 0043-8022

Article
Publication date: 12 June 2019

Kaijun Cai, Weiming Zhang, Wenzhuo Chen and Hongfei Zhao

Based on virtual maintenance, this paper aims to propose a time prediction method of assembly and disassembly (A&D) actions of product maintenance process to enhance existing…

Abstract

Purpose

Based on virtual maintenance, this paper aims to propose a time prediction method of assembly and disassembly (A&D) actions of product maintenance process to enhance existing methods’ prediction accuracy, applicability and efficiency.

Design/methodology/approach

First, a framework of A&D time prediction model is constructed, which describes the time prediction process in detail. Then, basic maintenance motions which can comprise a whole A&D process are classified into five categories: body movement, working posture change, upper limb movement, operation and grasp/placement. A standard posture library is developed based on the classification. Next, according to motion characteristics, different time prediction methods for each motion category are proposed based on virtual maintenance simulation, modular arrangement of predetermined time standard theory and the statistics acquired from motion experiment. Finally, time correction based on the quantitative evaluation method of motion time influence factors is studied so that A&D time could be predicted with more accuracy.

Findings

Case study of time prediction of products’ various A&D processes is conducted by implementing the proposed method. The prediction process of diesel cooling fan disassemble time is presented in detail. Through comparison, the advantages and effectiveness of the method are demonstrated.

Originality/value

This paper proposes a more accurate, efficient and applicable product A&D time prediction method. It can help designers predict A&D time of a product maintenance accurately in early design phases without a physical prototype. It can also provide basis for the verification of maintainability, the balance of the design of product structure and system layout.

Details

Assembly Automation, vol. 39 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 1 September 1969

AT the request of the Director‐General of the International Labour Office Mr. Petre Lupu, Rumania's Minister of Labour, has described the benefits brought to his country through…

Abstract

AT the request of the Director‐General of the International Labour Office Mr. Petre Lupu, Rumania's Minister of Labour, has described the benefits brought to his country through setting up a Management Development Centre.

Details

Work Study, vol. 18 no. 9
Type: Research Article
ISSN: 0043-8022

Article
Publication date: 11 April 2018

Fernanda Assef, Cassius Tadeu Scarpin and Maria Teresinha Steiner

The purpose of this paper is to present a precise comparison between a pre-determined time rules and the evaluation performed with the help of a manual chronometer using data from…

Abstract

Purpose

The purpose of this paper is to present a precise comparison between a pre-determined time rules and the evaluation performed with the help of a manual chronometer using data from a line assembly in an automotive industry besieged in the state of Paraná, Brazil. Nowadays, it is possible to verify several tools of measurement of task times, some taking less time and causing less wear of the evaluator than others, but not being in accordance with the real conditions of the workers of a certain industry.

Design/methodology/approach

The developed paper has its methodology based on two methods of time analysis, one of them being an adaptation of the MODular Arrangement of Predeterminated Time Standard (MODAPTS) method – called MODAPTS 2. This method is used by the industry in analyzed in this work and the other through the use of simple manual timing, through the digital timer, of the stages developed in a workstation.

Findings

The study shows that for each operation analyzed, thus presenting a situation of minimum waste, it becomes possible to judge which reasons exist for the operator during manual timekeeping not to reach the optimum times generated by the system of pre-determined times and movements (PMTSs) questioned.

Research limitations/implications

This study is conducted on an automotive enterprise in a period of confidentiality, which means that only a single workstation is able to be studied. This means that the comparison obtained between the time measurements methods used, and the evaluation of the MODAPTS is carried out with the best possible movements and gestures, disregarding then that the wastes can still be postulated to the whole assembly line.

Originality/value

With the automation in industry, where assemble tasks are usually developed manually, it is believed possible to discard the option of measuring task times in its classic and manual form, using a timer, yet during this process, there will be variables that may not be considered by pre-determined measurements methodologies. The work developed by this paper presents different variables that are not examined by the methods of PMTS, not frequently seen in the literature, as well as the difference that occurs between the measurement of times with stopwatch and the use of PMTS, which, in its original form, disregards the wastes that the operator has in their movements.

Details

Journal of Manufacturing Technology Management, vol. 29 no. 5
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 12 September 2016

A.N. Mustafizul Karim, Saravanan Tanjong Tuan and H.M. Emrul Kays

The purpose of this paper is to address and solve operational problems of an automotive industry in reaching production target by adopting Maynard Operation Sequence Technique…

1031

Abstract

Purpose

The purpose of this paper is to address and solve operational problems of an automotive industry in reaching production target by adopting Maynard Operation Sequence Technique (MOST) as lean and productivity improvement strategies.

Design/methodology/approach

In the undertaken case of auto-car rear window assembly line, a recurring production shortfall in fulfilling the daily demand is seemingly due to inappropriate work method. Initial observation of the operations led to suspect certain lapses in initiatives to adopt the time standards, to reduce or eliminate non-value added motions, to design suitable aisle and to assign tasks among workstations in a balanced manner. Subsequently an attempt is made to pinpoint the causes of poor performance and the bottlenecks through process flow analysis and time study by applying MOST. The elemental tasks are closely examined for possible reduction of workstation times by choosing efficient work methods with ergonomic features. Thus appropriate hand tools, jigs and fixture with nominal investment are prescribed to incorporate in the assembly works. The operational changes as steered by the MOST application have enhanced the workflow with a shorter cycle time which led to a substantial increase in productivity.

Findings

The productivity of the assembly line is increased by more than 29 percent from the earlier capacity through the MOST application which is deemed to meet the current level of demand.

Originality/value

The adopted framework for recognizing the effectiveness of MOST to expose and rectify the flaws in work methods without much investment is expected to be beneficial for a manufacturer in securing the competitiveness.

Details

International Journal of Productivity and Performance Management, vol. 65 no. 7
Type: Research Article
ISSN: 1741-0401

Keywords

Article
Publication date: 1 August 1981

ONCE upon a time, in the true spirit of fairy stories, it was our job to get fewer people to produce more of whatever they were making. It certainly did not make us popular. There…

Abstract

ONCE upon a time, in the true spirit of fairy stories, it was our job to get fewer people to produce more of whatever they were making. It certainly did not make us popular. There were times when the appearance of a work study engineer in any factory was enough to start off a strike. Even the best regulated workers were known to slow down deliberately if only to give them and their mates some leeway when the “rate for the job” (whether the pay rate or production rate) was under consideration.

Details

Work Study, vol. 30 no. 8
Type: Research Article
ISSN: 0043-8022

Article
Publication date: 1 July 1970

Words like Participation tend to be labels stuck on generalities, signifying nothing. They are used as verbal bromides by publicists anxious to cover harsh realities with an…

Abstract

Words like Participation tend to be labels stuck on generalities, signifying nothing. They are used as verbal bromides by publicists anxious to cover harsh realities with an attractive veneer. As a rule, once they have served their purpose, they are conveniently forgotten.

Details

Work Study, vol. 19 no. 7
Type: Research Article
ISSN: 0043-8022

Article
Publication date: 1 September 1976

IT was in last June of flaming memory that we posed the question “What will the Bullock Committee achieve?” Well, there is still a little hope that this committee, like so many…

Abstract

IT was in last June of flaming memory that we posed the question “What will the Bullock Committee achieve?” Well, there is still a little hope that this committee, like so many others in the past, will produce a report that will simply be shelved. But this hope is very small.

Details

Work Study, vol. 25 no. 9
Type: Research Article
ISSN: 0043-8022

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