MANPOWER PRODUCTIVITY IMPROVEMENT IN MANUFACTURING INDUSTRY USING INDUSTRIAL ENGINEERING TOOLS

摘要

Title: Productivity Improvement in Manufacturing Industry Using Industrial Engineering Tools Objectives: "To improve manpower productivity by implementing Industrial engineering tools" for Mill Chock Servicing & Work roll Assembly from 36 Man-hours to 24 Man-hours per work roll set. Methods: Initial workplace audit was conducted based on the 5 'S, Ergonomic aspects, Engineering tools & tackles, Maintenance practices, workplace layout, Material flow etc. This also includes activities sequence and the activity time to analyse existing work patterns. As the objective was to implement best workplace design with the world-class industry practices & improved manpower productivity using Industrial Engineering tools. Systematic Work study was carried out for each operation using the advanced Video recording techniques after creating SIPOC (Supplier, Input, Process, Output & Customer) model of a process to eliminate non value added (NVA) activities & time. Team brainstorming was carried out to identify internal and external activities, Manual, Auto, Waiting & Walking time was mapped. Then Waste matrix was mapped to identify Value added and Non-Value added activities. Finally actions were proposed based on Eliminate, Combine, Reduce & Simply (ECRS) Techniques followed by standardization and training on Standard Operating Procedures (SOP) developed using Augmented (AR) & Virtual Reality (VR). Results: With the application of various Industrial Engineering tools such as Work study, Ergonomic Study, 5'S & Lean Management the "Manpower Productivity was improved for M4 Chock Servicing & Work roll Assembly from 36 Man-hours to 25 Man-hours per work roll set." Conclusion: From the project studies, it was found that 1) Integrating ergonomics into the method study helps to standardize processes effectively & prevent worker discomfort helps to improve productivity and product quality. 2) Eliminate, Combine, Reduce & Simply (ECRS) Techniques helps to optimize the work sequence & activity time. 3) Unlike Single Minute Exchange of Dies (SMED) separation of internal and external setups, performing simultaneous activities helps to reduce unproductive time. 4) Lean tools when effectively combined with Work Study Methods can help to resolve problems regarding the productivity. If implemented in proper order.