TIME AND MOTION STUDY

AN IMPACT TIME MOTION STUDY ON SMALL MEDIUM ENTERPRISE ORGANIZATION

      ABDUL TALIB BON,

  ALIZA ARIFFIN

ABSTRACT:

          The purpose of this research is to improve production capabilities for Small Medium Enterprise (SME) industry. Research focused on SME, which produce chili sauce. This research used Time and Motion technique to improve work process at SME, and the research objectives towards accomplished this study is to identify problems in the production work process and improved it in terms of production time, number of process and production layout by proposing an efficient work process to SME.  

1.     Introduction

1.1 Background of Study

Small Medium Enterprise or SME Industry consists of small numbers of employees and annual turnover.  There can categorize into three criteria – primary agriculture, manufacturing and services.  One of the SME Industry was SME that produces sauce. The small of its enterprise caused difficult for them to competing with other firmed companies such as Jalen, Kimball, Maggie and Life. Thus, this research takes initiative to used Time and Motion technique to improve the work process in order to permit them to compete with international rivalry.

1.2 Objective of Study

The objective towards accomplishing the study are :

(i)       Using the time and motion study to identify problems in the production work process.

(ii)   Improving the work process in terms of production time, number of processand production layout by proposing the new work process to SME.

1.3 Scope of Study

The scopes of this research are:

(i)      This study concentrates on Small Medium Enterprise (SME) Industry, SME

(ii)    The scope of study is the work process in producing chili sauce that contains   5kg for each bottle.

(iii)    The research is focused on time and the flow of work process in production department from the start until it produces finish products

(iv)    The data that needs to be carried out in this study is flow chart of the work process, the details for each process, the required time for specific process, number of employees, distance and number of products that they produced in specific time.

1.5 Benefits from this study

This study was chosen because it will give many benefits to production and operation management. Among the advantages for SME in producing their sauce are:

(i)      Eliminate the Unnecessary

(ii)    Change the Sequence of Operations

(iii)   Simplify the Necessary Operations

2. Research Methodology

2.1 Research Design

This research was conducted through field study.  Field study is all the methods of research are made from direct observations towards the live study situations.   Researcher collected data by observing and recorded the research subject during the observation. 

2.2 Variables

The variables in this study can be classified into two types,  

• independent (time and motion technique and 
• dependent  variable (an impact in the work process for producing sauce)

2.3 Basic Procedure for Research

There are four steps to complete this study.  There are given below according to their sequence :

(i) Select:  select the process or job to be studied.

(ii) Record:  observe and record all the relevant facts related to the work process.

(iii) Examine: examine each recorded fact critically

(iv) Develop:  develop the most efficient work process.

2.4 Data Collection

This research requires to collect data that are related to the time during the work process occurs, the movement or distance for each process and number of products that they can produces in specific time, which was collect based on several methods :

(i)   Systematic Observation  (ii) Stopwatch Time Study  (iii) Process Chart

3. Data Analysis and Outcomes

3.1 Data Collection

Data collection is done to determine the data required for building the process design.  The data collected can explain how the process operates, when, where and how the activities takes place. The data was included :

1.   flow chart for the process
2.   the detail operation for each process
3.   production time
4.   layout
5.   the motion from one process to another process

3.2 Work Process

Based on systematic observation, we know that there are seven main work processes in producing chili sauce.  Each work process included minor process.  The process started with cleaning the raw material, mixture, cooking, filling, labelling and the end process is packaging the sauce into four bottles for each.

3.3 Work Process Operations

Overall process takes as much as twenty five processes and each process can be summarized as operation, transport, inspection, delay or storages. Numbers of operation in producing chili sauce  is fifteen processes or 60% from the entire processes. Among the operations process are cleaning  the  raw  material,  blend,  mixture,  cooking  and  packaging.

3.4 Production Time

Production department is the functional area responsible for turning inputs into finished outputs through a series of production processes. The data was taken by using stopwatch time study and recorded in the Process Chart form on its process and production layout for making work more efficient.

Based on its owner, the whole process will be completed in the period of four hours.  But, based on data collected, it is more than four hours with the total time is 4.10 hours and it indicates that they are not punctual in producing their products.  Thus, these analyses are important in order to identify improvement opportunities in the production department.

3.5 Statistical Analysis of Data

In a simulation model, raw data that has been collected must be analyzed and interpreted, so the system operation is correctly represented in the model.  Prior to developing a representation of model, the data should be analyzed to ascertain their  suitability for use in the simulation model. 

3.5.1 Stat: Fit Software

Besides that, the data were also tested with Kolmogorov – Smirnov as normality test to decide whether the data will be accepted or rejected.  If the value greater than 0.05, means the data will suitable to run the simulation.  Table 2 shows the data testing for each process using Stat::Fit.

Table 2: The Data Testing for Each Process

Process	Distribution	Rank	Acceptance
Cooking	Exponential	98.7	Do not reject
To steam area	Lognormal	100	Do not reject
Steam the material	Triangular	86.5	Do not reject
To filling tank 1	Exponential	100	Do not reject
To filling tank 2	Lognormal	100	Do not reject
To labeling (F1)	Triangular	100	Do not reject
To labeling (F2)	Lognormal	100	Do not reject

3.6 Actual Production Layout

An effective layout facilitates the flow of materials, people and information within and between areas.Actual production layout takes 54m² space utilization and the production layout must be analyzed because layout is one of the key that determine the long-run efficiency of work process.  Based on observation and data collection, there are find that layout is one of the factors that contributes to the delay in production.  Based on current production layout, we can see that the layout lacks in the arrangement of machine and equipments especially at filling tank 1 and filling tank 2, where it involves packaging processing.  The arrangement of packaging equipments is not suitable because it utilizes more space in the production. Thus, as a consequence, these situations caused the excessive in the production time in producing the products.

4.0 Discussion And Conclusion

4.1 Recommendation to Enterprise

It can be conclude that the problem occurs in the work process are related to production time, where it takes extra time in producing its products and from the analysis, we know that the problems may occur in the packaging activities because of the arrangement of its filling tank machine. Thus, the fact that related in this identified problems are :

•   Number of process
•   Production time
•   Production layout

From the observation, data collection and data analysis, then, researcher develops the actual simulation to identify the problems. The comparison between the current work process and new work process explained in Table 3.

Table 3: The comparison between the current and new work process

	Current layout	Proposal I	Proposal II
Number of Process	7	5	5
Time utilization (hour)	4.10	3.41	3.45
Space utilization (m2)	54	44.4	46.8

                An effective layout facilitates the flow of materials, people and utilizes the minimal area.  An effective layout can also help and  support an enterprise to achieve some improvement. A good layout results in a streamlined flow with minimal movement thus minimizing material handling. The changes of equipment arrangement will help to solve the current work process problem.  The machine and equipments are arranged according to the sequence of operations because it is a continuous work process. 

4.2 Recommendation for Future Research

There are several affairs that must be attended during collecting data.  The data collections are the important part for analyzing and obtain accurate outcomes.  Among the recommendations are :

•   All the machines or equipments that are found in the production layout needs to measure their dimension in order to develop accurate actual layout.
• All matters that are related to distance between processes needs to record to obtain useful comparison.
•  Collection of operating time must be recorded in more systematically to prevent error or mistake during data analysis.

4.3 Limitation

The limitation in performing the proposed work process is the new work process only can reduce the total production time and space utilization, which cannot enhance the number of products.

4.4 Conclusion

From the discussion of the three parameters, it can be concluded that this process can be improved based on the three parameters that cause the problems.  With combination of work process and time measurement and the changes of production layout, it will improve the current work process.  These modifications are made by eliminating the wasted time and reduction of the work contents. From the comparison between current and new work process in table 5.1, it indicates that the best alternative towards this problem by choosing proposal 1.These improvements was successful to achieve the project goals and objectives, which the improvements was included the processes, production layout, economy in human effort and the reduction of unnecessary fatigue.

4.5 Pro Model Software

Pro Model software works as simulation tools for developing a system design.   The developed model acts as a surrogate for the actual or real-world system.  Knowledge gained from experimenting on the model can be transferred to the real system.  In this respect, simulation can be thought of as a virtual prototyping tool for demonstrating proof of concept.

4.6  Contribution to Enterprise

The contribution of ProModel software to the enterprise is, it can develop a new system design and stimulate the model in order to find their flow.  The concept is much easier rather than the traditional approach because a new design of work process can be developed much easier and it can actually show how it will operate.  

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