Time and motion study applied to a production line of organic lenses in Manaus Industrial Hub

Cury, Pedro Henrique Araújo; Saraiva, José

doi:10.1590/0104-530X2881-18

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Original Article • Gest. Prod. 25 (4) • Oct-Dec 2018 • https://doi.org/10.1590/0104-530X2881-18 copy

Time and motion study applied to a production line of organic lenses in Manaus Industrial Hub

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract

This article presents a case study on the utilization of the time and motion technique applied to a production line of organic lenses in a multinational company located in Manaus Industrial Hub (PIM), Amazonas state, Brazil. The goal of this study is to enable insertion of five-minute breaks every production hour, maintaining productivity without changing the demand or increasing the operators' workload. Specifically, the main time and motion techniques were utilized in order to optimize operations, identifying value-added and non-value-added activities, and wastes. The case study describes the company’s current scenario, proposed situation, data treatment, and results.

Keywords:
Time and motion study; Organic lenses; Operation optimization; Wastes

	Skill			Effort
0.15	A1	Superskill	0.13	A1	Excessive
0.13	A2		0.12	A2
0.11	B1	Excelent	0.10	B1	Excelent
0.08	B2		0.08	B2
0.06	C1	Good	0.05	C1	Good
0.03	C2		0.02	C2
0.00	D1	Average	0.00	D1	Average
-0.05	E1	Fair	-0.04	E1	Fair
-0.10	E2		-0.08	E2
-0.16	F1	Poor	-0.12	F1	Poor
-0.22	F2		-0.17	F2
	Conditions			Consistency
0.06	A	Ideal	0.04	A	Perfect
0.04	B	Excelent	0.03	B	Excelent
0.02	C	Good	0.01	C	Good
0.00	D	Average	0.00	D	Average
-0.03	E	Fair	-0.02	E	Fair
-0.07	F	Basic	-0.04	F	Basic

	Physical effort	Mental effort	Recovery		Monotony
	Physical effort	Mental effort	% Recovered time	Factor B	Cycle duration (min)	%
Effort	%	%	0-5	1	0 a 0.05	7.9
Effort	%	%	6-10	0.9	0 a 0.05
Very light	1.8	0	11-15	0.8	0.06 a 0.25	5.4
Very light	1.8	0	16-20	0.71	0.06 a 0.25
Light	3.6	0.6	21-25	0.62	0.26 a 0.50	3.6
Light	3.6	0.6	26-30	0.54	0.26 a 0.50
Average	5.4	1.8	31-35	0.46	0.51 a 1.00	2.1
Average	5.4	1.8	36-40	0.39	0.51 a 1.00
Heavy	7.2	3	41-45	0.32	1.01 a 2.00	1
Heavy	7.2	3	46-50	0.26	1.01 a 2.00
Very Heavy	9	0	51-55	0.2	2.01 a 3.00	0.5
Very Heavy	9	0	56-60	0.15	3.01 a 4.00	0.2
Environmental conditions
Thermal		Atmospheric		Other
Temperature	%	Local	%		%
0 a 7 °C	3.6	Well-ventilated	0	Noise	Low level	0
8 a 15 °C	1.8	Poorly-ventilated or light smoke	2.4	Noise	Requires hearing protection	1.8
16 a 25 °C	0	Poorly-ventilated or light smoke	2.4	Humidity	Dry and pleasant environment	0
26 a 34 °C	1.8	Heavy smoke or dust	5.6	Humidity	High (> 25 °C)	1.8
35 a 40 °C	3.6	Heavy smoke or dust	5.6	Vibration	Ground or machine	1.8

The research in regard to	Classification of the methodological procedure
Technical procedures	Case Study
Goals	Exploratory
Nature	Applied
Approach	Qualitative and quantitative

F/S	Cycle time analysis	Value		Cycle 1
30	Video name:	VA: 1 NVA: 0	First	Last	Frames
1	Operation 1	0	x1	y1	y1-x1
2	Operation 2	0	x2	y2	y2-x2
3	Operation 3	0	x3	y3	y3-x3
4	Operation 4	0	x4	y4	y4-x4
5	Operation 5	0	x5	y5	y5-x5
6	Operation 6	1	x6	y6	y6-x6
7	Operation 7	0	x7	y7	y7-x7
8	Operation 8	1	x8	y8	y8-x8
9	Operation 9	1	x9	y9	y9-x9
10	Operation 10	0	x10	y10	y10-x10
	Total				Sum

Cycle time analysis (in seconds)
#	Video:	Cycle 1	Cycle 2	Cycle 3	Cycle 4	Cycle 5	Average	R	Ideal number of cycles
1	Unclipping	1.57	1.60	1.40	1.47	1.57	1.52	0.20	5
2	Brushing	1.70	1.99	1.81	1.97	1.90	1.87	1.17	5
3	Gasket feeding	1.72	1.34	1.60	1.71	1.74	1.62	0.80	12
4	Assembly	2.50	2.28	2.49	2.58	2.56	2.48	1.29	3
5	Inspection	1.59	1.33	1.53	1.39	1.30	1.43	0.58	8
6	Clipaping	1.25	1.58	1.50	1.68	1.58	1.52	0.83	16
7	Filling	1.74	1.41	1.43	1.50	1.46	1.51	1.33	10
8	Lens organization	1.96	1.94	2.22	2.06	2.04	2.04	0.56	4

Cycle time analysis (in seconds)
#	Video:	Average	V	TN
1	Unclipping	1.52	0.01	1.54
2	Brushing	1.87	0.06	1.98
3	Gasket feeding	1.57	0.05	1.65
4	Assembly	2.42	0.04	2.52
5	Inspection	1.46	0.18	1.72
6	Clipping	1.55	0.03	1.60
7	Filling	1.54	0.05	1.62
8	Lens organization	2.05	0.04	2.13

Cycle time analysis (in seconds)
#	Video:	Average	V	TN	P	FT
1	Unclipping	1.52	0.01	1.54	8%	1.091
2	Brushing	1.87	0.06	1.98	6%	1.065
3	Gasket feeding	1.57	0.05	1.65	8%	1.089
4	Assembly	2.42	0.04	2.52	7%	1.076
5	Inspection	1.46	0.18	1.72	8%	1.082
6	Clipping	1.55	0.03	1.6	8%	1.087
7	Filling	1.54	0.05	1.62	7%	1.078
8	Lens organization	2.05	0.04	2.13	5%	1.058

Cycle time analysis (in seconds)
#	Video:	Average	V	TN	FT	TP
1	Unclipping	1.52	0.01	1.54	1.091	1.67
2	Brushing	1.87	0.06	1.98	1.065	2.11
3	Gasket feeding	1.57	0.05	1.65	1.089	1.80
4	Assembly	2.42	0.04	2.52	1.076	2.71
5	Inspection	1.46	0.18	1.72	1.082	1.86
6	Clipping	1.55	0.03	1.60	1.087	1.74
7	Filling	1.54	0.05	1.62	1.078	1.74
8	Lens organization	2.05	0.04	2.13	1.058	2.26

F/S	Cycle time analysis	Value	Current state of cycle time
30	Video: Assembly	VA: 1 NVA: 0	Frame average	Time per group	Time per unit	VA	NVA
1	Remove the mold and the gasket from the conveyor belt	0	13	0.11	0.43		0.43
2	Clean the gasket with compressed air	0	18	0.15	0.60		0.60
3	Place the gasket on the holder	0	11	0.09	0.37		0.37
4	Raise the mold	0	8	0.07	0.27		0.27
5	Clean the mold with compressed air	0	22	0.18	0.73		0.73
6	Place the mold on the holder	0	13	0.11	0.43		0.43
7	Disassemble the mold	1	26	0.22	0.87	0.87
8	Clean the concave side of the mold with compressed air	0	40	0.33	1.33		1.33
9	Assemble the concave side of the mold	1	38	0.32	1.27	1.27
10	Raise the lens	0	17	0.14	0.56		0.56
11	Inspect the lens	0	8	0.07	0.28		0.28
12	Place the lens on the conveyor belt	0	10	0.08	0.33		0.33
13	Clean the convex side of the mold	0	28	0.23	0.90		0.90
14	Assemble the convex side of the mold	1	23	0.19	0.77	0.77
15	Place the assembled mold back on the conveyor belt	0	16	0.13	0.53		0.53
	Total		290	2.42	9.67	2.91	6.77

F/S	Cycle time analysis	Value	Future state of cycle time
30	Video: Assembly	VA: 1 NVA: 0	Time per group	Time per unit	VA	NVA
1	Remove the mold and the gasket from the conveyor belt	0	0.11	0.43		0.43
2	Clean the gasket with compressed air	0	0.15	0.60		0.60
3	Place the gasket on the holder	0	0.09	0.37		0.37
4	Raise the mold	0	0.07	0.27		0.27
5	Clean the mold with compressed air	0	0.18	0.73		0.73
6	Place the mold on the holder	0	0.11	0.43		0.43
7	Disassemble the mold	1	0.22	0.87	0.87
8	Clean the concave side of the mold with compressed air	0	0.33	1.33		1.33
9	Assemble the concave side of the mold	1	0.32	1.27	1.27
10	Raise the lens	0	0.00
11	Inspect the lens	0	0.00
12	Place the lens on the conveyor belt	0	0.08	0.33		0.33
13	Clean the convex side of the mold	0	0.23	0.90		0.90
14	Assemble the convex side of the mold	1	0.19	0.77	0.77
15	Place the assembled mold back on the conveyor belt	0	0.13	0.53		0.53
	Total		2.21	8.83	2.91	5.93

Cycle time analysis (in seconds)
#	Video:	Average	V	TN	FT	TP
1	Unclipping	1.52	0.01	1.54	0.091	1.67
2	Brushing	1.87	0.06	1.98	0.065	2.11
3	Gasket feeding	1.57	0.05	1.65	0.089	1.80
4	Assembly	2.21	0.04	2.30	0.076	2.47
5	Inspection	1.46	0.18	1.72	0.082	1.86
6	Clipping	1.55	0.03	1.60	0.087	1.74
7	Filling	1.54	0.05	1.62	0.078	1.74
8	Lens Organization	2.05	0.04	2.13	0.058	2.26

F/S	Cycle time analysis	Value	FUTURE STATE OF CYCLE TIME
30	Video: Assembly	VA: 1 NVA: 0	Time per group	Time per unit	VA	NVA
1	Remove the mold and the gasket from the conveyor belt	0	0.07	0.43		0.43
2	Clean the gasket with compressed air	0	0.10	0.60		0.60
3	Place the gasket on the holder	0	0.06	0.37		0.37
4	Raise the mold	0	0.04	0.27		0.27
5	Clean the mold with compressed air	0	0.12	0.73		0.73
6	Place the mold on the holder	0	0.07	0.43		0.43
7	Disassemble the mold	1	0.14	0.87	0.87
8	Clean the concave side of the mold	0	0.22	1.33		1.33
9	Assemble the concave side of the mold	1	0.21	1.27	1.27
10	Raise the lens	0	0.00
11	Inspect the lens	0	0.00
12	Place the lens on the conveyor belt	0	0.06	0.33		0.33
13	Clan the convex side of the mold	0	0.15	0.90		0.90
14	Assemble the convex side of the mold	1	0.13	0.77	0.77
15	Place the assembled mold back on the conveyor belt	0	0.09	0.53		0.53
	Total CT		1.47	8.83	2.91	5.93

Cycle time analysis (in seconds)
#	Video:	Average	V	TN	FT	TP
1	Unclipping	1.52	0.01	1.54	0.091	1.67
2	Brushing	1.87	0.06	1.98	0.065	2.11
3	Gasket feeding	1.57	0.05	1.65	0.089	1.80
4	Assembly	1.47	0.04	1.53	0.076	1.64
5	Inspetion	1.46	0.18	1.72	0.082	1.86
6	Clipping	1.55	0.03	1.60	0.087	1.74
7	Filling	1.54	0.05	1.62	0.078	1.74
8	Lens organization	2.05	0.04	2.13	0.058	2.26

Universidade Federal de São Carlos Departamento de Engenharia de Produção , Caixa Postal 676 , 13.565-905 São Carlos SP Brazil, Tel.: +55 16 3351 8471 - São Carlos - SP - Brazil
E-mail: gp@dep.ufscar.br

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[1] Source: Adapted from Barnes (1977) Barnes, R. M. (1977). Estudo de movimentos e de tempos: projeto e medida do trabalho . São Paulo: Edgard Blucher. .