Modification and Development of Process for Improving Productivity

Abstract

This paper discusses about the modification and development of process for improving productivity of plastic product manufacturing unit.The factory is renowned for its plastic products.This unit is present in Electronic Zone, Hingna MIDC ,Nagpur .This factory has plastic injection molding machine for product manufacturing .In the project , we are going to modify the existing process ,the existing ways of doing work in the industry to increase its productivity. Also reducing time consumption for particular process and reducing workers fatigue is our main focus. We are using Industrial Engineering principles, tools and techniques such as work study,method study ,work measurement ,plant layout, material handling ,ergonomics to upgrade the existing ways of production in the industry.The modification of manufacturing line will lead to increased productivity of the production unit.

Introduction

I. OBJECTIVES OF THE MODIFICATION

The development and application of more effective methods to reduce cost, increase overall productivity and efficiency .is the main objective.Following are some more objectives :

1. Reducing Time consumption, human efforts and reducing travel distance of raw materials from unloading point to storage room.
2. Reducing total travel distance of material within industry.
3. Reducing time consumption for processes like mold changing by introducing new technologies. .
4. Reducing use of workers and resources by introducing newer ways of production to the industry.
5. Increasing overall productivity of the manufacturing unit.

II. LITERATURE REVIEW

1. Martand Telsang (1) in his book named Industrial engineering and Production management discussed various material handling systems and equipments used in industry to transfer the material from one place or workstation to another place or workstation.
2. Akash Verma,Aniket Gaikwad(2) studied the existing process of the plastic product manufacturing company having plastic injection molding machines. The author suggested new methods of increasing productivity in that company. The author has shared his studies and concluded about introducing automation in some processes and modifying plant layout.
3. V.P.Kulkarni(3) studied the present method of a machining industry which manufactures products like engine cover, wind turbine parts, etc. His research uses work study techniques to solve the problems in that machining industry.
4. Ashish Kalra, Sumit Sharma(4) conducted the study at automobile assembly plant which aims to reduce cycle time of different workstations to complete work in time.
5. P R Akkoni, Vinayak N Kulkarni and V N Gaitonde(5)applied work study techniques to improve productivity at valve manufacturing industry. The author analyzed existing plant layout and proposed new plant layout which reduces total time cycle.
6. Khalid, S. and Saleh(6) have studied the existing process in automobile industry and using operation process chart and simulation software Arenaand they have obtained solution which increases the industry's manufacturing capacity.
7. Dr. M. K. Sonpimple, Sagar D. Shelare, Anurag N. Raghorte(7) designed the motorized hand truck use for material handling. The authors discussed merits  of hand truck applications in the industry instead of transferring material manually by workers.

III. METHODOLOGY

1. Studying ,analyzing and examining the details of existing working processes in an industry.
2. Finding new solutions to eliminate problems which were occurred in studies.
3. Proposing  change in plant layout,new material handling systems in the industry according to problem .
4. Analyzing and examining the results of modified processes which were proposed.
5. Recommendation of new method to concerns.

IV. RELATED TERMINOLOGIES

1. Plant Layout: According to Moore,”Plant layout is a plan of an optimized arrangement of facilities including personnel, operating equipment,material handling equipment,storage space and all other supporting services along with the design of best structured unit to contain all these facilities”.The main objectives of plant layout are as follows :

• Streamline material flow.
• Minimized material handling.
• Minimized material travel distance.
• Make full utilization of space.
• Facilitate the manufacturing process.

2. Material Handling: Material handling can be defined as movement of bulk, packaged and individual products by means of manual human effort of by power actuated machines within the industry limits. Main objectives of Material Handling are as follows :

• Minimizing  cost of material handling in industry.
• Minimizing time consumption in material transfer within industry.
• Increasing the productivity.

3. Types Of Material Handling Equipments:

• Conveyors:Belt conveyor, Roller conveyor, Pipeline conveyor,Screw conveyor.
• Cranes and Hoists: Overhead travelling crane, Jib crane, Gantry crane,Hoists:Chain hoists, Pneumatic hoists, Electric hoists.
• Industrial Trucks: Forklift Truck, Platform truck, Powered Hand truck.
• Material handling equipments images :

3. Ergonomics: It may be defined as a study of man in relation to his work. It is also called as human engineering. It focuses on human worker interaction with the machines and environment in his workplace. The main objective is

• Increasing efficiency and effectiveness in work.
• Reduce human efforts, fatigue, stress and improve quality of life.

4. Productivity: Productivity refers to the efficiency of production system .It is the concept that guides the management of production system. it is an indicator of telling that how well the  factors of productions are utilize i.e. utilization of land, labor ,capital and energy.

Productivity =Output /Input

5. Automation: Automation is the technology of doing processes or procedure without human assistance. It is implemented using a program of instructions combined with a control system which executes the instructions, To automate a process,power is required for both to run the process itself and to operate the program and control system. Although automation can be applied in a multiple areas, it is mostly associated with the manufacturing industries.

2) Reduction in Total Material Travel distance within industry :

Reduction in Total material travel distance =Present distance travelled -Modified distance travelled

Reduction in Total material travel distance =110 meters - 50 meters

Reduction in Total material travel distance =60 meters

• Percentage Material Travel distance reduced=54%

3) Time reduction in mold changing :

Reduction in time consumption =Existing Time Consumption - Modified Time consumption

Reduction in time consumption =45 min -5 min

Reduction in time consumption =40 minutes.

• Percentage Time saved = 88%

4) Man power consumption reduction in mold changing operation :

Reduction in mold changing operation =Existing requirement - modified requirement

Reduction in mold changing operation =2-0

Reduction in mold changing operation =2 man power units

• Percentage Man Power saved=100%

A significant amount of reduction in stress, fatigue among workers can be observed after modification.The use of above solutions can increases efficiency and productivity of the Industry.

VII. MAJOR SUGGESTIONS

1. Construction of separate raw material unloading point to reduce Total Material Travel distance .
2. Use of powered hand truck or trolley for transferring material from unloading point to raw material storage room.
3. Use of quick mold changing system to save time in mold changing operation.
4. Use of industrial robots for manufacturing operations to increase productivity, efficiency and to save time.
5. Use of comb and dendrite arrangement flow line pattern  for packaging unit.

Conclusion

Following points can be concluded in this live industrial project : 1) Applying principles of Industrial Engineering, Productivity and Efficiency of a manufacturing unit can be increased. 2) Decrease in Total Material Travel distance is achieved after modification. 3) Elimination of large time consuming processes is achieved. 4) Introduction to newer technology of quick mold changing and industrial robots decreases risk of injuries to workers and reduces stress and fatigue of worker. 5) Also, Manpower is saved by applying newer method and doing modifications.

References

[1] Martand Telsang, “Industial Engineering and Production Management”(second edition),S Chand and Company Limited Publication,2017. [2] V.B.Vaidya,Akash Verma, Aniket Gaikwad, “A Work Study for Upgradation of Plastic Product Manufacturing Unit”,2024. [3] V.P.Kulkarni,“Method and Time Study” ,International Research Journal of Engineering and Technology(IRJET),e-ISSN:2395-0056,Volume: 07 Issue: 07,July 2020. [4] Ashish Kalra,Sumit Sharma,“Increasing Productivity by Reducing Cycle Time in Assembly line of an Automotive Industry using Work Study Techniques”, International Journal of Engineering Research & Technology (IJERT) ,ISSN: 2278-0181,IJERTV5IS020330,Vol. 5 Issue 02, February-2016 . [5] P R Akkoni, Vinayak N Kulkarni and V N Gaitonde, “Applications of work study techniques for improving productivity at assembly workstation of valve manufacturing industry”,ICMSMT 2019 IOP Conf. Series: Materials Science and Engineering 561 (2019) 012040 doi:10.1088/1757-899X/561/1/012040. [6] Khalid, S. and Saleh , “Productivity improvement of a motor vehicle inspection station using motion and time study techniques.”,Journal of King Saud University-Engineering Sciences,2011 Jan 1;23(1):33-41. [7] Dr. M. K. Sonpimple, Sagar D. Shelare, Anurag N. Raghorte, “Design and Modification of Innovative \"Motorized Hand Truck”,International Conference on Science and Engineering for Sustainable Development (ICSESD-2017),International Journal of Advanced Engineering, Management and Science (IJAEMS),Special Issue-3,ISSN : 2454-1311

Copyright

Copyright © 2024 V. B. Vaidya, Aniket Lanjewar , Bhushan Jawalkar , Neerajkumar Chauhan. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.