INCREASING THE DAILY QUOTA OF H.S. CRAFT MFG. CORP.CHAPTER I

PROBLEM AND ITS BACKGROUND

IntroductionChristmas lights are strands of electric lights used to decorate homes, public/commercial buildings and Christmas trees particularly during Christmas season heightening the Yuletide excitement are amongst the most recognized form of Christmas lighting. Christmas lights come in a dazzling array of configurations and colors. The tradition of stringing electric lights may have started as a Christmas thing. This custom goes back to the use of candles to light up the Christmas tree in every homes way back during the 18th Century. It was occasionally decorated with candles, which at the time was a comparatively expensive light source. Candles for the tree were glued with melted wax to a tree branch or attached by pins. This kind of lighting in which candles were used until technology marks the beginning of a new Christmas light display. By the time 1880 rolled around, early electric Christmas lights were introduced with electrification.Incandescent lights are the ones that started it all. Even though they're well over a hundred years old now, the technology largely remains the same. The shapes and sizes of the bulbs, on the other hand, have been in constant flux. Now we're left with major types of incandescent Christmas light bulbs. The Mini/Fairy Light is the big kahuna. If you haven't seen one of these by now, then you've probably never seen Christmas lights. Traditionally, the set is wired in series, hence the age old problem where if one bulb goes out, the rest won't light. But it's not hard to find sets that are wired in parallel nowadays.LED lights have been growing in popularity for the past few years. Regardless of what you think of their light output, there's no denying that they're much more energy efficient than incandescent bulbs, and give off less heat. LED lamps have a lifespan and electrical efficiency that is several times better than incandescent lamps, and significantly better than most fluorescent lamps.

Company Profile

The company H.S. Craft Mfg. Corp. was founded by George Tsai, a Taiwanese business man. During late 1980s the first branch was in RMT Industrial Complex, Tunasan Muntinlipa which only produces Christmas lights to be exported in US markets. After one year, the company added a new production line for tree top and icicle.After eight years, many changes were made and the company was moved in Silang Cavite with a bigger production space and more automatic machines. More improvements were made as the business continues to be known in the market. As the IT (Information Technology) era came, the H.S. Craft was also into call center which cater orders from individuals from the US. More customers/orders came and more workers were given opportunity.As years passed by, H.S. Craft continue to enhance its product and improves its production by increasing and improving their machines and workers.As H.S. Craft Mfg. Corp. continues its workmanship and service in producing Christmas lights, it will make sure that it will continue to brighten our Christmas season.

Background of the Study

The common tool used by Industrial Engineers to gather detailed information on process is time and motion study. This study is the scientific study of the conservation of human resources in the search for the most efficient method of doing a task. A fascination with the word efficiency began in the late 19th and early 20th centuries when it was considered one of the most important concepts. Time study began in the 1880s as a means of wage-rate setting by Frederick W. Taylor, who is regarded as the father of scientific management. It consists of a wide variety of procedures for determining the amount of time required, under certain standard conditions of measurement, for tasks involving some human activity. Motion study was developed by Frank B. Gilbreth and Lillian M. Gilbreth and consists of a wide variety of procedures for the description, systematic analysis, and means of improving work methods.

The concept of time study is connected to motion study. In time studies, the observer must have basis for the categories which they record in time data. Activities are broken down into categories such as transport, operation, inspection, delay, and storage. Those divisions are the foundation for motion study. Motion studies are typically characterized by very detailed human motion into the most basic movements.

The Christmas lights produced by H.S. Craft Mfg. Corp. were made by machine operated by trained personnel and man power for the manual works. H.S. Craft Mfg. Corp. is into planning, designing, and producing Christmas lights to be exported abroad and delivered to different companies like GE Holidays and Target Supermarkets.

According to the interview with the Production Head, the H.S. Craft Mfg. Corp. can produce 8.4M Christmas lights during their Production month (September March). With these data, the researchers found out that they can produce 58,333 set of Christmas lights a day and they can increase their daily quota to achieve more finished product with the same production time.

Statement of the Problem

This study sought to determine the increase in production by increasing their daily quota by 11% in the same consumable production time without affecting the H.S. Craft Mfg. Corp. standard in the quality of their product.

General ProblemThe daily quota of the production is low

Specific ProblemThe wide range of distances of production area The researchers used Time and Motion Study in H.S. Craft Mfg. Corp. to monitor the production of Christmas lights. The company needs to be monitored in order to control the cycle time and labor power. This study suited in H.S. Craft Mfg. Corp. because 90 percent of the production in this company is manual basis and the best tool to measure the work is time and motion study because it includes the rating factor and allowances. It can also be used as a tool for productivity improvement and increase efficiency. Since time and motion study is important for the company, it has to be done precisely with the element of allowance, rating factor and head count to produce a standard time which can be used as reference to conclude the whole performance of production.

ObjectivesGeneral:To increase daily quota by 11% to produce more productsTo use time and motion study to improve the layout of the production area to eliminate excess distance to be travelled Specific: To find suitable rating factor and allowance using a stopwatch for the time and motion study that is suitable for the manual product at H.S. Craft.To be able to have record of time, establish standard time and perform motion study, this can be used as a reference by the company.

Significance of the Study

To the company This study can help the workers finish their work in less time and less energy exerted. This study will also be beneficial for the workers because this will aim to propose alternative production layout. It is also beneficial for the company because they will reach high daily quota and will be able to produce more products with the same production time. It will also provide simplification, increased productivity, increased profit and increase earning.

To the students This study will enhance their skills in using time and motion study. This will also enhance their skills in analyzing problems in manufacturing companies and be able to meet and socialize with other people in the same field. This can also be a guide for future researchers especially those concerned in operation and time management.

To the readers This can serve as a reference and can help the readers to be knowledgeable about time and motion study.

Scope and Delimitations of the Study

The researchers conducted company visit last January 31, 2015 and gathered time and motion study data. The following days were used to research about the company itself and other sources like lectures from Methods Engineering course, internet, and articles.The study was conducted at H.S. Craft Mfg. Corp. located at #1 Maguyam Road Bo. Biga, Silang Cavite. This study is focused on production of Christmas lights. It also focused on the process, time management and motion of workers. The age, gender, and lifestyle of workers in the company are not tackled. The study conducted a time study by observing the worker and giving rating factors and allowances to produce standard time. This study is taken using a stopwatch time study technique. This study does not include the process of transport and the number of workers who transports the product.

CHAPTER IICONCEPTUAL FRAMEWORK

The basis for conceptualizing the production rate of H.S. Craft Mfg. Corp. is to provide an alternative facility layout that can keep the distance not too far away from each element by using time and motion study and to increase their daily quota by 11% to maximize work time.

Related Literature and Studies

Productivity Improvement by Method StudyThere are a number of approaches to improving productivity: the best-known currently is probably Lean (more later) but such approaches go back many years to the days of the early productivity .Essentially because of the nature of the productivity ratio all are concerned with making better use of existing resources or reducing the resources needed to produce current outputs.This introduction to productivity improvement methodologies will focus on just one of them (others will follow but all of them are some form of variation of the same underlying approach.Many people (and especially people of a certain age) will immediately think of time and motion when asked to describe a productivity methodology. This refers to the early days of work study when the aim (as it often still is today) is to reduce thetimetaken by, and the motion involved in, work. This is reflected by the fact that work study was made up of 2 complementary techniques: method study and work measurement. Work measurement as the name suggests involves measuring how long work takes as the basis of understanding how time can be reduced and as the basis of comparing different ways (methods) of carrying out the work.However, the improvement methodology of work study was method study and an understanding of method study gives a real insight into how all productivity improvement methodologies work.Source:http://www.evancarmichael.com/Productivity/3310/Productivity-Improvement-via-Method-study.html

Time and Motion Studies about Slow ProductionIn practice the slower people would fail to meet targets set and the faster more able operators would slow down to only produce the target causing an actual reduction in output. Where incentive schemes were introduced for exceeding targets the operators would often take short cuts such as failing to do quality checks to try to gain bonus leading to higher levels of rejects at the customer. For example the activity timing for lean manufacturing, with lean we try to simplify the activity timing as much as possible, we also try to identify the individual work elements and identify them as either adding value or as being non-value adding and wasteful steps to be eliminated or reduced. Lean manufacturing tools are team tools, by this I mean they should not be used by an expert who comes to town to implement their changes on the workplace; they are for the use of the people involved in the workplace to help them create and agree their own improvements by identifying each work element as being either value adding or non-value adding we have an opportunity for the teams to either totally eliminate the non-value adding steps or to reduce them making their processes more efficient and also easier and safer for themselves. They can also create additional improvements by considering the work method study itself and comparing between shifts and individuals to find the most efficient way. These methods can be used within your kaizen teams to ensure continual improvement of processes.Source:http://leanman.hubpages.com/hub/Work-Study-Method-Study-and-Activity-Timing

Time studies Taylor argued that even the most basic, mindless tasks could be planned in a way that dramatically would increase productivity, and that scientific management of the work was more effective than the "initiative and incentive" method of motivating workers. The initiative and incentive method offered an incentive to increase productivity but placed the responsibility on the worker to figure out how to do it. To scientifically determine the optimal way to perform a job, Taylor performed experiments that he called time studies, (also known as time and motion studies). These studies were characterized by the use of a stopwatch to time a worker's sequence of motions, with the goal of determining the one best way to perform a job. The following are examples of some of the time-and-motion studies that were performed by Taylor and others in the era of scientific management.Pig IronIf workers were moving 12 1/2 tons of pig iron per day and they could be incentivized to try to move 47 1/2 tons per day, left to their own wits they probably would become exhausted after a few hours and fail to reach their goal. However, by first conducting experiments to determine the amount of resting that was necessary, the worker's manager could determine the optimal timing of lifting and resting so that the worker could move the 47 1/2 tons per day without tiring. Not all workers were physically capable of moving 47 1/2 tons per day; perhaps only 1/8 of the pig iron handlers were capable of doing so. While these 1/8 were not extraordinary people who were highly prized by society, their physical capabilities were well-suited to moving pig iron. This example suggests that workers should be selected according to how well they are suited for a particular job.The Science of ShovelingIn another study of the "science of shoveling", Taylor ran time studies to determine that the optimal weight that a worker should lift in a shovel was 21 pounds. Since there is a wide range of densities of materials, the shovel should be sized so that it would hold 21 pounds of the substance being shoveled. The firm provided the workers with optimal shovels. The result was a three to four fold increase in productivity and workers were rewarded with pay increases. Prior to scientific management, workers used their own shovels and rarely had the optimal one for the job.BricklayingOthers performed experiments that focused on specific motions, such as Gilbreth's bricklaying experiments that resulted in a dramatic decrease in the number of motions required to lay bricks. The husband and wife Gilbreth team used motion picture technology to study the motions of the workers in some of their experiments.Source:http://www.netmba.com/mgmt/scientific/

Case Study Application of Time Study Model in Aluminum CompanyThis paper presents a case study in the development and application of a time study model in a hollowware aluminum manufacturing plant. The organization engages in the production of three product lines: kettles, frying pans, and cooking pots of diverse categories. The motivation for this study was the need to intervene in frequent crises that normally arose between the employee-association and the management of the company regarding questions of productivity. The three products have similar production processes. Hence, the method of breaking down the processes into jobs and tasks was adopted and analyzed through the use of differential calculus. This method was applied to the manufacturing processes with the kettle production system drawn as an example. The kettle production process consists of several major activities including stamping and oiling, press forming, trimming, spinning, degreasing, polishing, labelling, wiping and wrapping, spout holing and bumping, inspection, riveting, and packing. By understanding and applying the model, managers can logically trace the effects of time wastages on the production output of systems and their effects. The studys most important finding is that the time of producing a unit of product is directly proportional to the number of production stages involved and the time spent at each stage. This can be represented by some structural equations, which are characteristics of the system being studied. The limitations of the study lie in the variability of the major components of the system. The model does not incorporate some variables which may influence decisions made based on the computation of time for which the model may be used.Source:http://www.google.com.ph/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact=8&ved=0CB4QFjAA&url=http%3A%2F%2Fakamaiuniversity.us%2FPJST7_2_153.pdf&ei=o-juVJOII5DmoAS_nYKIDw&usg=AFQjCNH90oaf6wACetVaAEFodBJtnPAMXw&bvm=bv.86956481,d.cGUTime and Motion Studies What are they and Can They Help You?Time and Motion studies are an appropriate solution when theefficiencyof a drug, medical device, or intervention is the outcome of interest. In the current environment of more stringent evidence requirements by regulators and payers alike, real-worldevidencethat complements traditional efficacy and safety data is warranted to ensure successful market access and product uptake.Per theU.S. Department of Health & Human Services, a time and motion study is an observation method used to determine the timing and duration of tasks or procedures. These non-interventional studies collect observational data to quantify the impact of a medical intervention on the dynamics of health care professional involvement within a process, as well as the resources consumed in terms of time and consumables. For example, in a time and motion study, observers may follow clinicians and record how long specific tasks, such as completing a prescription or listening to a patient describe her symptoms, take to complete. Researchers and practice managers may use that data to evaluate whether and to what extent health information technology applications, including computerized provider order entry, electronic prescribing, and electronic health records, could increase efficiency and allow clinicians more time for other tasks.UBC experts perform time and motion studies in order to demonstrate value for new pharmaceutical products in late stage development. For example, when collecting time and motion data for intravenous (IV) and subcutaneous (SC) processes, value messages for a switch from IV to SC administration could be expressed as staff time saved or infusion chair time freed up for either an individual patient or for a center population. Time savings can be monetized to reflect the opportunity cost of freeing up personnel and/or facility time. Such derived evidence can serve as crucial inputs for activity-based costing exercises or to inform healthcare management decisions. These studies and the evidence they collect can also inform health economic analyses that include budget impact models.Time and motion methodology is a robust study design solution forlate phase researchwhen efficiency is a key attribute of a products value proposition.Source:http://www.ubc.com/blog/time-and-motion-studies-what-are-they-and-can-they-help-you

Time and Motion Studies of Lagoon There is a widely held view that work systemscan be improved upon through time and motionstudies. This also applies to play systems as the StrawbridgePointers demonstrated last week whenseven skippers told their loved ones theyd be backin five minutes and then proceeded to enjoy themotions of a gently pitching deck on Eastern Covefor the rest of the daytime taken to record the weather forecast washardly worth the motion however, as the predictedstiff northerlies and fresh souwesters evaporated,leaving a fluky noreaster to send the fleet overthe bay in a kindly fashion. Weather forecasters spend a lot of time for littlemotion it seems. Angels Wings, complete with a newly patchedhull, wasted no time in getting canvas aloft withthe Jar Cat setting a brisk pace on the reach toBaud inBeach. Rubicon offers a most kindly motion when atsea, the commodore and the Churchills sippingfrom fine china with pinkies raised and steppingback in time as they dunked Glens cookies. Protagonists of time and motion studies emphasizethat they encourage a fair days work.This was obviously misconstrued aboard IbisII as a long days play, as former electronics mogul,B. Uren and his crew-for-hire enjoyed a terrificrun from Shoal Bay to join the fleet. The zest on 40 is ideal for long stretches ofleisure afloat but will be hard at work in the NewYear as she tries to wrest the Ballast Head Cupfrom the mainland invaders. Time and motion was stuck in fast-forward onGolden Odyssey this last week as Tim Williamshas dismantled, rebuilt, re-bolted and re-positionedhis ageing Yammer, all in record time forhim to host the Thompsons on the gaffer, Runssmoothly too, no shifters or pliers clattering aboutin the bilge. No time wasted by Andy Wood on Sapphire,either. He and Russell Colman skimmed about thebay, sailing rings around some lethargic craft. Sapphires profile looking very chic with astrategically placed dodger keeping the lads in theshade. Never slaves to the stopwatch, Nick and Prueand Greg had the beautiful Dauntless trailingalong following a belated start. Shed barely cleared the beacon before beingalmost run down by an Orange Roughie-led stampedeof hungry sailors, intent on lunch aboard LaHoya, moored at the head of Pelican Lagoon. The fleet dodged moorings and boats beforerafting up in glorious sunshine alongside GlenWingates Petersen 44 - time slowed to a waltzand motion was restricted to short elbow movementsor taking a nap.The underlying principles of time and motionstudies were exhibited later in the afternoon whenthe commodore allowed his boat inker to proceeddown the boat ramp in extremely rapid time topick up Dauntless for her annual bottom scrub. Time stood still for most onlookers and scaredthe motions out of Nick. No shortage of candidates for the porthole thisweek, but Tim W finally awarded the esteemedboard to Andy Wood for being the only one to dothings right. Or so he said.Source:http://www.theislanderonline.com.au/story/2758428/time-and-motion-studies-at-lagoon/

Research ParadigmPROCESSOUTPUTINPUT

A solution to the companys problem which is to lessen the distance to travelled and to increase their quota to producemore products which can lead to a higher sales and income Progress of our study

Proposed Flow process chart Proposed flow charts Proposing new facility layout Proposing cost and effect diagram Knowledges that accumulate from the company are: Lectures Articles Observing Asking question Listening Record time(using stopwatch), motion and the area of the company

Knowledges that we accumulate form the company

Definition of terms Definition of Terms

Methods Study - Subjecting each part of a given piece ofworkto closeanalysisto eliminate every unnecessaryelementoroperation, as ameansof approaching the quickest and best method of performing the work. It also includes formulation ofincentiveschemes,andimprovementandstandardizationofequipment,methods,operatortraining,working conditions, etc. Also calledmethodsengineering.Productivity - An economic measure of output per unit of inputElement A division of work that can be measured with stopwatch equipment and that has readily identified terminal point or break points Delay - a situation in which something happens later than it shouldFatigue - is a subjective feeling of tiredness which is distinct fromweakness, and has a gradual onset.Flow process chart -inindustrial engineeringis a graphical andsymbolic representationof theprocessingactivities performed on the work piece.Process is an instance of a computer program that is being executed. It contains the program code and its current activity.Motion Study - Method for establishing employee productivityProcess layout - is a design for the floor plan of a plant which aims to improve efficiency by arranging equipment according to its function.Technician - is a worker in a field oftechnologywho is proficient in the relevant skills and techniques, with a relatively practical understanding of the theoretical principles.Quotas - is simply a legal quantity restriction placed on a good imported that is imposed by the domestic government.

Pig iron - is the intermediate product of smeltingironore with a high-carbon fuel such as coke, usually with limestone as a flux

Shoveling - is a tool for digging, lifting, and moving bulk materials, such as soil, coal, gravel, snow, sand, or ore.

Brick iron is abrickhaving a sprinkling of dark spots caused by the presence of ironsalts.

Sector An area of an economy, a part of an economy that includes certain kinds of jobs Management - in business and organizations is the function that coordinates the efforts of people to accomplish goals and objectives using available resources efficiently and effectively.

CHAPTER IIIMETHODOLOGY

Research Design

The method we used to define the nature of the workplace is via descriptive research. It is the type of research that is mainly concern in describing the condition and the degree in detail of the present situation. It exists on the time of the study and to explore the cause of the particular phenomenon. It aims to obtain an accurate profile of the people, events, or situation around the workplace. Pertaining to this research type, it is very essential that the researcher has a broad understanding in performing time and motion study.

The first hand data from the company that is formulated, rationalizes and has sound conclusions is very approached descriptive and quick in the practical way and requires financial aspects. It has a great advantage for the researcher as well as to the instructor so that the procedures is plainly stated and illustrated. This method is either considered qualitative or quantitative data, giving us greater options in determining how the HS Craft Mfg. Corp. can increase their quota every day.

Under descriptive research, it explores the causes of why in some areas they need to exceed the number of quota of produced Christmas lights in their monthly allocation in the production line. The accomplices in this research study are the workers of HS Craft Mfg. Corp. last January 2015.

The qualitative method will equip us, the readers to develop knowledge through the data gathered from the company- by research and interview. Analysis of statistical data, identification of the problems, formation of the conclusion, presentation of solutions, and recommendations comes afterwards to fulfill the qualitative method throughout the study at HS Craft Mfg. Corp. provided significant inputs for the researchers study. It focus in the data such as background of the company and the observation per worker which are their motions considering the time and distant places in the process lay-out using stopwatch as a tool.

The researchers conducted several trial in every elements corresponding to the employees and the workers line of actions inside the company. We taught about their views regarding to their kind of business they are in. Provided with the information from them, the researchers decided to propose alternative and different ways to improve what was to improve and continue the actions in line to exceptional methods in creating Christmas lights. This will help them to alleviate some of their workload and to increase the number of production. All of this data were treated full confidential and with extra care for thesis purposes only.Data Gathering ProceduresGathered information regarding time and motion study concerning the flow of production.Conducted time and motion study at HS Craft. Mfg. Corp. Located at No.1, Maguyam Road Bo. Biga,Silang, CaviteThe researchers gave the letter of approval for conducting methods study to the HR Dept. of HS Craft Mfg. Corp.

Implemented the proposed alternative processes to HS Craft. Mfg. Corp. for the betterment of the said company

Analyzed the computed statistical data and comes up with the answer to the problem of HS Craft. Mfg. Corp.Create alternative processes that help HS Craft. Mfg. Corp. to increase daily quotas and to decrease inefficiency

Previously, the researchers wrote a letter to the Human Resource Dept. of HS Craft. Mfg. Corp. stating, that if we can conduct research study pertaining to time and motion study of their production of Christmas lights. Another letter for the management is informing them about the said line of actions. After the approval, the researchers obtained the operation processes inside the company and the breakdown of the tasks given to every sector of production.

The researchers also conducted some interview with Ms. Gems working schedules, time of arrival and departure in the workplace, break time and time on performing their jobs correlated to the things she had stated to us. Then we preceded with observations which doing their jobs occur and started their recording time by using the stopwatch. Then after the observing and recording, analysis and adjusting the schedule would enhance workers problem of fatigue. Processes were made by the researchers to minimized the consumed and distance travelled by the workers.

Research Instruments

The data collected are gathered through interviews and company files with Ms. Gemma Cruzs help and the workers of HS Craft Mfg. Corp.Time and motion study were implemented by the researchers. It means in conducting this research study, the researchers must perform actual observations on the facilities and operations inside the company. The researchers monitored the workers, the more trials the more accurate precision in finding the statistical mean for every method in the company.

Time and Motion Study Formula:

Sample size, n = Where: h = accuracy level desired as percent of job statement, expressed as a decimal (Ex: 5%=0.05)z= number of standard deviations required for the desired level of confidences = standard deviation of the initial samplex = mean of the initial sampleNote:

Allowance Factor = Non-work time / Total timeAverage Element time = Element times / No. of cyclesNormal time = Average element time x Performance ratingStandard time = Total normal time / 1- Allowance factorWork Sampling Sample size

Where:p = estimated value of sample proportion (of time worker is observed busy or idle)h = accuracy level desired in percent, expressed as decimalNormal time = (Total time) (% of time working) (Rating) / No. of units producedStandard time = Normal time / 1- Allowance

Data Gathering Instrument

A stopwatch was used by the researchers for accurate and precise time of motion of the workers while doing the procedures in making the Christmas lights. The researchers also made a scheduling time table, normal time including the break time of the workers. Calculators was also used in computing the statistical way of finding the standard time, deviations, allowance time, and other computed numerical data. These particular instruments are tested and proven that are reliable in dealing with time and motion study. Delay occurs in the production area, the daily quota on operation is low, and the wide range of distances of production area is broad. This is the basic problems in the company that needed improvement. By this method and with the proper gathering instruments, we can sort the problem in no time.

Research Locale

The study was conducted to the workers of HS Craft Mfg. Corp. at No. 1 Maguyam Road Bo. Biga, Silang, Cavite. This place was selected for knowing the efficiency of the said study on determining the daily quota of Christmas lights they produced. We would guarantee after this methods study, we can raise the number of quota by 10% and improve their working measures that they produced here in the said company.CHAPTER IVPRESENTATION, ANALYSIS AND DATA INTERPRETATIONElementsTrial 1Trial 2Trial 3Trial 4Trial 5Trial 6Trial 7Trial 8Trial 9Trial 10Mean

1Bulb wire assembly into base/husk10.839.399.299.239.149.189.4310.0310.339.739.66

2Bulb wire assembly into lamp holders0.54250.540.56030.63780.550.65020.55310.52120.62370.54250.5721

3Twisting2.312.212.292.252.182.122.192.152.142.302.21

4Plug assembly0.77470.67870.9280.80570.680.690.88670.69310.68040.78140.7599

5Bulb pushing2.953.023.022.523.082.473.143.782.982.792.98

6Bundling/ packing8.688.626.216.197.197.316.416.387.158.267.24

7Light testing 11.041.061.011.051.041.061.091.011.021.041.04

8Light testing 2/ Final packaging1.001.001.001.001.001.001.001.001.001.001.00

The following data gathered above are the process time (in minutes) an element is being done. There are eight elements in making a Christmas tree; Bulb wire assembly into base/husk, Bulb wire assembly into lamp holders, Twisting, Plug assembly, Bulb pushing, Bundling/ packing, Light testing 1, Light testing 2/Final packaging. In every element, the researchers conducted ten trials. The mean is the total gathered time over ten trials (in minutes). These data are necessary to complete the needed computations.

Formula:Normal Time = Average Element time x Personal RatingStandard Time = Normal Time (1 + Allowance Factor)Where:Personal rating = 95%Allowance Factor = 11%Average Element time = Mean per element

Computation:Element 1Normal Time = 9.66min x .95 = 9.18minStandard Time = 9.18min (1+.11) = 10.19min = 0.0102min/pcx 100pcs = 1.02min 1000pcsElement 2Normal Time = 0.5721min x .95 = 0.5435minStandard Time = 0.5435min (1+.11) = 0.6033minx 2pcs = 1.21min

Element 3Normal Time = 2.21min x .95 = 2.10minStandard Time = 2.10min (1+.11) = 2.33min

Element 4Normal Time = 0.7599min x .95 = 0.7219minStandard Time = 0.7219min (1+.11) = 0.8013min

Element 5Normal Time = 2.98min x .95 = 2.83minStandard Time = 2.83min (1+.11) = 3.14min

Element 6Normal Time = 7.24min x .95 = 6.88minStandard Time = 6.88min (1+.11) = 7.64min

Element 7Normal Time = 1.04min x .95 = 0.988minStandard Time = 0.988min (1+.11) = 1.10min

Element 8Normal Time = 1.00min x .95 = 0.95minStandard Time = 0.95min (1+.11) = 1.05min Total Standard Time = 18.29min

The Christmas lights produce by the H.S. Craft has 100 light bulbs per set. In getting the Standard Time of the element 1, since theBulb wire assembly into base/husk produces 1000 pieces of bulbs in its process time and the researchers are after the pieces done per minute, the minutes gathered in element 1 will be divided by 1000 light bulbs and multiply by 100 light bulbs. For element 2, since the Bulb wire assembly into lamp holders only produces 50 light bulbs with lamp holders per process time it will be multiply by 2 to have its 100 light bulbs. The next elements are already into 100 light bulbs so it will be computed as is.

Total set per minuteElementStandard time per pieceWorkers/MachinesPieces per minute

1Bulb wire assembly into base/husk1.02min/pc20 machine20.4pcs/min

2Bulb wire assembly into lamp holders1.21min/pc16 machine19.31pcs/min

3Twisting2.33min/pc140 workers326.2pcs/min

4Plug assembly0.8013min/pc100 workers80.13pcs/min

5Bulb pushing3.14min/pc120 workers376.8pcs/min

6Bundling/ packing7.64min/pc120 workers916.8pcs/min

7Light testing 11.10min/pc120 workers132pcs/min

8Light testing 2/ Final packaging1.05min/pc120 workers126pcs/min

Total set per minute1997.64 set/min

The table shown above is the computation of set of Christmas lights that can be produced in a minute. It can be determine by getting the standard time of an element and multiplying it to the numbers of workers or machine. The total set per minute is computed by adding the pieces per minute of all elements.

8 hrs x 60 min = 480 min 1 hr480 min = 26.24 cycle18.29min

1997.64 set/min x 26.24 cycle = 52425.76 set

Formula:Percent can increase = Standard production of the company Computed production of the company=58333.33 set52425.76 set= 1.11 or 111%

Therefore it can increase their production by 11%.

FISH BONE DIAGRAM

EXISTING FACILITY LAYOUT

PROPOSED FACILITY LAYOUT

EXISTING FLOWCHART1

Bulb wire assembly into base/husk2

Bulb wire assembly into lamp holder3

Twisting4

Plug Assembly1

Inspection5

Bulb Pushing2

Inspection6

7

Binding/Packaging8

Light testing 1

Light testing 2/Final packaging

PROPOSED FLOW CHART

Bulb wire assembly into base/husk1

2

Bulb wire assembly into lamp holder

3

Twisting

4

Plug Assembly

1

Inspection

6

Bundling/ Packaging7

Light Testing 1

8

Light Testing 2/ Final Packaging

EXISTING PROCESS FLOWCHART

Element DescriptionDistance (m)Time (min.)

1. Bulb wire assembly into base/husk

0 m

2. Bulb wire assembly into lampholder10 m

3. Twisting30 m

4. Plug Assembly130 m

5. Inspection0 m

6. Bulb Pushing140 m

7. Inspection0 m

8. Bundling/ Packaging150 m

9. Light testing 143 m

10. Light Testing 2/ Final Packaging10 m

PROPOSED PROCESS FLOWCHART

Element DescriptionDistance (m)Time (min.)

1. Bulb wire assembly into base/husk

0 m

2. Bulb wire assembly into lamp holder10 m

3. Twisting30 m

4. Plug Assembly130 m

5. Inspection0 m

6. Bundling/ Packaging150 m

7. Light testing 143 m

8. Light Testing 2/ Final Packaging10 m

CHAPTER VSUMMARY OF FINDINGS, CONCLUSION AND RECOMMENDATIONS

This chapter considered the most important data that are digested and outcomes that are subsequently drawn. It tackles the most important parts of the study. Suggestions and recommendations are made in the light of the generated data from this research project. The researchers also recommend some approaches that could be used as basis in increasing the throughput of H.S. Craft Mfg. Corp.

5.1 Summary of FindingsThis study aims to use Time and Motion study in order to increase their daily quota. Plant visit and observations was conducted for the research purposes. The main research problem of this study is to identify what causes the low daily production.The research revealed that by finding the standard time of every element in the cycle of production, it is possible to increase the daily quota of H.S. Craft Mfg. Corp. by 11%.

5.2 ConclusionSince the production of Christmas lights were combination of Manual and Machine works. We conclude that condition of workers affects and plays a big role in production. Workers may not be physically and mentally prepared to perform their particular jobs. Health, environment and extra-curricular activities such as Chatting with their co-workers, Call of nature, and seldom sleeping during work hours may cause a lot of delays. Fatigue due to complicated processes in the production is also one of the major reasons of delays. To minimize these delays, we recommend that the supervisor conducts an hourly monitoring on areas that manual work is present to fully supervise the production in order to avoid unnecessary delays.

Machines also play a big role in the production. Electricity is a main need in order for the machine to run and function well. Machine malfunction is a part of the daily routine in the production, to avoid this problems that will surely cause delays that can be the reason of low set of daily quota since machine works were present in the early part of the production, the company provided an In-house technician in order to act fast and fix whatever the problem causing the machine malfunction. Also, frequent monitoring and check-up of the machine must be conducted to monitor the conditions of machine, tools and equipment to keep them in great shape to avoid delays. They should also increase the number of the machines they have to reduce manual works and to make the production faster.

Newly assigned workers may also take part in delays that might be the reason of having a low quota. Lack of knowledge and expertise in one area or procedure may bring confusion to workers in performing such task. We, the researchers recommends that workers must be trained well before placing them in a particular workplace same with the supervisor in order for them to attend and assist workers that are having a hard time during production.

5.3 Recommendations

The researchers proposed new production of Christmas Lights procedures wherein the distance and time was reduced. We also recommend the next batch of students who will conduct a research study in HS Craft Mfg. Corp. to do the following: Measure the time delay and allowances factor to enable them to complete the given time and motion study. Include the process of transport and the number of workers in this process Conduct the research study during the whole production month of the company (September March) to make the data more accurate.42