xii
6. RECOMENDATIONS AND CONCLUSION
6.1.1 Performing work study on operator‟s activity
90 6.1
Summary 90
6.1.2 Standard time establishment 91
6.1.3 Determine the current operator‟s utilization
91 6.2
Recommendations to achieve ideal man to machine ratio 94
6.2.1 Elimination of Non Value Added activities. 94
6.2.1.1 Preparing end plug 95
6.2.1.2 Run 2 95
6.2.1.3 Improvements after eliminating „preparing end plug‟ and „run 2‟
96 6.2.2 Standard Operation Procedure SOP for new operators
96 6.2.3 Increase man to machine ratio
98 6.3
Conclusion 101
REFERENCES 103
APPENDICES A
MOST Data Card General Move B
MOST Data Card Controlled Move C
MOST Data Card Tool Move D
ILO
xiii
LIST OF TABLES
2.1 Symbol used for process charting
15 2.2
Types of process charts 16
2.3 Operation Charts
16 2.4
Performance Rating Table 25
2.5 Comparison on Average Actual Times and Times
33 Determined from Predetermined Time Data
3.1 Gantt Chart for PSM I
51 3.2
Data collection table 59
3.3 MOST table for data computation
61
5.1 MOST table description
72 5.2
Overall activity summary for STI 1 and 2 74
5.3 Activity task for starting lot preparation
75 5.4
Overall activity summary for STI 13 and 14 79
5.5 The OEE calculation for STI 1, 2, 13 and 14
85 5.6
The comparison between MOST analysis and overall calculation for operato
r‟s utilization for STI 1 and 2
87
5.7 The comparison between MOST analysis and overall
calculation for operator‟s utilization for STI 13 and 14 89
6.1 Comparison between the time taken to complete same task
by different operator 92
6.2 Comparison between of MTM before and after
eliminating Non-value added activities 96
6.3 Suggested SOP for new operators
96 6.4
MOST for STI 1 and 2 revised and proposed 100
6.5 MOST for STI 13 and 14 revised and proposed
100
xiv
LIST OF FIGURES
1.1 Productivity Growth, Malaysia and Selected
4 OECD Countries, 2007
1.2 Productivity Growth, Malaysia and Selected
4 Asian Countries, 2007
2.1 Example of Flow Process Chart in manufacturing
17 a product
2.2 Example of Process Flow Chart in manufacturing
18 a product
2.3 Example of Assembly Process Chart
19 2.4
Example of Operation Chart: Simo Chart 20
2.5 Work measurement method
23 2.6
Example of Personal and Fatigue allowance used by 27
a company 2.7
Example of time study sheet 29
3.1 Research flow chart
53 3.2
Data collection flow chart 57
4.1 Layout of EOL of QFN department
66 4.2
Flow Chart of assembly process in QFN 67
5.1 MOST table
71 5.2
MOST table for STI 1 and 2 73
5.3 MOST table for STI 13 and 14
78 5.4
Example of time calculation task with allowance accumulation 83
5.5 The time calculation of activities per lot by using frequency
84
xv
LIST OF ABBREVIATIONS, SPECIALIZED NOMENCLATURE
BMT -
Basic Motion Time Study CAD
- Computer Aided Design
EOL -
End of Line GDP
- Gross Domestic Product
GI -
General inspection ICT
- Information and Communication Technology
ILO -
International Labor Organization IMVP
- International Major Vehicle Program
MNC -
Multinational Company MOST
- Maynard Operation Sequence Technique
MS -
Machine Specialist MTBA
- Mean Time Between Assist
MTM -
Man to Machine MTM
- Methods Time Measurement
OEE -
Overall Equipment Efficiency PFD
- Personal, Fatigue and Delay
PMC -
Post Mold Cure PO
- Process Operator
PTS -
Predetermined Time System QFN
- Quad Flat No Lead
SMI -
Small and Medium Industry SOP
- Standard Operation Procedure
TI -
Texas Instruments Inc TIM
- Texas Instruments Malaysia
TMU -
Time Measurement Unit TPS
- Toyota Production System
UK -
United Kingdom
xvi US
- United States of America
VM -
Visual Mechanical WTO
- World Trade Organization
1
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