Productivity

Transcript

Productivity By Prof. Sameer Nikam AIMS. Pune University. Industrial Engineering qIndustrial Engineering: integrates knowledge and science with support of Information Sciences. q qThe Industrial Engineer comprehends knowledge in those sciences in order to increase the productivity of processes, achieve quality products and assures Labor safety. Technical Science Industrial Engg. Human Science Economic Science Productivity q Productivity is defined as the output per unit of input. q Measure of process improvement q Productivity improves standard of living (productivity is closely link with quality) q Productivity : a measure of performance q Effective utilization of Man Machine Material Method and capital. q Important for manufacturing as well as service industry  Productivity 4 qIt is frequently measured using labor or technological benchmarks. q qHigher productivity can be obtained by improving worker skills, improving technology, additional management training, efficient distribution systems. q qProductivity is positively impacted by capital-intensive processes. q qProductivity is directly related to economical growth q OPM 533 q Prepared by : Productivity q A capital-intensive process is a production process that uses a high ratio of capital to labor inputs. For example the U.S. auto industry is a capital intensive industry. q q Industries where significant capital investments have made an impact include agriculture and computer manufacturing. q q Productivity can also be improved by investing in human capital. q And what is human capital? It is the knowledge and skills possessed by the work force. This includes the amount of education, training, and experience the workforce contains. q q Higher productivity is derived from using highly educated workers in capital-intensive production processes. Increasing the number and quality of high school and college graduates improves human capital and the productivity of the work force. q Levels of productivity            1. Individual productivity Unit productivity Company productivity Industry productivity Country productivity 2. 3. 4. 5. Objective of Productivity q To bring technological change q Efficiency q Cost Saving q Improving process q Living standard q Methods for improving Productivity q Through operations and management q Through motivation and involvement q Improve technology and facilities q Increase training q Increase research and development Spending q Increase employee participation q Adopt automated and robotic systems q Improve reward systems q Enhance speed q Enhance flexibility q Factors affecting Productivity  Macro a) b) Micro Production Capacity Company policies a) Infrastructure Free market policies Fiscal & monetary policies Social Eco. environment Work ethics Human resource development b) c) Corporate Management Organization & Administration c) d) d) e) e) Corporate culture f) f) Training & development Factors… q The macro factors determine the national environment in which  a business is regulated and the quality of resources available  q The micro factors refer to the competence of individual  organizations in transforming the available resources into value  added products and services.  q It is on a combination of these two factors that the  competitiveness of a country depends Techniques Value Analysis & Value Engineering Value.. Desired performance (P) Value = Overall Costs (C) Value can be increased by either improving the Performance or reducing the cost. Value Engineering Value Engineering : Technique applied to identified optimum value solution during new product development. Value Analysis : Technique applied for improving existing product process or service. Objective is to reduce cost bit to improve the performance and quality. It is a powerful problem-solving tool that can reduce costs while maintaining or improving performance and quality requirements.  Value Analysis, is a systematic and function-based approach to improving the value of products, project or service.  Work Study Work Study  It is a Systematic examination of methods of carrying on activity so as to improve the effective use of resources and to setup standards of performance for the activities carried out   Work Study succeeds because it is systematic both in the investigation of the problem being considered and in the development of its solution.   Work study focuses on process & human activity and can increase productivity at a lower cost.  Objective  Finding better ways of doing work.  Increased production and productivity(by Effective utilization of resources & Avoiding waste).  Improvement of conditions, which involve an element of excessive fatigue or danger  Optimum utilization of human, machine and material for accomplish the goal.  Reduced costs - labour, material, overheads  Method Study : Examining a job and finding more efficient method to perform it Work Study Work Measurement : Determining the time necessary to perform a job and its elemen Higher Productivity Improved Process Work study Method study Selection Recording Flow process chart Examine Develop Install Maintain Motion chart Work measurement Time Study Work sampling Higher Productivity Method study   Finding new or better way of doing work Def : Examination of existing and propose way of doing a work with a view to develop and apply easier and more productive method of doing the same    Method study is the systematic recording and critical examination of ways of doing things in order to make improvements. Need of Method Study 1. Bottlenecks in the system resulting in long delivery time or unbalanced workflow. 2. 3. Idle plant labor shows under utilization of resources . 4. 5. Poor moral of workers may affect the quality of the product. Due to this there may be high absentism. 6. 7. Inconsistent earnings also advocate for the review of prod’n method.  Improved layout of office, working areas of factories.  Improved design of plant and equipment.  Effective handling of materials.  Improved flow of work.  Improved safety standards.  Standardization of methods.  Better working conditions. Basic procedure of method study Select Record Examine OK Develop Install Maintain Selection of job  Finding out problem area  There are three factors that should be kept in secd when selecting a job.  1) Economic consideration  2) Technical consideration 3) Human consideration   Recording  Collection of data , observation  There are various recording techniques, selection of work is depend on nature of work  The success of the whole procedure depends on the accuracy with which the facts are recorded, because they will provide the basis of both the critical examination and the development of the improved method.  Recording serves essentially as a basis for following analysis and examination . Flow process chart Operation Transportation Inspection Delay Storage  Motion chart 30 sec 30 sec 30 sec 25 sec 25 sec 25 sec 20 sec 20 sec 20 sec working time 15 sec 15 sec 15 sec 10 sec 10 sec 10 sec Idle time 5 sec 5 sec 5 sec Machine 1 Man Machine 2 Examine Examination is done by critical analysis Use of question technique  Primary Questions      The PURPOSE The PLACE The SEQUENCE The PERSON The MEANS for which at which in which by whom by which     Secondary Questions (purpose, place, sequence, person, Means ) Development Implementation of new method Finding alternate options Minimizing non-value added activity Making necessary changes where it is require. Work measurement  Work measurement is the application of techniques designed to establish the time for a qualified worker to carry out a task at a defined rate of working.   The basic objective of work measurement is to determine the allowed time for a qualified worker to perform a given task, using a prescribe method, under a given set of condition.   Management tool   Objective of worker Measurement :      Reduce cost Reduce unwanted time Increase the motivation and set benchmark for improvement Measure & Improve performance of resources To schedule work and allocate capacity Data collected is use for  Manning  Task planning  Estimation of production cost  Cost reduction  Process improvement  Incentives  Set standard data  Training others  To check performance Work measurement Time Study Work sampling Time study  Time study is a technique of work measurement to established time for qualified worker to carry out a specific task under specific conditions  Most widely used technique  Applicable for short cycle repetitive jobs  Direct observation  Using stopwatch  Time require to perform a task during a cycle Time study procedure  Select the task  Select the operator  Record necessary details  Break the task  Measure the duration of every elements  Measure normal time  Calculate allowance  Calculate standard time of the job Work Sampling nWork Sampling is a technique of finding the percentage occurrence of certain activity by random observation and statistical sampling. nLabor standard is set using output and % of time worker spends on tasks. observing worker at random times over a long period. nInvolves nThe work-sampling technique collects data at intervals of time. element is based on this law of probability: If a procedure is nStatistical observed a sufficient number of times, the results will be as reliable as when the procedure is observed continuously over a period of time. Work Sampling  Used for    delay studies Setting labor standards Measuring worker performance The Seven Step Work Sampling Procedure  Compute the sample size required  Take a preliminary sample to obtain an estimate of the parameter value  Prepare a schedule for observing the worker at appropriate times  Observe and record worker activities; rate worker performance The Seven Step Work Sampling Procedure - continued nRecord the number of units produced during the applicable portion of the study nCompute nCompute the normal time per part the standard time per part Advantages over Time Studies  Longer time periods can be studied,  Does not require analyst to make continuous observations,  Operator is not subject to continuous observation,  Many operations & workers can be studied by a single analyst.  Require less cost  Time study is more labor-intensive method of data collection  Time study for Short cycle work processes work sampling for long-cycle work processes.  Business Process Reengineering  Process : Set of activity which converts input into output  Business Process : Set of logical activity follows sequentially to get some business outcome  Reengineering : fundamental rethinking and radical redesign Business Process Reengineering  The fundamental rethinking and radical redesign of business processes to achieve dramatic improvements in critical contemporary measures of performance, such as cost, quality, service, and speed   An approach aiming at improvements by means of elevating efficiency and effectiveness of the business process that exist within and across organizations   Brings improvements in  Cost  Quality  Speed,  Service     What to Reengineer ? How to Reengineer ? Methodology….  Determine Customer Requirements &Goals for the Process  Map and Measure the Existing Process  Innovation  Analyze and Modify Existing Process  Design a Reengineered Process  Implement the Reengineered Process  Monitoring &  Current Process Vision Measure Change New Process Transforming Methodology Objective  Improve Efficiency e.g reduce time to market, provide quicker response to customers  Increase Effectiveness e.g deliver higher quality  Achieve Cost Saving in the longer run  Provide more Meaningful work for employees  Increase Flexibility and Adaptability to change  Enable new business Growth Examples. Walmart was carrying 6to7 weeks inventory now it has come down to 1or2 weeks Dell used to take more than 15 days to deliver goods to customer, now it is delivered in 6 to 7 days Thank You