DEVELOPING IMPROVED WORK STANDARD IN A LEADING FOOD SERVICES COMPANY
By
ERIC HARTAWAN 11407007
BACHELOR’S DEGREE in
INDUSTRIAL ENGINEERING
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten, 15143 – Indonesia
JULY 2018
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Eric Hartawan
____________________________________________
Student Date
Approved by:
Ir. Setijo Awibowo, MM
____________________________________________
Thesis Advisor Date
Dr. Eng. Sumarsono, S.T., M.T., OCP
____________________________________________
Thesis Co-Advisor Date
Dr. Irvan S. Kartawiria, S.T., M. Sc.
____________________________________________
Dean Date
ABSTRACT
DEVELOPING IMPROVED WORK STANDARD IN A LEADING FOOD SERVICES COMPANY
By
Eric Hartawan, Student Ir. Setijo Awibowo, MM, Advisor
Dr. Eng. Sumarsono. S.T., M.T., OCP, Co-Advisor SWISS GERMAN UNIVERSITY
This research is conducted in a leading food services company. The objective of this thesis is to improve the efficiency in the tray assembly line and improve its worker’s safety in doing their jobs. Based on the observation and data analysis, it is found that there are motion wastes in the current work method that makes the assembly process inefficient, and the working postures performed by the operators in the assembly line may cause health hazards. There are two improvements proposed in this thesis, the first proposed improvement is the adjustment of the assembly area, this is so the workers can work in the safest way with minimum reach. The second proposed improvement is the simplification of the existing work methods. The work methods are simplified into two movements instead of the previous 2 to 4 movements using motion economy principle as the basis. After implementing the proposed improvements, the company is able to improve the efficiency of the assembly line, increase their production capacity, as well as improve the workers safety in the assembly line.
Keywords: Production Level, Efficiency, Assembly Line, REBA, RULA, OWAS, Time and Motion Study, Tecnomatix Plant Simulation, Jack Simulation
© Copyright 2018 by Eric Hartawan All rights reserved
DEDICATION
I dedicate this thesis to the Almighty God, for the ability to finish this research To my beloved family and friends, who always support me
And to my lecturers, who always guide me throughout this study
ACKNOWLEDGEMENTS
First and foremost, I would like to thank the Almighty God for all His blessings throughout my study and the making of this thesis work.
I would also like to express my deepest gratitude to Ir. Setijo Awibowo MM and Dr.
Eng. Sumarsono S.T., M.T., OCP for all the valuable guidance, patience, support to finish this thesis work.
I also thank Mr. Sri Sardjananto, Mr. Dadan Daniswara, and Mr. Agung Boediono for giving me the chance to do this thesis in the company. Not to mention my friends in the company, Wulan, Ryan, Dewi, Selly, Nike, Adji, and Ratih, thank you very much for the time spent.
Next, I would like to thank Vilia for the endless support and encouragement for me to finish this thesis. Also, to all my best friends in Industrial Engineering Class 2014, thank you for all the unforgettable moments in our four-year study. Best of luck for you guys.
Last but not least, I want to thank my families for the support and prayers that contribute to the accomplishment of this thesis.
TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
Chapter 1 – INTRODUCTION ... 13
1.1. Background ... 13
1.2. Research Problem ... 14
1.3. Research Objectives ... 14
1.4. Scope and Limitation ... 14
1.5. Assumptions ... 15
1.6. Significance of Study ... 15
1.7. Thesis Organization... 15
Chapter 2 – LITERATURE REVIEW ... 17
2.1. Lean Manufacturing ... 17
2.1.1. Lean Manufacturing Waste ... 17
2.2. Airline Catering ... 19
2.3. Work Measurement ... 19
2.3.1. Direct Time Study ... 20
2.3.2. Indirect Time Study ... 20
2.4. Performance Rating ... 20
2.4.1. Westinghouse System of Rating ... 21
2.4.2. Synthetic Rating ... 22
2.4.3. Speed Rating ... 22
2.4.4. Objective Rating ... 22
2.4.5. Physiological Evolution of Performance Level ... 22
2.7. Relationship and Utilization of Motion and Time Study ... 24
2.8. Manual Work Design ... 24
2.8.1. Motion Economy Related to the Use of Human Body ... 25
2.8.2. Motion Economy Related to the Arrangement of the Workplace ... 25
Chapter 3 – RESEARCH METHODOLOGY ... 27
3.1. Research Method ... 27
3.2. Problem Identification ... 28
3.3. Literature Review ... 28
3.4. Set Objectives ... 28
3.5. Data Acquisition ... 28
3.5.1. Motion Study ... 29
3.5.2. Time Study ... 29
3.6. Data Processing ... 30
3.6.1. Normal Time and Standard Time Calculation ... 30
3.7. Data Analyzing ... 31
3.7.1. Tecnomatix Plant Simulation ... 31
3.7.2. Jack Simulation ... 31
3.7.3. Rapid Entire Body Assessment (REBA) ... 33
3.8. Improvement ... 39
3.9. Conclusion and Recommendation ... 39
3.10. Summary of Research Methodology ... 39
Chapter 4 – RESULTS AND DISCUSSIONS ... 41
4.1. Data Acquisition ... 41
4.1.1. Company Overview ... 41
4.1.2. Field Observation ... 42
4.1.3. Product Overview ... 42
4.1.4. Assembly Line Process ... 43
4.1.5. Current Layout ... 44
4.1.6. Existing Work Method and Processing Time ... 44
4.2. Data Analysis ... 49
4.2.1. Tecnomatix Simulation Results ... 49
4.3. Proposed Improvement ... 63
4.3.1. Assembly Area Adjustments... 63
4.3.2. Work Method Redesign ... 66
4.4. Improvement Analysis ... 70
4.4.1. Bottleneck Analysis ... 70
4.4.2. Cycle Time Analysis ... 71
4.4.3. Productivity Analysis ... 72
4.4.4. Financial Analysis ... 72
4.4.5. Ergonomic Analysis ... 74
4.5. Work Instruction ... 77
Chapter 5 – CONCLUSIONS AND RECOMMENDATION ... 78
5.1. Conclusions ... 78
5.2. Recommendations ... 79
5.3. Future Works ... 79
GLOSSARY ... 80
REFERENCES ... 81
APPENDICES ... 83
APPENDIX A – Rapid Entire Body Assessment (REBA) Worksheet ... 83
APPENDIX B – Standard Time Calculation ... 84
APPENDIX C – Tecnomatix Plant Simulation... 85
APPENDIX D – RULA Results for Current Working Postures ... 86
APPENDIX E – RULA Results for Postures After Improvement ... 90
APPENDIX F – OWAS Results for Current Working Postures ... 94
APPENDIX G – OWAS Results for Postures After Improvement ... 98
APPENDIX H – REBA Worksheet for Current Working Postures ... 102
APPENDIX I – REBA Worksheet for Postures After Improvement ... 109
APPENDIX J – Work Instruction for GA YC Domestic Assembly Line ... 117
CURRICULUM VITAE ... 121
