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The project deals with finding out the most accurate method for operator
evaluation . 1st part of project consist of creating a database of skills of workers by
time study using & also by PCSMOE system developed by Dr. Prabir jana & Dr.
Deepak Panghal , to understand the strength & weakness of each operator .
In 2nd part of project , workers will be allocated in the line using traditional
way(without using skill matrix), then by using time study skill matrix & third by
using PCSMOE system & then output of the workers will be compared to find out
the best operator evaluation method
Objective
Creating skill matrix using Time study method and also by PCSMOE system.
Comparing efficiency and output of each operator to find out the most accurate
method for operator evaluation.
Research paper under study
HYPOTHESIS
Alternate Hypothesis
Line balancing using skill matrix gives more output in comparison to traditional
method
Null hypothesis
line balancing using skill matrix does not increase output in comparison to
traditional method
To get a balanced line from day one, select operators for the operations based on
operators skill levels and capacity required for the task. So we needed to develop
a skill matrix of all operators.
To have all basic information in one table, you need to capture following data.
Operation name,
LINE BALANCING
Line Balancing is the distribution of work on the line in such a way that everyone
gets the same output of work in terms of time.
Objectives of line Balancing
Table 1
FROM SKILL INVENTORY OPERATOR PERFORMANCE AVAILABLE ARE
OPERATOR A B C D
COLLAR 66 75 72 48
MAKING
CUFF MAKING 85 89 130 65
Table 2
Dynamic balancing
From the Tables 1 and 2 for a setting the operators are selected as B & C because
the operational efficiencies of these operators are as per the required for the
particular jobs which will have the effective use of all operators' skills.
When you are conducting a regression analysis with one independent variable,
the regression equation is Y = a + b*X where Y is the dependent variable, X is the
independent variable, a is the constant (or intercept), and b is the slope of the
regression line.
Experimental Data
Capacity study
MODEL 1
Left and right Amina O/L 0.82 0.3 96.77 776 73.47
panel join
Left and right Nurbanu F/L 0.53 0.62 109.09 103 112.50
panel ts and tc
Sleeve panel ts and Sokina F/L 0.47 0.49 122.45 104 126.76
tc
Zipper tuck with Naher L/S 0.36 0.42 142.86 118 168.22
body
MODEL 2
FOR MODEL 1
P value is less
than 0.05%
Scatter diagram
Model I II
Trendline y = 0.324x + 41.42 y = 0.470x +
equation 56.70
We found out that MODEL II has higher output than Model I which proves our
null hypothesis is wrong and our Alternate hypothesis is correct i.e Line balancing
using skill matrix produces more output in comparison to traditional method.
Also it proves, Skill matrix helps in allocating right person for the right job which
helps in achieving desired performance level. It keeps record of all operations an
operator had done in the past and efficiency level in each operation. Engineers /
line supervisors need minimum time to find and select most efficient operators
for an operation from the pull of operators.
For line balancing, operators can be selected according to work content. When
someone is absent, supervisor can easily find suitable person from the skill matrix
table and replace. To analyses the skill availability and distribution throughout the
factory. This can be compared with the skill requirement for a particular time
period and shortage/excess skill availability to achieve at the training
requirement. So productivity can be achieved by allocating skill & semi-skilled
workers to the right place and unskilled operator should be trained properly.
Also after line is set using skill matrix ,capacity study is done to further find
bottlenecks in the line . the main job is to reduce/eliminate WIP between
operations to improve the output.