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The document is a manpower assessment study report of Grasim Bhiwani Textiles Ltd conducted by the National Productivity Council. It analyzes the current and proposed manpower deployment across various departments of the textile company including spinning, weaving, processing and support functions. Key findings are:
- The present manpower deployment across all departments studied is 1959 against the proposed requirement of 1679 based on the current production levels.
- Departments covered include Elegant and BTM spinning, weaving, processing, maintenance, logistics, quality assurance and others.
- The study methodology involved time-motion studies, data collection on activities, frequencies and machine details, and rationalization of
The document is a manpower assessment study report of Grasim Bhiwani Textiles Ltd conducted by the National Productivity Council. It analyzes the current and proposed manpower deployment across various departments of the textile company including spinning, weaving, processing and support functions. Key findings are:
- The present manpower deployment across all departments studied is 1959 against the proposed requirement of 1679 based on the current production levels.
- Departments covered include Elegant and BTM spinning, weaving, processing, maintenance, logistics, quality assurance and others.
- The study methodology involved time-motion studies, data collection on activities, frequencies and machine details, and rationalization of
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The document is a manpower assessment study report of Grasim Bhiwani Textiles Ltd conducted by the National Productivity Council. It analyzes the current and proposed manpower deployment across various departments of the textile company including spinning, weaving, processing and support functions. Key findings are:
- The present manpower deployment across all departments studied is 1959 against the proposed requirement of 1679 based on the current production levels.
- Departments covered include Elegant and BTM spinning, weaving, processing, maintenance, logistics, quality assurance and others.
- The study methodology involved time-motion studies, data collection on activities, frequencies and machine details, and rationalization of
Drepturi de autor:
Attribution Non-Commercial (BY-NC)
Formate disponibile
Descărcați ca PDF, TXT sau citiți online pe Scribd
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani
Nat i onal Product i vi t y Counci l , Bangal ore
Confidential
REPORT ON
MANPOWER ASSESSMENT
At GRASIM BHIWANI TEXTILES LIMITED (A Subsidiary of Grasim Industries Limited) BHIWANI 127 021
NATIONAL PRODUCTIVITY COUNCIL (Under Ministry of Commerce & Industry, Govt. of India) REGIONAL PROFESSIONAL MANAGEMENT GROUP BANGALORE Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
C O N T E N T S
Section Chapter Description Page No Acknowledgement Executive Summary 1 I Introduction 2 II Methodology 4 III Departmental reports 1 Elegant Spinning - Production 6 2 A Elegant Spinning Mechanical Maintenance 85 2 B Elegant Spinning Electrical Maintenance 107 3 BTM Spinning - Production 109 4 A BTM Spinning Mechanical Maintenance 181 4 B BTM Spinning Electrical Maintenance 254 5 A Fiber Dyeing 256 5 B Yarn Development 286 6 Weaving - Preparatory 295 7 Weaving - Loomshed 315 8 A Weaving Maintenance - Mechanical 334 8 B Weaving Maintenance - Electrical 341 9 Weaving QA 355 10 Checking, Mending And Finishing 362 11 Process House - Production 409 12 Process House - Maintenance 453 13 Logistics 467 14 Thermal Power Plant 502 15 Yarn Godown 528
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
ACKNOWLEDGEMENT
We wish to place on record our sincere thanks to the management of M/s Grasi m Bhiwani Textiles Limited, for having given us the opportunity to conduct a study on Manpower Assessment in their plant located at Bhiwani. In particular, we sincerely thank Shri S. Krishnamoorthy (President) and Shri Manmohan Singh (Unit Head) for having entrusted the study to us.
We are grateful to Shri R. Subramaniam (VP-Operations) for providing critical & valuable inputs during the study and for ensuring that the study is carried out as per the schedule.
We express our sincere thanks to Shri Arun Verma (AVP HR & IR) and Shri Kaushal Tanwar (GM HR & IR) for the timely coordination provided by them during the study.
We acknowledge the valuable time & effort spared and the timely provision of the information & data, by all the Officers and Staff of the plant during the study.
We also credit all the employees for their cooperation to the NPC team during the study.
Bangalore M.L.Suryaprakash 27 t h March 2012 Regional Director
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
Executive Summary
The summary of the present and the proposed manpower for the various departments studied is detailed in table 1. 1 below. The manpower proposed for the current level of production is 1679 against the present deployment of 1959.
The present and the proposed manpower numbers are basic manpower (without inclusion of any relief off and leave).
Table 1.1 Summary of the Present and Proposed Manpower S.No Department Manpower (Numbers) Present Proposed 1 ELEGANT SPINNING - PRODUCTION 281 275 2 A ELEGANT SPINNING - MECHANICAL MAINTENANCE 31 30 2 B ELEGANT SPINNING - ELECTRICAL MAINTENANCE 14 14 3 BTM SPINNING - PRODUCTION 393 355 4 A BTM SPINNING - MECHANICAL MAINTENANCE 38 33 4 B BTM SPINNING - ELECTRICAL MAINTENANCE 21 21 5 A FIBER DYEING 58 46 5 B YARN DEVELOPMENT 16 16 6 WEAVING - PREPARATORY 122 91 7 WEAVING LOOMSHED 126 119 8 A WEAVING MAINTENANCE - MECHANICAL 5 6 8 B WEAVING MAINTENANCE - ELECTRICAL 18 16 9 WEAVING QA 7 7 10 CHECKING, MENDING AND FINISHING 249 184 11 PROCESS HOUSE - PRODUCTION 220 199 12 PROCESS HOUSE - MAINTENANCE 25 22 13 LOGISTICS 230 154 14 THERMAL POWER PLANT 70 69 15 YARN GODOWN 35 22
TOTAL 1959 1679
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
Chapter I Introduction
1.1 The Adit ya Birla Group (ABG) is an Indian multinational conglomerate corporation headquartered in Mumbai, India. It operates in 33 count ries with more than 133, 000 employees worldwide. The group has diversified business interests and is dominant player in all the sectors in which it operates such as viscose staple fibre, metals, cement, viscose filament yarn, branded apparel, carbon black, chemicals, fertilisers, insulators, financial services, telecom, BPO and IT services. The group is a US$ 35 billion conglomerate which gets 60 % of its revenues from outside India. The Adit ya Birla Group has been adjudged the best employer in India and among the top 20 in Asia by the Hewitt - Economic Times and Wall Street Journal Study 2007.
1.2 The Adit ya Birla Group is the world' s largest player in the Viscose Staple Fiber industry. Apart from viscose staple fiber, the group also owns acrylic fiber businesses in Egypt and Thailand, viscose filament yarn businesses and spinning mills at several locations all over India and South East Asia. The Adit ya Birla group is also a major player in the branded garments market in India.
1.3 The Adit ya Birla Group wanted to improve their productivit y in three of their textile units in India and accordingl y they have requested National Productivit y Council (NPC) to take up the study.
1.4 M/s. Grasim Bhiwani Textiles Limited (GBTL) is a verticall y integrated textile mill with two spinning division, one we aving division and a fabric processing division.
1.5 Scope of Grasim Bhiwani Textiles Limited (GBTL):
1.5.1 The scope of the study includes the assessment of manpower (workmen onl y) for operating the BTM Spinning and Elegant Spinners having combined spindle capacit y 35, 728 nos. and other related & support functions e.g. maintenance, engineering and qualit y assurance.
1.5.2 The manpower assessment study shall also be conducted for the workmen of weaving department of 140 looms and fabric processing having capacit y of 15 lakhs meters per month and related & support functions e. g. maintenance, engineering and qualit y assurance.
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
1.5.3 The study will also cover the manpower deployed in logistics (Warehouse and Dispatch) and Yarn Godown activities.
1.5.4 The study will be limit ed to the manpower requirement of non-executive (workmen category) cadre employees of the plant operation. Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
Chapter II Methodology
2.1 The manpower assessment study was carried out by a team of consultants of National Productivit y Council, led by the Chief Consultant and the individual consultants drawn from the Bangalore office and New Delhi office. NPC deputed a team of four Consultants to carry out the detailed studies. The field studies in Bhiwani were carried out from 16 t h November 2011 till 14 t h January 2012.
2.2 The assignment was kicked off by an opening meeting with the unit head and the HODs of the various departments. The methodology to be followed by the team, expectation from the various stakeholders and the various time lines were clearl y explained in the meeting. This was followed by a plant visit and initial discussions amongst the team members. The following steps were followed for the detailed studies in the concerned areas.
2.3 The manpower requirement of Permanent and Contract employees (other than maintenance) was determined by the following process
2.3.1 Collection of the data regarding the activities, frequencies, machine characteristics, for all the personnel involved in all the departments.
2.3.2 NPC consultants conduct ed detailed time and moti on studies for all the jobs involving both the categories of workmen.
2.3.3 NPC also collect ed the requisite clarifications regarding the activities carried out, frequency of occurrence and records maintained through discussions with the employees, direct observation and also through perusal of past records and documents.
2.3.4 The rest and relaxation allowances were computed based on ILO recommendations and NPC' s own experience in this area.
2.3.5 The manpower was rationalized through reallocation of duties / tasks to even out the variations in work loads, if required. Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
2.4 The manpower requirement of Permanent and Contract employees in the maintenance departments was determined by the following process
2.4.1 Collection of the data regarding the activities, frequencies, and crew deployed for the breakdown maintenance and preventive activities. NPC consultants conducted the time and motion studies on a sample basis for the maintenance activities and the observations made were applied to the preventive and breakdown maintenance activities.
2.4.2 Appropriate rest and relaxation allowances were computed based on ILO recommendations and NPC' s own experience in this area and applied to the various works.
2.4.3 For the general shift personnel who are predominantl y performing preventive maintenance works and major breakdown maintenance works, the manpower has been calculated for 80 % loading. The rationale is explained in the individual departmental sheet s.
2.4.4 Work sampling studies were carried out during the shift for the crew to determine the utilization of the personnel in the various activities, wherever required.
2.5 The report was submitted to the GBTL management on 20 t h
February 2012. Detailed discussions were conducted with the management team of the GBTL which comprised of AVP (Operations), AVP (HR & IR) and the concerned HOD and a presentation was performed to the President. Based on the inputs provided during the discussions, appropriate changes were made in the manpower deployment and the finalized manpower deployment is presented in t his report.
Manpower Assessment St udy Report of Grasi m Bhi wani Text i l es Lt d, Bhi wani Nat i onal Product i vi t y Counci l , Bangal ore
________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 ELEGANT SPINNING - PRODUCTION ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.1 I II III G T I II III G T 1 Mixing Mixing man 7 7 7 - 21 6 6 6 - 18 Waste Sorter - - - 3 3 - - - 3 3 2 Blow Room Tenter 3 3 3 - 9 3 3 3 - 9 3 Carding. Tenter 3 3 3 - 9 3 3 3 - 9 4 Draw Frame Sider 2 2 2 - 6 2 2 2 - 6 5 Speed Frame Sider 3 3 3 - 9 3 3 3 - 9 Doffer 2 2 2 - 6 2 2 2 - 6 Jobber 1 1 1 - 3 1 1 1 - 3 Jam Cutter - - - 1 1 - - - 1 1 6 Ring Frame Sider 9 9 9 - 27 9 9 9 - 27 Doffer 16 16 16 - 48 16 16 16 - 48 Doffer-Reliever 2 2 2 - 6 2 2 2 - 6 Jobber 1 1 1 - 3 1 1 1 - 3 Seggerator 1 1 1 - 3 1 1 1 - 3 Checker 1 1 1 - 3 1 1 1 - 3 ELEGANT SPINNING - PRODUCTION Manpower Deployment * S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.1 I II III G T I II III G T ELEGANT SPINNING - PRODUCTION Manpower Deployment * S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks Floor Cleanner 1 1 1 - 3 1 1 1 - 3 7 Autoconer Jobber 1 1 1 - 3 1 1 1 - 3 Checker 1 1 1 - 3 1 1 1 - 3 Winder 7 7 7 - 21 7 7 7 - 21 Winder -Reliever 1 1 1 - 3 1 1 1 - 3 Doffer 1 1 1 - 3 1 1 1 - 3 Bobbin Sorter 2 2 2 - 6 2 2 2 - 6 Floor Cleaner 1 1 1 - 3 1 1 1 - 3 8 Cheese Winding Winder-RJK 4 4 4 - 12 4 4 4 - 12 Winder-SSM 2 2 2 - 6 2 2 2 - 6 Winder-Reliever 1 1 1 - 3 1 1 1 3 Cone winding(Rewinding ) - - - 1 1 - - - 1 1 9 Two-for-one(TFO) Jobber 1 1 1 - 3 1 1 1 - 3 Doff Carrier 1 1 1 - 3 1 1 1 - 3 Tenter 8 8 8 - 24 8 8 8 - 24 _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.1 I II III G T I II III G T ELEGANT SPINNING - PRODUCTION Manpower Deployment * S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks Tenter-Reliever 1 1 1 - 3 1 1 1 - 3 Floor Cleaner 1 1 1 - 3 1 1 1 - 3 Sweeper - - - 1 1 - - - 1 1 10 Packing Checker - - - 3 3 - - - 3 3 Lot-Final Checker - - - 1 1 - - - 1 1 Packer - - - 6 6 - - - 4 4 11 Cone-Tipping - - - 1 1 - - - 1 1 12 Yarn Conditioning - - - 2 2 - - - 1 1 13 Quality Assurance Investigator 1 - - - 1 - - - 1 1 Checker 2 2 1 1 6 2 2 1 1 6 88 87 86 20 281 86 86 85 18 275 * The above manpower deployment table is for 30s Count. Total _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.2 1.2.1 I a) b) c) d) P r o d u c t i o n
( k g s )
/ H o u r P a r a m e t e r s 21 14.6 148 320 115.5 120 spindle/ machine CARDING-LR D/F Breaker 15 Kg/ Can D/F Finisher Speed frame ELEGANT SPINNING - PRODUCTION Proposed Changes & Observations I n p u t
p e r
s h i f t
p e r
m a c h i n e O u t p u t
Q u a n t i t i e s Methodology 15 Kg/Can 4.80 35 Kg/ Can 12.92 The machine efficiency and operator workload are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of machines to be alloted per personnel. It is assumed that machines are subject to stops at random and unpredictable intervals. It is also assumed that the operator will service a machine with the minimum delay after the machine has stopped, and that if two or more are stopped at one time,he will attend to them by taking the nearest first. This method of servicing is called random tending. Thomas F.O' Connor, provided the table for calculating the machine efficiency and operators workload in this type of multimachine assignment problem in the book: Efficiency and Productivity Tables for Textile Machine Operation, Institute of Textile Technology,Virginia. CARDING- CROSSROL 170.67 462.00 15 kg/Can 2 Kg/ Roving 7.79 61.60 78.93 170.67 Carding,Drawframe and Speedframe 8.98 33.83 o u t p u t
p e r
s h i f t
p e r
m a c h i n e The frequency values are taken from the following tables for the repsective sections: M / C
N a m e In Carding, Drawframe and Speed frame sections, the operator is responsible for the operation of more than one machine, if two machines stop at a time and require tenter's attention simultaneously,one of the machine must wait until he completes his work on the other. This time loss representing waiting time due to overlapping of machine stoppage is called "Interference loss". ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.2 ELEGANT SPINNING - PRODUCTION Proposed Changes & Observations 1.2.1 II a) b) c) d) e) f) r = (b-1) / [ gN{K+(b-1)C}] The running efficiency is arrived by the following formula provided by the research paper. The working pattern of operators in Ringframe, Autconer, Cheese winding and Two-for- One(TFO) is entirely different from the preceding section.In this areas,the operator's services the machine in a cyclical manner and attends to each machines(drums) as he comes to it. The difficulty in dealing with these problems lies in calculating the effect of "interference" which is the term used for incidence of simultaneous stoppages at several machines. In fact, if the optimum number of machines is being controlled by one operative, the machine efficiency required will be a marked feature. The research paper "The Efficiency of N machines Uni-Directionally patrolled by single operative" by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957), has been used to arrive the machines running efficiency for the different number of machines handled by the operators in the above sections considering the following working methodology: Ringframe, Autoconer, Cheesewinding and Two-for-One(TFO) r = Running Efficiency, i.e the percentage of running time to total (stopped + running) time.Stopped means time lost due to interference and breaks includes rectification of breaks. C - Time to repair and restart the machine The operative walks round the machines in a defined order and repairs and restarts any machine which is found stopped, passing after inspecting and/or servicing any machine which is running. It is assumed that the machine stops at random with the same mean frequency and independent of each other. g - Random breakdowns in running time @ each machine/drum N - Number of machines K- Mean walking time from one machine to next machine, includes inspection time b = exp(gNK) The operator workload is calculated by multiplying the time taken for different activities to be performed with the frequency of the activities for the allotted number of machines. Methodology ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.2 ELEGANT SPINNING - PRODUCTION Proposed Changes & Observations 1.2.1 g) h) M / C
N a m e P r o d u c t i o n
( K g s ) /
H o u r M a c h i n e
P a r a m e t e r s O u t p u t A v a i l a b l e
h o u r s /
S h i f t M / C
a v a i l a b l i t y
l o s t
%
M / C
A v a i l a b i l i t y
( % ) T o t a l
T i m e
a v a i l a b l e
f o r
p r o d u c t i o n / S h i f t I n p u t
p e r
s h i f t
( o f
r e s p
e f f i c i e n c y )
p e r
m / c o u t p u t
p e r
s h i f t
( o f
r e s p
e f f i c i e n c y )
p e r
m / c R/F 16.95 576 spindle/m achine 60 gms Bobbin 8 8 92% 7.36 62.38 2079.20 Autoco ner- Murate ch 77.5 60 spindle/m achine 2 Kg Cone 8 30 70% 5.6 7233.33 217.00 Autoco ner- Savio 77.5 60 spindle/m achine 2 Kg Cone 8 25 75% 6 7750.00 232.50 Cheese Windin g-RJK 150 160 spindle/m achine 1 Kg Cheese 8 28 70% 5.6 420.00 840.00 TFO 10.2 156 spindle/m achine 2 Kg Cone 8 2.5 97.5% 7.8 79.56 39.78 1.2.2 I a) The frequency values are taken from the following tables for the repsective sections: Proposed Changes Mixing Blenders: In view of low utilisation (69.44 %), it is recommended to deploy six personnel instead of the present seven personnel in a shift for three mixing blenders operation. The proposed utilisation of six personnel would be 81.01% The running efficiency values and operator workload are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel. Methodology ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.2 ELEGANT SPINNING - PRODUCTION Proposed Changes & Observations 1.2.2 II a) III a) b) IV a) 1.2.3 I a) Yarn Conditioning Room In view of low utilsation 39.77 % of two personnel,it is recommended to deploy one person in the yarn conditioning operation.The proposed utilisation of the personnel would be 79.55% Carding It was observed that the carding tenter, dump the different coloured sliver waste collected together in a single place near the machine. Say for example, brown colur with the black colour waste. Hence,the waste is again to be segregated by waste sorter. It is recommended that the tenter's should not mix the waste and advice to dump different coloured waste separately. Observations Deploy four personnel as the packer instead of present six personnel. The proposed utilisation of the group is 72.33 %. Keeping in mind,the number of trolley and weighing machine,space constraint on the packing table,and in order to prevent mixing, four personnel is recommended. Packing - Packers Carding Tenter: Deploy two operator for carding machine operation and deployment as follows: one operator - 12 crossrol machine Second operator- 6 LR + 4 Crossrol machines. The third operator is provided as the reliever for carding tenters(2 personnel),Drawframe tenter(2 nos). Presently drawframe tenter is being relieved by jobber. Proposed Changes ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.2 ELEGANT SPINNING - PRODUCTION Proposed Changes & Observations 1.2.3 II a) III a) Observations The machine gets stopped because of lack of coloured cans. Bands are used presently to differentiate count/colur. It was observed that there is no fixed standard for this.Hence, there would be a chance of mixing. It is suggested to makke visual display of the colour combinations(can colour+band colour) and their repsective count. Presentlyas there is no proper visual board or colour standards,operators are waiting for the checker/jobber's help in changing or using the cans. Effective Co-ordination- Ringframe Doffers Drawframe From the field study, it has been observed that the time taken for count change in ringframe section purely depends on the people management skill level of doffer leader. During the day of study, it was observed that because poor planning, the ringframe was stopped more than two-three hours for count change In the middle, they have taken another machine for ring travellours change. It affects the machine availability time for the production. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1.0 1.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Mixing Man ESP/W/01 ELEGANT SPINNING - PRODUCTION Workload Sheets Summary Area of work WLS Number Carding Tenter ESP/W/05 & A Cheesewinding-Winder(RJK) ESP/W/27 Blowroom Tenter-1&2 ESP/W/03 Blowroom Tenter-3 ESP/W/04 Cheesewinding-Winder(SSM) ESP/W/26 Drawframe -Sider ESP/W/06 Speedframe Tenter ESP/W/07 Speedframe Doffer ESP/W/08 Speedframe Jobber ESP/W/09 ESP/W/10 Speedframe-Jam cutter Packing -Packer ESP/W/38 Autoconer-Winder ESP/W/21 & A Autoconer-Doffer ESP/W/23 QA-Checker ESP/W/42 QA- Investigator ESP/W/41 Cheesewinding-Winder Reliever ESP/W/28 TFO- Tenter Reliever ESP/W/33 Cheesewinding-Rewinding ESP/W/29 Cone tipping ESP/W/39 Yarn conditioning Room ESP/W/40 Autoconer-Bobbin Sorter ESP/W/24 Autoconer-Floor Cleaner ESP/W/25 Packing - Checker ESP/W/36 Autoconer-Jobber ESP/W/19 Packing -Lot Final Checker ESP/W/37 Ringframe-Checker ESP/W/17 Ringframe-Floor cleaner ESP/W/18 TFO- Tenter ESP/W/32 Ringframe-Sider ESP/W/11 Ringframe-Doffer ESP/W/12 Ringframe-Jobber ESP/W/15 Ringframe-Doffer Reliever ESP/W/14 Ringframe-Doffer Leader ESP/W/13 Waste Sorter ESP/W/02 & A TFO- Jobber ESP/W/30 TFO- Doff Carrier ESP/W/31 Ringframe-Segregator ESP/W/16 Autoconer-Checker ESP/W/20 TFO- Sweeper ESP/W/35 TFO- Floor Cleaner ESP/W/34 Autoconer-Winder Reliever ESP/W/22 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7 7 7 - Designation Proposed Manpower 6 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 a 1 1 4.95 4.95 b 1 1 2.48 2.48 c 2 1 10.50 21.01 d 1 1 4.00 4.00 e 1 1 1.13 1.13 2 a 2 5 3.92 39.15 b 1 5 1.42 7.11 c 1 2275 0.026 59.32 d 1 2275 0.028 62.73 e 1 20 3.85 77.00 a 2 3 3.92 23.49 f 1 3 1.42 4.26 g 1 1225 0.026 31.95 h 1 1225 0.028 33.78 i 1 3500 0.08 280.00 3 a b 4 a b 385 3500 0.11 1 3500 0.11 385 Cut the material vertically in the mixing bin,lift and feed on blender belt conveyor WLS No: ESP/W/01 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Mixing Room Bring the chemical ( AS 400) from the plastic drum in the presence of supervisor after weighing Bring the chemical ( AS 200) from the plastic drum in the presence of supervisor after weighing Bring the hot water in a plastic drum from geyser Blender Mixing Boy Activity Description Spin Finish Solution preparation ( No 1 & 3)(in front of shift incharge) Do layering by spreading polyester and viscose on the alternate layer by manually Mix the AS-200 & AS-400 one by one in the hot water Bring the polyester bags from respective area to near the machine Layering Open the bales of polyester bags Bring the viscose bags from respective area to near the machine Take the polyester from bags and put it on the belt conveyor(feed end) Open the bales of viscose bags Take the viscose from bags and put it on the belt conveyor(feed end) To pickup the viscose from beater & spread in mixing Spread the blender output (inside the bin) evenly by manual Second Toppling (Mixing) Cut the material vertically in the mixing bin,lift and feed on blender belt conveyor Spread the blender output (inside the bin) evenly by manual 1 Keep the empty chemical cans in the respective area Spray the spin finish solution uniformly on the every layer of polyester fibre using spray pump Spread the blender output (inside the bin) evenly by manual First Toppling (Mixing) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7 7 7 - Designation Proposed Manpower 6 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: ESP/W/01 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Mixing Room Blender Mixing Boy Activity Description 5 a b 6 a b c d A 1869.52 B 17 C 2187.34 D 450 E 69.44% F 6 G 81.01% 1 3500 0.11 385 Proposed Utilisation(%) Target - 2500 Kg /person * 7 persons / shift =17500 kg / shift . Each batch have 5 steps. It becomes 3500 kg batch ( 3500 * 5 steps = 17500 kg) P/V (65/35) mixing is considered. Hence , 3500 *65% Polyester = 2275 kg / shift , 3500 * 35% Viscose =1225 kg/ shift. As minimum two personnel required per mixing room, six personnel is being recommended per shift for three blowrooms. Lot Change ( Shade Change) Clean the bins before starting the mixing. Final Toppling (Mixing) Rest & Relaxation Allowances ( % ) 1 1 62.17 Basic Workload per Shift ( in man minutes) Clean the blender & beater Clean the floor area around the machine To remove the jam of beater & blender ( if any) Spread the blender output (inside the bin) evenly by manual Cut the material vertically in the mixing bin,lift and feed on blender belt conveyor 62 Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 20 101.00 101.00 2 1 20 9.40 9.40 3 1 2 38.00 38.00 4 1 4 48.00 48.00 5 1 1 25.00 25.00 A 221.40 B 13 C 250.18 D 480 E 52.12% F 1 G 52.12% WLS No: ESP/W/02 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G PREPARATORY Basic Workload per Shift ( in man minutes) MIXING WASTE SORTER/CARRIER Activity Description Putting waste from carding m/c into bags & weighing Sewing the bags Cleaning the area Bring material from store(antistatic, stationery etc.) Deliver waste report to post spinning and then to raw material dept. Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 238.64 477.29 2 2 26.57 53.14 3 2 4 42.40 84.80 4 2 20 bags 22.00 44.00 A 659.23 B 13 C 744.93 D 480 E 77.60% F 2 G 77.60% G PREPARATORY Cleaning the whole area with broom Helping in weighing of bags WLS No: ESP/W/02 A WORK LOAD DETAILS SHEET ELEGANT Shifts A B C MIXING WASTE SORTER Activity Description Waste sorting-Avg. waste coming in =294.57KG/shift 120 KG Placing the sorted out material in respective bags Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 - Designation Proposed Manpower 2 2 - Sl. No Cre w Size Freq/ machi ne / Shift No of machi nes Basic Time (Mins) Total Time (Mins) 1 1.1 1 1 2 2.00 4.00 1.2 1 1 2 5.00 10.00 2 1 1002 2 0.073 146.29 3 1 78 2 0.23 35.88 4 1 78 2 0.15 22.78 5 1 78 2 0.13 20.59 6 1 76 2 0.36 54.26 7 1 76 2 0.15 22.34 8 1 78 2 0.21 32.45 9 1 1 2 2.00 4.00 10 1 1 2 2.31 4.62 11 1 2 2 4.00 16.00 12 1 0.44 2 90.00 79.20 13 1 1 2 4.00 8.00 A 460.42 B 15 C 529.48 D 450 E 58.83% F 2 G 58.83% Lot change - 4 machine/(3 shifts*3 machine) = 0.44 /shift/machine Machine Capacity - 155 kg/ hour * 8 hour * 80% machine availability= 992 kg /13 kg lap = 77 laps Rejection (0.01%) = 992*0.01 = 9.92 kg/13kg lap= 1 lap Total Workload ( in man minutes ) Net Available man-mins Rest & Relaxation Allowances ( % ) Basic Workload per Shift ( in man minutes) Total =992 kg+9.92 kg = 1002 kg C 2 2 Enter the lap weight and number in the Lap production Register Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Keep the lap rod in the machine for new lap At the shift end weigh the waste collected in the carding section and collect it. Break rejected laps into small tufts and feed them Clean the machine and area around the machine at the shift end and at intervals. Clean the machine during lot change Remove the lap rod from the machine and keep on the weighing machine and ensure that lap weight is under tolerance limit. +/-200 gms Take the polycover and tie on the lap Keep the lap in the respective zone To adject the lap weight if found above the limits Bring the materials from mixing bin room (vertical cut) & feed on the machine lattice Keep the spindle on machine stand for next lap Blowroom-1&2 Tenter Activity Description Shift Changeover activities Check the machine parameters like length counter,count,batch,shade no etc To counter check weight of 5 laps of out going shift. WLS No: ESP/W/03 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B G Blowroom ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ machi ne / Shift Basic Time (Mins) Total Time (Mins) 1 1.1 1 1 2.00 2.00 1.2 1 1 5.00 5.00 2 1 1002 0.073 73.15 3 1 78 0.15 11.39 4 1 78 0.13 10.30 5 1 77 0.36 27.49 6 1 77 0.15 11.32 7 1 78 0.21 16.22 8 1 1 2.00 2.00 9 1 1 2.31 2.31 10 1 2 4.00 8.00 11 1 0.44 90.00 39.60 12 1 1 4.00 4.00 13 14 A 212.77 B 15 C 244.69 D 450 E 54.38% F 1 G 54.38% Rejection (0.01%) = 992*0.01 = 9.92 kg/13kg lap= 1 lap Total =992 kg+9.92 kg = 1002 kg Lot change - 4 machine/(3 shifts*3 machine) = 0.44 /shift/machine Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Target per shift /tenter - 992 kg/13 kg lap = 77 laps Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Clean the machine during lot change At the shift end weigh the waste collected in the carding section and collect it. Stop the machine and check when alarm arised To inform the fitter/ electrician/supervisor if any abnormalities found. Enter the lap weight and number in the Lap production Register To adjust the lap weight if found above the limits Break rejected laps into small tufts and feed them equally Clean the machine and area around the machine at the shift end and at intervals. Keep the lap in the respective zone Blowroom-3 Tenter Activity Description Shift Changeover activites Check the machine parameters like length WLS No: ESP/W/04 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Blowroom Bring the materials from mixing bin room (vertical cut)& feed on the machine latice Keep the lap rod in the machine for new lap Remove the laprod from the machine and keep on the weighing machine and ensure that lap weight is under tolerance limit. +/-200 gms Take the polycover and tie on the lap To counter check weight of 5 laps of out going shift. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. 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( M i n s ) 1 t2 1 8 1.00 13 9.04 2 t2 12.92 8 0.24 16 28.93 3 t2 12.92 8 0.31 13 35.87 4 t2 12.92 8 0.44 15 52.66 5 t2 12.92 8 0.21 14 24.76 6 t2 1.84571 8 0.90 14 15.20 7 t2 1.84571 8 0.85 15 14.47 8 t2 1.84571 8 0.79 15 13.40 9 t2 1.84571 8 0.18 13 3.00 11 t2 4.8 8 0.63 13 27.34 12 t2 4.8 8 0.35 13 15.01 13 t 0.144 8 2.00 13 2.60 10 t1 2 2 4.36 13 19.71 14 t2 4 1 1.74 13 7.86 15 t2 1 8 0.50 13 4.52 16 t2 4 1 3.52 13 15.92 17 t1 1 1 0.60 13 0.68 18 t1 1 1 1.02 13 1.15 B C 3 3 WLS No: ESP/W/05 Elegant Spinning Shifts G Spinning WORK LOAD DETAILS SHEET A Bring the trolley with laps back to carding section Return back the lap rod and cover to blow room section Bring the empty can and keep on the machine Carding Tenter Activity Description Reset the machine parameter at the shift starting Load new lap rod on the machine stand from trolley/floor Remove the lap cover from the lap Feed the lap on the machine (from machine stand to roller) Remove the empty lap rod from the machine & place on the trolley Move the empty trolley to blow room from carding section Load the new laps from blow room section on the trolley (7 laps per trolley) Move the filled can from the machine and keep in the respective area Attend the sliver cut problem Check the suction hood working condition Clean the bruce wheel at the shift end and collect the waste Move the waste collected to blow room section yellow bag Remove the suction hood waste (in the blow room) Bring the yellow bag from blow room section Clean the work area around the machines 3 3 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) B C 3 3 WLS No: ESP/W/05 Elegant Spinning Shifts G Spinning WORK LOAD DETAILS SHEET A Carding Tenter Activity Description 3 3 19 t1 1 1 4.10 13 4.64 20 t 0.06 8 15.00 13 8.54 Clean the machine at the time of lot change Thomas O Connor table 8 94.36% 60.02% T (M/C running time per cycle) = 480 mins per shift *8 machines = 3840 mins The above values are depicted in the graph to find out the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: Hand over the waste collected in the carding section after weighment at the shift end 11 93.13% 90.16% 78.85% 91.74% 10 12 88.38% t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 26.18 mins t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running ) = 267.98 mins t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 11.15 mins No of Machines Machine Efficiency(%) Operator workload(%) 9 84.32% 14 84.17% 93.68% The machine efficiency and respective operative workload for the values above is found out from the Thomas O' Connar table and tabulated below: 66.64% 72.94% 13 86.38% 89.28% 15 81.75% 97.50% ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) B C 3 3 WLS No: ESP/W/05 Elegant Spinning Shifts G Spinning WORK LOAD DETAILS SHEET A Carding Tenter Activity Description 3 3 Lot change - 4 machine/(3 shifts*22 machines) = 0.06 /shift From the graph, the optimum number of machine can be allotted per operator is 12 nos. Remarks: Two operator and one common reliever for Blowroom and carding 8 9 10 11 12 13 14 Machine Efficiency(%) 94.36% 93.13% 91.74% 90.16% 88.38% 86.38% 84.17% Operator Workload(%) 60.02% 66.64% 72.94% 78.85% 84.32% 89.28% 93.68% 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00% E f f i c i e n c y ( % ) Carding-Crossrol ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) 1 t2 1 7 1.00 13 7.91 2 t2 12.92 4 0.24 16 14.46 3 t2 12.92 4 0.31 13 17.93 4 t2 12.92 4 0.44 15 26.33 5 t2 12.92 4 0.21 14 12.38 6 t2 1.84571 4 0.90 14 7.60 7 t2 1.84571 4 0.85 15 7.23 8 t2 1.84571 4 0.79 15 6.70 9 t2 1.84571 4 0.18 13 1.50 10 t2 4.8 4 0.63 13 13.67 11 t2 4.8 4 0.35 13 7.51 12 t 0.144 4 1.20 13 0.78 13 t2 8.98 3 0.24 16 7.54 14 t2 8.98 3 0.31 13 9.35 15 t2 8.98 3 0.44 15 13.73 16 t2 8.98 3 0.21 14 6.45 17 t2 1.28286 3 0.90 14 3.96 Carding WLS No: ESP/W/05 A Elegant Spinning Shifts B G Spinning A WORK LOAD DETAILS SHEET Load the new laps from blow room section on the trolley (7 laps per trolley) Bring the trolley (with laps) back to carding section Return back the lap rod and cover to blow room section Activity Description Reset the machine parameter at the shift starting Load new lap rod on the machine stand from trolley/floor Remove the lap cover from the lap Crossrol Move the empty trolley to blow room from carding section Remove the empty lap rod from the machine & place on the trolley Move the empty trolley to blow room from carding section Feed the lap on the machine (from machine stand to roller) Tenter Bring the empty can and keep on the machine Move the filled can from the machine and keep in the respective area Attend the sliver cut problem Feed the lap on the machine (from machine stand to roller) Remove the empty lap rod from the machine & place on the trolley LR Load new lap rod on the machine stand from trolley/floor Remove the lap cover from the lap C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) Carding WLS No: ESP/W/05 A Elegant Spinning Shifts B G Spinning A WORK LOAD DETAILS SHEET Activity Description Tenter C 18 t2 1.28286 3 0.85 15 3.77 19 t2 1.28286 3 0.79 15 3.49 20 t2 1.28286 3 0.18 13 0.78 21 t2 7.79 3 0.63 13 16.64 22 t2 7.79 3 0.35 13 9.14 23 t 0.2337 3 1.15 13 0.91 24 t1 4 3 1.06 13 14.37 25 t2 2 3 1.50 13 10.17 26 t1 4 3 1.61 13 21.87 27 t1 2 3 2.49 13 16.88 28 t1 4 3 1.21 13 16.37 29 t1 2 2 4.36 13 19.71 30 t2 4 1 0.87 13 3.93 31 t2 1 4 1.02 13 4.61 32 t2 2 1 3.52 13 7.96 33 t1 1 1 0.60 13 0.68 34 t1 1 1 1.02 13 1.15 35 t1 1 1 4.10 13 4.64 Attend the sliver cut problem Load the new laps from blow room section on the trolley (7 laps per trolley) Bring the trolley with laps back to carding section Bring the empty can and keep on the machine Move the filled can from the machine and keep in the respective area Clean the work area around the machines Check the suction hood working condition Clean the bruce wheel at the shift end and collect the waste Remove the suction hood waste (in the blow room) Front side top-LR Bring the yellow bag from blow room Move the waste collected to blow room section yellow bag Hand over the waste collected in the carding section after weighment at the shift end Front side wheel-LR Front side bottom-LR Back side bottom-LR side door-LR Return back the lap rod and cover to blow room section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) Carding WLS No: ESP/W/05 A Elegant Spinning Shifts B G Spinning A WORK LOAD DETAILS SHEET Activity Description Tenter C 36 t 0.063 7 15.00 13 7.47 Clean the machine at the time of lot change Thomas O Connor table T (M/C running time per cycle) = 480 mins per shift *7 machines = 3360 mins t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 95.66 mins t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running ) = 225.88 mins 7 95.75% Operator workload(%) 10 92.37% 94.76% t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 10.23 mins The above values are depicted in the graph to find out the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: The machine efficiency and respective operative workload for the values above is found out from the Thomas O' Connar table and tabulated below: 11 90.93% 65.74% 90.60% 98.11% 9 93.64% No of Machines Machine Efficiency(%) 74.36% 82.67% 8 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) Carding WLS No: ESP/W/05 A Elegant Spinning Shifts B G Spinning A WORK LOAD DETAILS SHEET Activity Description Tenter C From the graph, the optimum number of machine can be allotted per operator is 10 nos. Lot change - 4 machine/(3 shifts*22 machines) = 0.06 /shift/group Remarks: 7 8 9 10 11 Machine Efficiency(%) 95.75% 94.76% 93.64% 92.37% 90.93% Operator Workload(%) 65.74% 74.36% 82.67% 90.60% 98.11% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) Carding-LR+Crossrol ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 - Designation Proposed Manpower 2 - Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) A 1 t2 33.83 2.00 0.43 13.00 32.88 2 t2 33.83 2.00 0.37 13.00 28.29 3 t2 33.83 2.00 0.20 13.00 15.29 4 t2 78.93 2.00 0.21 13.00 36.57 5 t 4 2.00 0.98 13.00 8.86 6 t 4 2.00 0.50 13.00 4.52 7 t 1.579 2.00 0.40 13.00 1.43 8 t 1.579 2.00 0.51 13.00 1.83 9 t 0.33 2.00 0.17 13.00 0.12 B 0.00 1 t2 170.7 1.00 0.15 13.00 28.93 2 t2 170.7 1.00 0.43 13.00 82.93 3 t2 170.7 1.00 0.58 13.00 111.09 4 t2 170.7 1.00 0.19 13.00 36.64 5 t 4 1.00 0.98 13.00 4.43 6 t 4 1.00 0.50 13.00 2.26 7 t 3.413 1.00 0.55 13.00 2.10 8 t 1.707 1.00 0.57 13.00 1.10 9 t 0.66 1.00 0.17 13.00 0.12 Clean drafting zone and filter box once in every two hrs. Piece the ends during breakages Move the LDO/6 materials cans to the Cherry Hara D/F WORK LOAD DETAILS SHEET G Change top rolls once in every two hours Tenter 2 2 Remove the roller jam Piece the ends during breakages Remove the roller jam WLS No: ESP/W/06 Clean the drafting zone and filter box once in every two hours Bring the full materials cans(Carding sliver) from carding section Replace the empty cans by the full sliver can & join the sliver in LDO/6 Return the empty cans to the carding section & keep in the area earmarked Do the lot change cleaning A 2 2 Replace the empty cans by the materials cans & join the sliver in Cherry Hara Do the lot change cleaning Change top rolls once in every two hours Place the empty cans in Cherry Hara for doffing Remove the full cans from cherry hara & keep the cans in Materials cans area Elegant Spinning Shifts C Spinning Finishing Section Drawframe Activity Description Breaker Place the empty cans in LDO/6 for doffing B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 - Designation Proposed Manpower 2 - Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s / m a c h i n e N o
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m a c h i n e
s B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) WORK LOAD DETAILS SHEET G Tenter 2 2 WLS No: ESP/W/06 A 2 2 Elegant Spinning Shifts C Spinning Drawframe Activity Description B C t1 1 1.00 2.00 13.00 2.26 The machine efficiency and respective operative workload for the values above is found out from the Thomas O' Connar table and tabulated below: 4 83.42% Collect waste and hand over to mixing for weighment 3 74.77% 66.02% t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running ) = 372.61 mins t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 26.78 mins 69.80% 83.42% 92.08% Thomas O Connor table T (M/C running time per cycle) = 480 mins per shift *3 machines = 1440 mins t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 2.26 mins The above values are depicted in the graph to find out the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: 5 6 57.83% 96.78% No of Machines Machine Efficiency(%) Operator workload(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 - Designation Proposed Manpower 2 - Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s / m a c h i n e N o
o f
m a c h i n e
s B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) WORK LOAD DETAILS SHEET G Tenter 2 2 WLS No: ESP/W/06 A 2 2 Elegant Spinning Shifts C Spinning Drawframe Activity Description B It is recommended that one operator per two breaker and one finisher machine. Lot change - 4 R/F machine/day = 4/(3shifts*2 machine) = 0.66 /machine/shift Remarks: 3 4 5 6 Machine Efficiency(%) 83.42% 74.77% 66.02% 57.83% Operator Workload(%) 69.80% 83.42% 92.08% 96.78% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) Drawframe-Tenter ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s N o
o f
M a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e ( % ) T o t a l
T i m e
( M i n s ) 1 t2 32 2 0.30 13 21.70 2 t2 32 2 0.17 13 12.29 3 t2 480 2 0.08 13 85.70 4 t1 4 2 3.17 13 28.66 5 t1 1 2 2.80 13 6.33 6 t1 1 1 2.70 13 3.05 7 t1 240 2 0.08 13 41.76 8 t 4 2 4.83 13 43.66 9 t 4 2 1.00 13 9.04 10 t 4 2 4.17 13 37.70 11 t 4.62 2 0.77 13 8.04 12 t 2.31 2 0.91 13 4.75 13 t 2.31 2 0.60 13 3.13 14 t 4.62 2 0.90 13 9.40 15 a t2 0.26 2 36.00 13 21.15 b t2 0.26 2 20.40 13 11.99 WLS No: ESP/W/07 Elegant Spinning Shifts G Spinning Speed Frame Tenter Activity Description Idle spindle Piece the ends of Finisher Sliver Move the full DF cans from D/F can storage area to S/F machine& replace empty cans. Keep the empty cans colour wise near the D/F Clean the draft zone Clean the machine floor and area between the cans Clean the machine floor (front side) Clean the bottom and top clearer (while machine is in running) Lot Change Put the Jodi in the empty rovings Clean the bottom and top clearer at every doff* Clean the fan waste of S/F at every doff Actually machine stops for 15 mins for doffing. Extra time of (15-5.83=9.17 mins) Other interruptions Remove the Top/Bottom Roller jam Piece the broken roving 3 WORK LOAD DETAILS SHEET 3 C A B 3 3 Put the empty cans colour wise near the D/F Move the full DF cans from D/F can storage area to S/F machine& put the sliver from can to top roller ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s N o
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M a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e ( % ) T o t a l
T i m e
( M i n s ) WLS No: ESP/W/07 Elegant Spinning Shifts G Spinning Speed Frame Tenter Activity Description 3 WORK LOAD DETAILS SHEET 3 C A B 3 3 c t 0.26 2 27.36 13 16.08 16 t 0.07 2 60.00 13 8.95 t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 79.80 mins Machine Efficiency(%) 64.21% T (M/C running time per cycle) = 480 mins per shift *2 machines = 960 mins Calculation of workload using Thomas O Connor table: 2 82.54% t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 140.75 mins No of Machines 4 68.80% 107.04% The machine efficiency and respective operative workload for the values above is found out from the Thomas O' Connor table and tabulated below: 3 76.04% 88.72% Operator workload(%) t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running ) = 152.83 mins The above values are depicted in the graph to find out the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: Perform Count changing activity(replace empty can with the full can, piece the sliver with the roving &start the machine) Piece the silver from top roller to roving ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s N o
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( M i n s ) A l l o w a n c e ( % ) T o t a l
T i m e
( M i n s ) WLS No: ESP/W/07 Elegant Spinning Shifts G Spinning Speed Frame Tenter Activity Description 3 WORK LOAD DETAILS SHEET 3 C A B 3 3 No of D/F cans to be replaced (respective machine efficiency) - 50 per shift * 5 machine = 250 cans Lot change - 4 R/F machine/day = 4/(3shifts*5 machine) = 0.26 /machine/shift * For applying in the formula, machine stoppage time of 15 mins is considered in t. S/F doffers replaces 150 cans . So only remaining cans to be replaced by sider. Hence, 100 cans/ 5 machine = 20 cans/machine Whereas in Count change, all the activity is performed, when machine is in stopped condition. Doffers helps during count change. Count change - 1 machine / day = 1/(3 shifts* 5 machine) = 0.066 / shift / team During lot change, half of the machine is running condition and they change the remaining half. Machine gets stopped only hen piecing of sliver with roving done. It is considered that all the activities for lot change has been performed only by the tenter. Remarks: 2 3 4 Machine Efficiency(%) 82.54% 76.04% 68.80% Operator Workload(%) 64.21% 88.72% 107.04% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) Speedframe-Tenter ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 8.67 8.67 2 2 2000 bobbin 62.07 124.14 3 2 5 doffs 48.40 96.80 4 2 5 78.70 157.40 5 2 14 14.00 28.00 6 2 2000 bobbin s 20.00 40.00 7 2 166 cans 37.35 74.70 8 2 4 17.40 34.80 9 1 10 1 11 1 3 30.00 90.00 A 664.50 B 13 C 750.89 D 450 E 83.43% F 2 G 83.43% To put the empty S/F bobbins in the spindle To keep the trolly of S/F Bobbins near the Rack WLS No: ESP/W/08 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G SPEEDFRAME DOFFER Activity Description To come on duty 15 min before shift start and report to jobber. To bring empty S/F bobbins from Rack in plastic tapa PREPARATORY To do the doffing in S/F. To keep all S/F Bobbins colour/lot wise wise in Rack To creel full D/F Cans in S/F and put off Empty cans . 10.00 To keep the unwanted items in Unwanted box To relieve the S/F sider for lunch To clean Preparatory Deptt. With Floor cleanning Brush time to time To keep the clg.items in clg. Box 5 10.00 Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Proposed Utilisation(%) Remarks: Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 24.33 24.33 2 1 1 30.83 30.83 3 1 1 15.00 15.00 4 1 5 1 6 1 7 1 8 1 3 61.67 61.67 9 1 1 15.00 15.00 10 1 1 30.00 30.00 11 1 1 12.00 12.00 12 1 1 12.17 12.17 13 1 43.00 43.00 A 294.00 B 13 C 332.22 D 450 E 73.83% F 1 G 73.83% To attend Hand shortage at shift change time To make attendence report of Preparatory Section and hand over it time keeper. WLS No: ESP/W/09 WORK LOAD DETAILS SHEET ELEGANT Shifts A 20.00 20.00 To Check the wrapping of D/F of new lots B C To distrubite the Attandance Cards at the end of the Shift G CARDING,D/F,S/F JOBBER Activity Description To come 30 min before shift change and take charge of deptt and write in charge Register. 30.00 30.00 To maintain house keeping during the shift. PREPARATORY Remarks: Ensure colorwise segregation of S/F bobbin & D/F cans To lookafter all work of Preparatory Section workers and maintain all systems 1 To see mateial setting and do lot change/count change as per planning and Deptt Required To attend all the abnormalities shown by incoming shift at the charge time. To relieve the D/F Tenter for lunch To keep the D/F Material covered with polythene sheet To Check the wrapping of Carding of new lots 4 Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 5 57.50 57.50 2 1 65 trolleys 232.05 232.05 A 289.55 B 13 C 327.19 D 480 E 68.16% F 1 G 68.16% WLS No: ESP/W/10 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G Remarks: PREPARATOTY Remove the trolley Jam Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) SPEEDFRAME JAM CUTTER Activity Description Collect trolleys from the dept. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 9 - Designation Proposed Manpower 9 - Sl. No Crew Size Freq/ Shift No of Mach ine Basic Time (Mins) Allowan ce(%) Total Time (Mins) 1 1 576 1 0.13 13 84.61 2 1 1 1 20.52 13 23.19 3 1 1 1 15.00 13 16.95 4 1 1 1 15.00 13 16.95 5 1 41.6 3 0.54 13 76.15 1 41.6 3 0.22 13 31.03 1 41.6 3 0.40 13 56.41 6 1 0.012 3 4.00 13 0.16 1 0.012 3 4.00 13 0.16 7 1 0.051 3 4.00 13 0.69 1 0.051 3 4.00 13 0.69 8 1 18.9 3 0.02 13 1.47 1 18.9 3 0.41 13 26.27 1 18.9 3 0.02 13 1.47 9 1 1 1 5.00 13 5.65 A 341.86 B 480 C 71.22% Net Available man-mins Present Utilisation(%) Count change Remove the top clearer, clean and keep on the lammba Put the top clearer on the machine after the count change over S/F Roving Change Basic Workload per Shift ( in man minutes) Put the top clearer on the machine after the count change over Clean the creel To attend idle spindles in his m/c Remove roller lapping using hexablade knife Piece the broken threads Bring the S/F roving near the machine from the S/F roving storage area Replace the empty rovings with the full roving Keep the empty rovings back in the rack To collect pneumafil waste and hand over it to mixing for weighment at the shift end. Clean the Jockey pulley Ringframe-LR 9 Roving thread piecing Lot change Remove the top clearer, clean and keep on the lammba C G Spinning Activity Description Clean the Top clearer Clean Drafting zone 9 Sider 9 9 WLS No: ESP/W/11 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 9 - Designation Proposed Manpower 9 - Sl. No Crew Size Freq/ Shift No of Mach ine Basic Time (Mins) Allowan ce(%) Total Time (Mins) Ringframe-LR 9 C G Spinning Activity Description 9 Sider 9 9 WLS No: ESP/W/11 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B 5 2880 (5*576) 77.55% 98.24% 2592 (4.5*576) 79.33% 91.48% The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: Running Efficiency () (%) Operator workload(%) 2304 (4*576) 81.20% 84.73% 2016 (3.5*576) 83.15% 77.98% The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). r = (b-1) / [ gN{K+(b-1)C}] 1728 (3*576) 85.20% 71.22% The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums g - 0.0004901, N - 1728 (3*576), C- 0.22 , K-0.03 1728 (3*576) 2016 (3.5*576) 2304 (4*576) 2592 (4.5*576) Running Efficiency () (%) 85.20% 83.15% 81.20% 79.33% Operator workload(%) 71.22% 77.98% 84.73% 91.48% 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00% E f f i c i e n c y ( % ) Ringframe-LR ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 9 - Designation Proposed Manpower 9 - Sl. No Crew Size Freq/ Shift No of Mach ine Basic Time (Mins) Allowan ce(%) Total Time (Mins) Ringframe-LR 9 C G Spinning Activity Description 9 Sider 9 9 WLS No: ESP/W/11 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B * Time lost due to doffing,Travellours change,Lot/Count change and maintenance is collected from the management Speedframe rovings is changed mainly during the lot change and Count change. As the activities are performed during lot & count change it is being considered under the doffers workload. But small percentage(30%) of S/F rovings is being changed by sider ( while running).Number of rovings to be feed per ringframe per shift equals to 63 rovings. Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 1728 Spindle Actual machine efficiency (%) = 7.36 hours *0.852 = 6.27 hours/shift From the graph, the optimum number of drums to be allotted per operator comes to 3.5 to 4 machine. In practical , it is not possible to allocate 3.75 machine and also that the R/F efficiency is critical. It is suggested to provide one operator for three machines. Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to doffing,Travellours change,Lot/Count change and maintenance) = Machine running hours ( 8 hours * 92 % = 7.36 hours) Remarks: Count change - 1 machine / day = 1/(3 shifts* 26 machine) = 0.012 / shift Lot Change- 4 machine / day = 4/ (26 machine*3 shift) = 0.0512 / shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7 7 - Designation Proposed Manpower 7 7 - Sl. No Crew Size Freq/ Shift No of Spindl es/mac hine Basic Time (Mins) Total Time (Mins) 1 7 1 5.00 35.00 2 a 4 52 2.56 532.48 b 4 52 576 2.820 586.56 c 4 52 0.70 145.60 d 4 52 1.00 208.00 3 a 1 2 576 0.03 34.56 b 1 2 576 0.05 57.60 c 1 2 576 0.03 34.56 d 1 2 1 3.50 7.00 4 a 1 0.16 576 0.018 1.61 b 1 0.66 576 0.02 8.74 c 1 0.66 576 0.07 26.61 d 1 0.66 576 0.41 155.87 e 1 0.66 576 0.05 19.01 f 1 0.66 576 0.02 8.74 5 a 1 0.16 1 1.98 0.32 b 1 0.16 576 0.012 1.09 c 1 0.16 576 0.078 7.17 d 1 0.16 1.98 0.32 e 1 0.16 576 0.018 1.61 f 1 0.16 576 0.02 2.12 Put the new ring travellour in the spindle Close the doom(2 sides) WLS No: ESP/W/12 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B G C Spinning Join the thread roving and bobbin Take trays, got to autoconer area, Collect the empty R/F bobbins from Autoconer storage area,Reach the machine spot Keep the collected R/F bobbin trays in the R/F Sorting area Bobbin changing Remove the filled R/F bobbin from the spindle & Put the empty R/F bobbin in the R/F spindle(144 spindle timing) Arrange the S/F rovings from rack to trolley Count Change Bring the S/F roving near the machine from the S/F roving storage area Open the doom(2 sides) Move the empty trolley back to S/F rovings area Remove the lammba for the old count(288 spindle) Put the new count lammab on the machine(288 spindle) Clean the machine area after ring travellour change Bring the S/F roving near the machine from the S/F roving storage area(40 rovings/trolley) Remove the empty S/F bobbins from the R/F & Keep it in the trolley Arrange the S/F rovings from rack to trolley Join the thread roving and bobbin Put the S/F roving in the creel Join the thread after ring traveller put Lot Change 7 7 Remove the Old ring travellour from the spindle Ringframe Doffers Activity Description Shift Release activity Ring Travellour Change ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7 7 - Designation Proposed Manpower 7 7 - Sl. No Crew Size Freq/ Shift No of Spindl es/mac hine Basic Time (Mins) Total Time (Mins) WLS No: ESP/W/12 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B G C Spinning 7 7 Ringframe Doffers Activity Description g 1 0.16 576 0.05 0.01 h 1 0.16 576 0.07 6.45 i 1 0.16 576 0.41 0.07 j 1 0.16 576 0.02 2.12 6 1 1 2 10.00 20.00 1 1 806 0.02 14.11 1 1 806 0.04 31.34 7 1 2.00 14.00 7 1 1 5 63.00 315.00 A 2277.66 B 8 C 2459.87 D 480 E 73.21% F 7 G 73.21% Lot Change - 4 machine/day = 4/(3shifts*2 team) = 0.66 / shift / team Count change - 1 machine / day = 1/(3 shifts* 2 team) = 0.16 / shift / team Move the empty trolley to S/F rovings area Cleaning Remove the remaining threads from the S/F rovings To do the foot step area cleaning of the machine Arrange the cleaned S/F roving from trolley to rack Clean the doffing trolley wheel checking & cleaning 4 Doffings /machine /shift = 13*4 =52 times/ shift/ team Rovings consumption- (62 rovings / machine/shift) * (13 machines / team )= 806 rovings / shift / team One doffing team consists of 7 doffers and one co-ordinator. Relieve the sider for the break(Tea,breakfast or lunch) As reliever is provided, net available man mins becomes 480 mins. As the above activity frequency is for 480 mins. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % )(Total-13%-5% relieved by reliever+8% added in the workload) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift 13 R/F machine for one doffing team Rings travellor change- 2 machines / team /shift Put the new S/F roving in the creel Proposed Utilisation(%) Remove the empty S/F rovings from the R/F & Keep it in the trolley Remarks: Join the thread roving and bobbin ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 15.00 15.00 2 1 2 63 125.00 2 3 4 A 140.00 B 13 C 158.20 D 450 E 35.16% F 1 G 35.16% The above job is supervisory in nature. Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Remarks: Discussing with the supervisors, siders Perform the scheduled activities like ring travellours change, machine cleaning and lot change/count change with the doffers Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) WLS No: ESP/W/13 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Spinning Relieve the ringframe-doffers for breaks Ringframe Doffer-Leader Activity Description Shift Release activity Co-ordinate the doffing team effectively for minimising the machine downtime for changover ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 12 63 750.00 A 750.00 B 13 C 847.50 D 450 E 94.17% F 2 G 94.17% Remarks: WLS No: ESP/W/14 WORK LOAD DETAILS SHEET Elg Spg Shifts A Ringframe Activity Description Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Relieve-twelve ringframe-doffers for breaks Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins .Total - 63 mins/shift/person B C G Spinning Proposed Manpower per shift Proposed Utilisation(%) Reliever-Doffers ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 25.00 25.00 2 1 1 7.83 7.83 3 1 1 5.00 5.00 4 1 1 30.00 30.00 5 1 1 5.00 5.00 6 1 4 31.20 31.20 7 8 9 10 11 12 1 3 120.00 120.00 13 1 14 1 15 1 1 10.00 10.00 A 334.03 B 13 C 377.46 D 450 E 83.88% F 1 G 83.88% WLS No: ESP/W/15 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C To attend hands shortage at shift change time. To make attendance report of R/F and handover it to time keeper. To take the round of the deptt. With S/I To distribute the work to the deptt. Worker, sider, doffer, reliever RING FRAME To collect the attendance catds of R/F workers. To take the charge of S/F materials. 90.00 To look after all work of R/F workers and maintain all systems in R/F section To engage one hand for floor cleaning To monitor dept. waste (20 % of shift time) G RING FRAME JOBBER Activity Description To come 30 min before shift change and take charge of dept. and write charge register To make ringtraveller change and handover old rtr to shift officer 10.00 Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) To engage one hand for bobbin sorting To see material settling and do lot change/count change as per planning. Total Workload ( in man minutes ) Net Available man-mins Proposed Utilisation(%) Remarks: 10.00 To help for gaiting To distribute the attendance cards at the end of the shift Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.00 10.00 2 1 3 1 4 1 5 1 6 1 7 1 2 23.40 23.40 8 1 1 30.00 30.00 A 304.60 B 13 C 344.20 D 450 E 76.49% F 1 G 76.49% WLS No: ESP/W/16 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G RINGFRAME RINGFRAME BOBBIN SORTER Activity Description To come on duty 15 min before shift start and report to RF jobber. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) 241.20 To clean the m/c top area in off ends side To relieve RF checker For lunch. 241.20 To keep empty doffing tapas from A/C in proper way. To repaire faulty RF bobbins and hand over to A/C. To sort RF bottom bobbins and send it to A/C lotwise To maintain house keeping in his work area during the shift. To sort RF bobbins lotwise and colorwise. 5 4 0 5 9
b o b b i n s Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 20.00 20.00 2 1 1 3 1 1 4 1 1 30.84 30.84 5 1 26.00 26.00 6 1 7 1 8 1 13.00 13.00 9 1 10 1 11 1 23.70 23.70 12 1 8.40 8.40 13 1 1 63.00 63.00 A 318.26 B 13 C 359.63 D 450 E 79.92% F 1 G 79.92% WLS No: ESP/W/17 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G RINGFRAME 94.80 To Separate faulty RF bobbins and make their report. RINGFRAME CHECKER Activity Description To come 30 min before shift change and report to R/F jober To check the colour code of S/F & RF bobbins and new lots , final lots.. 25.00 Basic Workload per Shift ( in man minutes) 13.52 To write the RF hanks in hank Register. To hand over Final lot material to A/C after checking 25.00 To take charge of materials from B/R to R/F To Check & make report of all lots running from B/R to R/F. To put sample of new lot in sample register To check RF doffs during Shift 94.80 To check lot change Clg. &shift M/C cleaning. in R/F. To make rport of idle spindles in R/F. 13.52 To take the round of R/F after every 2 Hrs to check the colour & write in the register To relieve the Bobbin sorter for Lunch & tea Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.50 10.50 2 1 8 170.42 170.42 3 1 23 24.13 24.13 4 1 4 16.00 16.00 5 1 12 96.00 96.00 6 1 8 3.40 3.40 7 1 1 4.50 4.50 8 1 4 16.88 16.88 A 341.83 B 13 C 386.27 D 450 E 85.84% F 1 G 85.84% Present Utilisation(%) Net Available man-mins RINGFRAME To clean floor in RF section in between m/cs and allies out side the m/cs by Plate form brush To collect roller bonda from RF waste boxes Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) To come on duty 15 min before the shift starts and report to RF jobber. WLS No: ESP/W/18 WORK LOAD DETAILS SHEET ELEGANT Shifts A G RINGFRAME FLOOR CLEANER Activity Description B Proposed Utilisation(%) Remarks: Proposed Manpower per shift To collect waste from Over head Blowers . To do sorting of roller bonda, shadewise and keep them in separate bags To collect sweeping waste from floor and keep it separate from other wastes. To send Roller bonda waste, Swpg. Waste, & O.H.B. waste to mxg. For weighment. To move Magnet trolly in whole RF section to collect old Rtrs from floor. C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 2 1 1 3 1 1 45.00 45.00 4 1 1 40.00 40.00 5 1 1 12.00 12.00 6 1 4 32.00 32.00 7 1 1 35.00 35.00 8 1 1 45.00 45.00 9 1 1 15.00 15.00 A 249.00 B 13 C 281.37 D 450 E 62.53% F 1 G 62.53% WLS No: ESP/W/19 WORK LOAD DETAILS SHEET ELEGANT Shifts A Write down doff balance and R/F setup, autoconer drum setup & change as per doff balance & R/F setup Collect all workers card and adjust hands G POST SPG 25.00 25.00 Check running material, cone tip, bobbin color Total Workload ( in man minutes ) Net Available man-mins B C Check A/C idle drums and make a report Write m/c efficiency and production details AUTOCONER JOBBER Activity Description Take charge of his duty Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Make attendance report Syestematically adjust all empty & full tapa All new lot sample pasted in sample register Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 2 1 1 3 1 1 45.00 45.00 4 1 10 samples 30.00 30.00 5 1 1 30.00 30.00 6 1 1 60.00 60.00 7 1 1 46.00 46.00 8 1 1 15.00 15.00 9 1 1 15.00 15.00 10 1 1/3 36.00 36.00 A 302.00 B 13 C 341.26 D 450 E 75.84% F 1 G 75.84% G POST SPG 25.00 25.00 Note all m/c settings drum wise, count wise, bobbin and cone color in setting register and instruct winder WLS No: ESP/W/20 WORK LOAD DETAILS SHEET ELEGANT Shifts A All new lot sample pasted in sample register Check TFO m/c vereator and tension setting and note in register B C AUTOCONER CHECKER Activity Description Take charge of his duty Make cut report and hand over to shift supervisor Check and note single pack material random cone weight Collect final lot from ringframe checker and check Check each cone for faults and inform jobber and shift supervisor Note cheese winding breakage and report to jobber and shift supervisor Make TFO m/c idle report Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - Designation Proposed Manpower 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allowa nce ( %) Total Time (Mins) 1 1 26.61 0.75 13 22.55 2 1 26.61 0.10 13 3.01 3 1 7983 0.030 13 270.62 4 1 26.61 0.08 13 2.41 5 1 932 0.06 13 63.19 6 1 466 0.12 13 63.19 7 1 235 0.10 13 27.46 8 1 2 2.00 13 4.52 A 456.95 B 480 C 95.20% The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: 70 97.83% 111.06% 60 98.92% 95.20% Present Utilisation(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums Running Efficiency () (%) Operator workload(%) r = (b-1) / [ gN{K+(b-1)C}] g - 0.06469, N - 60, C - 0.09, K - 0.20 Collect the waste from the machine Basic Workload per Shift ( in man minutes) Net Available man-mins Keep the empty tray aside Attend the thread cuts in spindles Attend the thread cuts in spindles Take the empty auto cone from the machine tray, remove the filled cone and put the empty cone on the machine and start the machine Activity Description Bring the R/F Bobbin tray from R/F storing section ( in Tray) Take the trays and keep on the trolley Put the R/F Bobbins in the machine drum Autoconer-Savio 1 Winder 1 WLS No: ESP/W/21 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Post Spinning ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - Designation Proposed Manpower 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allowa nce ( %) Total Time (Mins) Activity Description Autoconer-Savio 1 Winder 1 WLS No: ESP/W/21 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Post Spinning * Time lost due to doffing,bobbin reject,extracycle,splice and bobbin change is collected from the management From the graph, the optimum number of drums to be alloted per operator is 60 drums Remarks: No of bobbins - 7750 bobbins/shift/60 drums Rejection (3 %) - 7750 * 3% = 232.5 bobbins . Total - 7750 +233= 7983 bobbins /shift Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to doffing,bobbin reject,extracycle,splice,bobbin change) = Machine running hours ( 8 hours * 76 % = 6.08 hours) Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 60 drums, Actual machine efficiency (%) = 6.08 hours *0.9892 = 6.014hours/shift 60 70 Running Efficiency () (%) 98.92% 97.83% Operator workload(%) 95.20% 111.06% 85.00% 90.00% 95.00% 100.00% 105.00% 110.00% 115.00% E f f i c i e n c y ( % ) Autoconer-Savio ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 - Designation Proposed Manpower 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allowa nce ( %) Total Time (Mins) 1 1 24.83 0.75 13 21.05 2 1 24.83 0.10 13 2.81 3 1 7450 0.030 13 252.56 4 1 24.83 0.08 13 2.24 5 1 868 0.06 13 58.85 6 1 434 0.12 13 58.85 7 1 217 0.10 13 25.35 8 1 2 2.00 13 4.52 A 426.23 B 480 C Present Utilisation(%) 88.80% 5 The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: 70 98.08% 103.59% The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). r = (b-1) / [ gN{K+(b-1)C}] 60 99.09% 88.80% The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums Running Efficiency () (%) Operator workload(%) Take the empty auto cone from the machine tray, remove the filled cone and put the empty cone on the machine and start the machine Activity Description Bring the R/F Bobbin tray from R/F storing section ( in Tray) Take the trays and keep on the trolley Put the R/F Bobbins in the machine drum g - 0.062789, N - 60, C - 0.09 , K - 0.20 Collect the waste from the machine Basic Workload per Shift ( in man minutes) Net Available man-mins C G Post Spinning Keep the empty tray aside Attend the thread cuts in spindles Attend the thread cuts in spindles Autoconer- Muratech 6 Winder 6 WLS No: ESP/W/21 & A WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 - Designation Proposed Manpower 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allowa nce ( %) Total Time (Mins) Activity Description C G Post Spinning Autoconer- Muratech 6 Winder 6 WLS No: ESP/W/21 & A WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 60 drums Actual machine efficiency (%) = 5.68 hours *0.9909 = 5.62 hours/shift * Time lost due to doffing,bobbin reject,extracycle,splice and bobbin change is collected from the management Remarks: No of bobbins - 7233 bobbins/shift/60 drums 3 % Bobbin rejection - 7449 bobbins /shift From the graph, the optimum number of drums to be alloted per operator is 60 drums Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to doffing,bobbin reject,extracycle,splice,bobbin change) = Machine running hours ( 8 hours * 71 % = 5.68 hours) 60 70 Running Efficiency () (%) 99.09% 98.08% Operator workload(%) 88.80% 103.59% 80.00% 85.00% 90.00% 95.00% 100.00% 105.00% E f f i c i e n c y ( % ) Autoconer-Muratech ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 4 63 250.00 2 1 2 17.42 34.84 3 1 7 1.88 13.16 4 1 3 2.00 6.00 5 1 1 10.00 10.00 A 314.00 B 13 C 354.82 D 450 E 78.85% F 1 G 78.85% Clean the full machine with the compressed air(open the pipe, clean and keep the pipe aside) Yarn trap checking WLS No: ESP/W/22 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C Time for wax application per machine - 16.8 mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Autoconer Reliever-A/C Winder Activity Description Basic Workload per Shift ( in man minutes) Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person G Post Spinning Attend cutting drum jam(if any) Collect the hard waste and handover and inform to supervisor Applying wax to machine is not considered ,because the activity is not being performed presently. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Relieve - Four autoconer-tenter's for breaks ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 26 0.33 8.58 2 1 26 2.01 52.26 3 1 26 0.330 8.58 4 1 51.23 0.38 19.47 5 1 15.37 1.67 25.67 6 1 51.23 0.28 14.35 7 1 7 1 7.00 8 1 3 63.00 189.00 A 324.90 B 13 C 367.14 D 450 E 81.59% F 1 G 81.59% G Post Spinning Collect cones from the autoconer belt conveyor(backside) and keep on the trolley(60 cones - Keep the trolley near the cheese winding area(60 cones/trolley) Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person WLS No: ESP/W/23 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C Autoconer Doffer Activity Description Take the empty trolley from cheese winding area Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Collect the empty autocones from rack and come to machine(30 cones) Arrange the cones on the machine slanting portion(100 cones =1.67 mins) Go back to rack Collect back the remaining cones of last batch if any Total Cones - 1537 cones / (60 cones per trolley) = 26 trolleys Relieve the winder-tenter for breaks(lunch/breakfast/tea/personal needs) Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Autoconer Muratech - 217 cones/shift * 6 machine = 1302 cones Autoconer Savio - 235 cones/shift * 1 machine = 235 cones Basic Workload per Shift ( in man minutes) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 55881 0.01140 637.04 2 1 32 0.94 30.00 3 1 16 2.000 32.00 4 1 16 0.75 12.00 5 1 32 0.16 5.17 6 1 2 0.69700 1.39 7 1 1118 0.04200 46.96 8 1 2 0.70000 1.40 9 1 1118 0.00700 7.83 A 773.79 B 14 C 882.12 D 450 E 98.01% F 2 G 98.01% WLS No: ESP/W/24 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A Clean the belt conveyor for jam and remove the threads at the sides Arrange the empty trays for segregation purpose(4 -5 different trays) G Post Spinning Autoconer Bobbin sorter Activity Description B C Sort the empty R/F bobbins @ autoconer belt Take the full bobbins/half bobbins and put on the autoconer tenter trays Remarks: No of bobbins fed per machine per shift - 7750 nos Clean the spilled bobbins in and around the machine Clean the bobbin for the remaining thread Basic Workload per Shift ( in man minutes) Move the trays to Yarn conditioning room Clean the bobbins using the thread cleaning machine Come back to machine area Segregate the bobbins colour wise Rejection ( 3%) - 233 nos Total bobbins to be sorted - 7750 +233 = 7983 nos *7 machines = 55881 nos No of bobbins to be cleaned for the remaining threads using machine - 7983*2% *7 machines = 1118 nos Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.00 10.00 2 1 2 24.00 24.00 3 1 5 225.00 225.00 4 1 1 20.00 20.00 A 279.00 B 13 C 315.27 D 480 E 65.68% F 1 G 65.68% POST SPG Check and do TFO overhead dust box cleaning. Do sweeping and collect hard waste WLS No: ESP/W/25 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G AUTOCONER FLOOR CLEANER Activity Description Take charge of his duty Dispose scrap in scrap yard Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 4 - Designation Proposed Manpower 4 - Sl. No Crew Size Freq/ Shift/s pindle No of spindle Basic Time (Mins) Allowa nce (%) Total Time (Mins) 1 1 2.625 120 0.0600 13 21.36 2 1 2.625 120 0.3440 13 122.45 3 1 5.25 120 0.1570 13 111.77 4 1 5.25 120 0.0350 13 24.92 5 1 5.25 120 0.0270 13 19.22 6 1 5.25 120 0.0192 13 13.67 7 1 5.25 120 0.0200 13 14.24 8 1 2.625 120 0.228 13 81.16 9 1 1 1 15.000 13 16.95 A 425.72 B 480 C 88.69% 1 140 83.37% 102.89% r = (b-1) / [ gN{K+(b-1)C}] g - 0.01 , N - 120 , C - 0.228 , K - 0.05 120 85.40% 88.69% 130 84.37% 95.79% The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums Running Efficiency () Operator workload(%) Total Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). Bring the empty cheese cone from the rack & keep on the machine Move the trolley to cheese storage area near the TFO Attend the thread break Clean the machine Replace the empty auto cone with full autocone & join Replace the full cheese cone with empty cheese cone Write the number on the cheese cone using chalk Collect full cheese cone from machine table and keep on trolley 4 Tenter 4 4 Activity Description Keep the auto cone from trolley to the machine table Cheesewinding- RJK 4 WLS No: ESP/W/27 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Post Spinning ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 4 - Designation Proposed Manpower 4 - Sl. No Crew Size Freq/ Shift/s pindle No of spindle Basic Time (Mins) Allowa nce (%) Total Time (Mins) 4 Tenter 4 4 Activity Description Cheesewinding- RJK 4 WLS No: ESP/W/27 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Post Spinning * Time lost due to doffing,general cleaning,Lot/Count change,electrical and maintenance cleaning is collected from the management Machine available hours * (Time lost due to doffing,general cleaning,Lot/Count change,electrical and maintenance cleaning) = Machine running hours ( 8 hours * 78 % = 5.76 hours) Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 120 drums Actual machine efficiency (%) = 5.76 hours *0.8540 = 4.919 hours/shift Remarks: To calculate operators workload,480 mins is taken as net available manmins. Because, one person (operator or reliever) present near the machine for 480 mins. The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: From the graph, the optimum number of drums to be alloted per operator is 120 drums Machine Efficiency: (Sample calculation) 120 130 140 Running Efficiency () (%) 85.40% 84.37% 83.37% Operator workload(%) 88.69% 95.79% 102.89% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) Cheesewinding-RJK ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 5 63 312.50 A 312.50 B 13 C 353.13 D 450 E 78.47% F 1 G 78.47% WLS No: ESP/W/28 WORK LOAD DETAILS SHEET Elg Spg Shifts A B C G Post Spinning Basic Workload per Shift ( in man minutes) Cheese Winding Reliever-Winder Activity Description Relieve-Five cheese winding-tenter for breaks Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 75 cones 120.00 120.00 2 1 100 bobbins 64.00 64.00 4 1 98 cones 60.00 60.00 5 1 20 cones 30.00 30.00 6 1 2 lots(2kg) 20.00 20.00 7 1 15 cones 20.00 20.00 8 1 72 cones 30.00 30.00 A 344.00 B 13 C 388.72 D 480 E 80.98% F 1 G 80.98% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Processing of defective bobbins(R/F) for 2nd quality Rewinding of SQC tested TFO cones Processing of TFO broken tape, zero TPI(at top) to 2nd quality Preparation of pair of final single cone Remarks: C G POST SPG Rewinding of single cones to remove jali, double etc Rewinding of classimate cones CHEESE WINDING REWINDER Activity Description Rewinding of packing rejection WLS No:ESP/W/29 WORK LOAD DETAILS SHEET ELEGANT Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 2 1 1 3 1 1 36.28 36.28 4 1 3 46.46 46.46 5 1 6 1 7 1 4 27.40 27.40 8 1 5 22.50 22.50 9 1 1 79.65 79.65 10 1 1 5.00 5.00 11 1 2 11.00 11.00 12 1 4 12.00 12.00 13 1 1 55.31 55.31 14 1 1 13.27 13.27 15 1 1 12.50 12.50 16 1 1 12.50 12.50 A 382.42 B 13 C 432.14 D 450 E 96.03% F 1 G 96.03% WLS No: ESP/W/30 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G POST SPG 22.00 22.00 Cheese winding drum set as per TFO set up and according to shift supervisor instruction. CHEESE WINDING & TFO JOBBER Activity Description Come on his duty 30 mins prior to shift timings, take over the charge 26.55 26.55 Collect all workers' card and adjust all workers as per supervisor instruction & manage hands shortage. Give instruction to all winders about running cone cheese , tfo tip, m/c count and lot. Systematically adjust all empty and full trolleys Check cheese winding idle drum and handover a report to shift supervisor 2 Basic Workload per Shift ( in man minutes) Remarks: Random Cheese weight Note cheese winding doffing time & make production report Rewinding 4 cheese and inform related person about any fault Check and set cheese winding tension wt. Check winder no. on cheese and tfo cone Check hard waste per tenter Count change slip receive by shift officer and particular change by maintenance fitter Bottom material collection and finish with winder help Alloted m/c cleaning check & approve by shift supervisor. Aid 4 knotters in maintenance cleaning Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Work Centre Present Manpower 1 1 1 Designation Proposed Manpower 1 1 1 Sl. No Crew Size Freq/ Shift Element al Time (Mins) Basic Time (Mins) Total Time (Mins) 1 1 1 10.00 10.00 10.00 2 1 1 10.00 10.00 10.00 3 1 1 8.30 8.30 8.30 4 1 1312 Cones 0.02 26.24 26.24 5 1 21.87 0.57 12.46 12.46 6 1 21.87 1.36 29.74 29.74 7 1 4.37 0.92 4.02 4.02 8 1 20 1.61 32.2 32.20 9 1 1312 0.02 26.24 26.24 10 1 1312 0.05 65.60 65.60 11 1 5 6 30.00 30.00 12 1 2 1 63.00 126.00 A 380.81 B 14 C 434.12 D 450 E 96.5% F 1 G 96.5% Section Ensure and keep all m/c head clean Elemental time of loading 1 cone to trolley WLS No: ESP/W/31 WORK LOAD DETAILS SHEET Elegant Spg. Shifts A B C G Post Spg. TFO Doff Carrier Activity Description Come on his duty 10 mins prior to shift Check and systematically arrange the material lotwise in packing & YCS room. Proposed Utilisation(%) Remarks: Elemental time for Marking the Cones with chalk in packing dept. Elemental Time for placing the cones lotwise in the packing area Cleaning 5 trolleys per shift Basic Workload per shift ( in man minutes) Rest & Relaxation Allowances ( % ) Relieve- Two TFO tenter's for breaks Standard Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per Shift Movement time propotionate to 1312 times the cone is fetched Movement time propotionate to no. of trips made to carry trolley to packing dept. & coming back Movement time propotionate to no. of trips made to carry trolley to Yarn Conditioning Room & coming back Movement Time of carrying empty trolley from the area where empty trolleys are kept to the respective m/c for doffing & Vice-a - versa. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 8 - Designation Proposed Manpower 8 - Sl. No Crew Size Freq/ Shift No of machi ne Basic Time (Mins) Allow ance (%) Total Time (Mins) 1 1 80.0 4 0.0782 13 28.28 2 1 80.0 4 0.5601 13 202.51 3 1 80.0 4 0.0790 13 28.57 4 1 39.8 4 0.0221 13 3.98 5 1 39.8 4 0.0147 13 2.65 6 1 39.8 4 0.2760 13 49.65 7 1 39.8 4 0.0380 13 6.83 8 1 19.9 4 0.4000 13 35.98 9 1 1 1 20.0 13 20.00 A 378.45 B 480 C 78.84% The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). r = (b-1) / [ gN{K+(b-1)C}] g - 0.00027794 , N- 624 (4*156), C- 0.4 , K - 0.07 The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums Running Efficiency () (%) Operator workload(%) Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Attend the thread cut Clean the machine Bring empty TFO cone from the cone room Keep the cones on the machine Remove the full TFO cone, place on the machine holder & keep empty paper cone & join Write the number on the paper cone Activity Description Bring the cheese winding cone from the storage area, arrange on the machine table, keep the empty trolley aside(per cone) Replace the empty cheese cone with the full cheese cone & keep the empty cheese on the machine table& tie Collect the empty cheese cone and arrange it on the rack colourwise TFO-VJ 8 8 Tenter 8 8 WLS No: ESP/W/32 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Post Spinning ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 8 - Designation Proposed Manpower 8 - Sl. No Crew Size Freq/ Shift No of machi ne Basic Time (Mins) Allow ance (%) Total Time (Mins) Activity Description TFO-VJ 8 8 Tenter 8 8 WLS No: ESP/W/32 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Post Spinning The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: From the graph, the optimum number of drums to be alloted per operator is 702 drums(4.5 machines).As it is difficult to breaks into half machine, it is recommended to assign four machine per operator, keeping in view of machine utilisation. Remarks: Collection of full TFO cones from machine table to trolley is performed by doffers Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown) = Machine running hours ( 8 hours * 98.5 % = 7.88 hours) 858 (5.5*156) 91.79% 106.85% 780 (5*156) 92.48% 97.51% 702 (4.5*156) 93.18% 88.18% 624 (4*156) 94.05% 78.84% 624 (4*15 6) 702 (4.5*1 56) 780 (5*15 6) 858 (5.5*1 56) Running Efficiency () (%) 94.05% 93.18% 92.48% 91.79% Operator workload(%) 78.84% 88.18% 97.51% 106.85% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) TFO-Tenter ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 8 - Designation Proposed Manpower 8 - Sl. No Crew Size Freq/ Shift No of machi ne Basic Time (Mins) Allow ance (%) Total Time (Mins) Activity Description TFO-VJ 8 8 Tenter 8 8 WLS No: ESP/W/32 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Post Spinning * Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is collected from the management Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 624 spindles, Actual machine efficiency (%) = 7.88 hours *0.9405 = 7.411 hours/shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 6 63 378.00 2 1 1 10.00 10.00 3 A 388.00 B 13 C 438.44 D 450 E 97.43% F 1 G 97.43% WLS No: ESP/W/33 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G TFO Reliever-Tenter Activity Description Relieve- Six TFO tenter's for breaks Post Spinning Collect the hardwaste and handover&inform to supervisor Perform the activities scheduled by supervisor/jobber like assisting the tenter where two machine open at a time , shift second quality cone to respective area,single &fatta tar cheese creel in TFO,etc Proposed Utilisation(%) Remarks: Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.00 10.00 2 1 2 24.00 24.00 3 1 5 325.00 325.00 4 1 1 20.00 20.00 A 379.00 B 13 C 428.27 D 450 E 95.17% F 1 G 95.17% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Proposed Manpower per shift Proposed Utilisation(%) Remarks: Present Utilisation(%) TFO FLOOR CLEANER Activity Description Take charge of his duty Check and do TFO overhead dust box cleaning. Do sweeping and collect hard waste Dispose scrap in scrap yard WLS No: ESP/W/34 WORK LOAD DETAILS SHEET ELEGANT Shifts A B C G POST SPG ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 4 57.76 231.04 2 1 16 0.96 15.36 3 1 16 2.00 32.00 A 278.40 B 13 C 314.59 D 480 E 65.54% F 1 G 65.54% WLS No: ESP/W/35 WORK LOAD DETAILS SHEET Elegant Spinning Shifts A B C G Elegant Walk Path Floor Cleaner Activity Description Clean the pathway using floor cleaning machine(from Blowroom to TFO) Post Spining Drain the used water in the drain Fill the water in the machine Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 A ELEGANT SPINNING - MECHANICAL MAINTENANCE ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 A 2.1 I II III G T I II III G T Fitter - - - 1 1 - - - 1 1 Cleaner - - - 1 1 - - - 1 1 Sr. Fitter - - - 2 2 - - - 2 2 Cleaner - - - 2 2 - - - 2 2 Jr.Fitter 1 1 1 - 3 1 1 1 - 3 Sr. Fitter - - - 1 1 - - - 1 1 Jr.Fitter - - - 1 1 - - - 1 1 Cleaner - - - 1 1 - - - 1 1 Sr. Fitter - - - 1 1 - - - 1 1 Buffing Room Fitter - - - 1 1 - - - 1 1 Jr.Fitter - - - 1 1 - - - 1 1 Cleaner - - - 7 7 - - - 7 7 Cleaning Gang Running Fitter 1 1 1 - 3 1 1 1 - 3 Sr. Fitter - - - 1 1 Fitter - - - 1 1 Jr.Fitter - - - 2 2 - - - 2 2 Cleaner - - - 1 1 - - - 1 1 Sr. Learner - - - 1 1 - - - 1 1 2 2 2 25 31 2 2 2 24 30 Total 1 1 - - - TFO Autoconer&Cheese Winding Ring Frame 4 Main Gang Blow Room D/F & Simplex Post Spinning 1 3 5 Carding 2 ELEGANT SPINNING - MECHANICAL MAINTENANCE Manpower Deployment S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks _______________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 A 2.2 2.2.1 a) b) c) d) e) f) - - - - - - - - - - g) The manpower has been computed with a loading factor of 80 % for the maintenance personnel. The 80 % loading has been considered to take into account the following: Bring tools/materials from store Ex: oil,grease,waste cloth, new parts Breakdown maintenance (Carding, Ringframe & Autowinding) data has been obtained for a period of two months and the same has been extrapolated for a month. Running maintenance data has been collected by detailed discussions with the incumbents and the supervisory personnel and compared with check studies and estimated. The sum of the preventive maintenance, breakdown maintenance(if any) and running maintenance (if any) workload for the month gives us the total workload for the mechanical personnel. Rest & Relaxation allowance is already included as a part of activity time and presented against the respective activities. Prepare attendance Write logbook Arranging of tools & parts in tool room Efforts variation required Clean the tool room daily morning The detailed time and motion study is recommended to arrive the standard time for the activities,whatever timings considered here,based on the group utilisation technique.And cannot taken for fixing standard times. ELEGANT SPINNING - MECHANICAL MAINTENANCE Proposed Changes & Observations Methodology Waiting for the machine for maintenance The preventive maintenance data was collected for all the category of machines. Check studies on a sample basis were carried out to ascertain the process being followed for the preventive maintenance. The data gathered during check studies has been applied to the remaining preventive maintenance activities in that section. PF - Permanent Fitter(Sr.Fitter,Fitter,Jr.Fitter) PH - Permanenent Helper/Cleaner Discard the waste cloth to the waste area daily after maintenance work Unavoidable delay. Ex: New activity cannot start after 4.30 pm as only 30 mins left for that day Change dress ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 A 2.2 ELEGANT SPINNING - MECHANICAL MAINTENANCE Proposed Changes & Observations 2.2.2 I a) b) 2.2.3 a) b) c) It is observed during the study that before all mechanical personnel arrived , the machine was stopped for scheduled maintenance. Scheduled maintenance activity is started with few personnel, then one by one joining the workplace. In Ringframe, Machine cleaning is carried out by six personnel and each have their specific 96 spindle area to be cleaned. In this situation, three helpers starts the activity early and finishes earlier, whereas the persons joined later finishes their portion of 96 spindles later. Total machine stopped hour for maintenance elongates because of this mismatch. Total Time provided for Scheduled Maintenance The time provided for scheduled maintenance activities are based on the company experience/estimation. However, it was observed during the study that the actual time required for the scheduled maintenance activities are less. So , it is recommended to go for in-depth time and motion study and fix standards for the regular maintenance activities. This will help in increasing the availability time of machine and also reduce maintenance personnel workload further. Autoconer & Cheesewinding In view of low utilisation Fitters(38.41%) , it is recommended to deploy one fitter instead of the present two fitter. Proposed Changes Scheduling & Planning The activities to be so planned and performed that the time taken is minimized. Activities that can be carried out in parallel have to be planned. It is observed in ringframe that maintenance personnel, going to bring grease gun, gear box oil and parts to be changed. If the schedule contain gearbox oil change, while coming itself it could have brought in the trolley. Observations During autoconer / cheese winding machine prevent maintenance activity, the respective machine production operator is forced to idle. It is suggested that the production operator also assist mechanical team while scheduled maintenance activities like cleaning with compressed air, cloth for which no special mechanical skill required. Thereby, manpower further could be reduced. It also helps in building sense of ownership. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 A 2.3 S.No 1 2 3 4 5 6 7 8 9 Autowinding&Cheese winding EMS/W/08 TFO EMS/W/09 Blowroom &Carding- Running Fitter EMS/W/03 Drawframe&Simplex EMS/W/04 Ring Frame-Running Fitter EMS/W/07 Ring frame-Cleaning EMS/W/05 Ring frame-Main Gang EMS/W/06 Blowroom EMS/W/01 Carding EMS/W/02 ELEGANT SPINNING - MECHANICAL MAINTENANCE Workload Sheets Summary Area of work WLS Number ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm _____________________________________________________________________________________________________________________________________________________ _ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+1 H Work Centre Blowroom & Mixing - - - 1F+1 H PF PH PF PH 1 Line Blender clg. 2 1 1 2.988 3 18 18 2 Hopper Feeder clg. 2 1 1 1.992 3 12 12 3 Conden. & Doffing Section Clg. 2 1 1 1.992 3 12 12 4 Scutcher Cleaning 3 1 1 2.988 3 27 27 5 Mixing Blender clg 2 1 1 2.988 3 18 18 6 Mixing Condenser cleaning 1 1 1 1.992 7 14 14 7 Gear Box/Shell Roll Checking 1/3 1 1 1.992 6 4 4 8 K. Beater Legs Change 1/9 1 1 3.984 3 1 1 9 V.F.O.Wire Change 1/12 1 1 5.976 1 0 0 10 Beater Cleaning by Petrol 26 1 0.996 1 0 26 11 Compactor Cleaning 26 1 0.05 1 0 1 12 Grid Bar Cleaning 4 1 1 1.992 1 8 8 13 Primary Filter Cloth Washing 4 1 1 0.996 1 4 4 14 Secondary Filter Cleaning 4 1 1 1.992 1 8 8 15 Running Problems(During General Shift) 26 1 1 1 26 A 152.33 153.52 B 166.4 166.4 C 91.54% 92.26% D 1 1 E 91.54% 92.26% WLS No:EMS/W/01 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) Monthly workload(Hours) Total Workload per month ( in man hours ) S. No Activity Description Frequency/ Month Crew Category Time (in Hours) No of Machine _____________________________________________________________________________________________________________________________________________________ ______ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm _____________________________________________________________________________________________________________________________________________________ _ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani PF PH PF PH Monthly workload(Hours) S. No Activity Description Frequency/ Month Crew Category Time (in Hours) No of Machine _____________________________________________________________________________________________________________________________________________________ ______ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 2F+2H Work Centre Carding - - - 2F+2H PF PH PF PH 1 Full Setting 2 2 1 2.7 22 239.08 119.54 2 Cyl Wire Change 1/24 1 2 14.5 22 13.28 26.56 3 Doffer Wire Change 1/24 1 2 14.5 22 13.28 26.56 4 Flat Tops Change 1/30 1 2 5.4 22 3.98 7.97 5 Stn Flats(Back) Change 1/9 1 2 1.8 22 4.43 8.85 6 Stn Flats(Front) Change 1/15 1 2 1.8 22 2.66 5.31 7 Lic-in Wire Change 1/6 1 2 0.9 22 3.32 6.64 8 Cyl. & Doffer Wire Grinding 1/6 1 2 0.9 22 3.32 6.64 9 Coiler Overhauling 1/18 2 1 3.6 22 8.85 4.43 10 Clearer roller Clothing Change 1/12 1 1 0.5 22 0.83 0.83 Daily Works 11 CTC Cleaning 26 0 2 0.03 12 0.00 20.80 12 Stripping Brush Cleaning 26 1 0.025 12 0.00 7.80 13 Regular checkup and fill the log book 26 1 0.12 1 3.03 0.00 A 296.07 241.94 B 166.4 166.4 C 88.96% 72.70% D 2 2 E 88.96% 72.70% Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Running fitter in the carding section, performs the CTC cleaning with the general shift maintenance personnel at the general shift starting. S. No Activity Description Frequency/ Month Crew Category Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) Proposed Manpower Monthly workload(Hours) Time (in Hours) No of Machine WLS No:EMS/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower _________________________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (mins) Total Workload (mins) 1 1 8 3.00 24.00 2 1 8 2.45 19.60 3 1 4 7.04 28.16 4 1 1 3.00 3.00 5 1 1 2.06 2.06 6 1 1 25.00 25.00 7 1 1 20.00 20.00 8 1 1/3 20.00 6.67 9 108.00 A 212.49 B 450.0 E 47.22% F 1 G 47.22% Date Shift No of problems Total Time (Mins) 03-Jan A 5 75 04-Jan A 3 35 08-Jan A 6 120 05-Jan C 5 100 09-Jan B 10 190 12-Jan C 7 105 13-Jan B 6 105 10-Jan A 6 65 06-Jan C 10 210 11-Jan B 6 120 64 1125 Lot change cylinder side checking K-beater & MBO beater cleaning Total Workload per shift ( in man mins ) Net Available man-mins per month Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) To assess the amount of time spent on attending running problems, the random samples shifts is selected from the past log books(Jan-2012). The random number is generated and number of problems attended and time spent for the problem is tabulated as follows: Total C G Mechanical Clean the primary ( 2nos) Check the card speed, sliver weight, limit switch of all card(22 nos) Remarks: Attend running breakdown(24% * 450mins = 108 mins/shift) Write log book Front side bottom jam CTC Cleaning(help the general shift gang),Flat brush cleaning Blowroom & Carding Running Fitter Activity Description Clean the Compactor WLS No: EMS/W/03 WORK LOAD DETAILS SHEET Elegant Spg Shifts A B _____________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (mins) Total Workload (mins) C G Mechanical Blowroom & Carding Running Fitter Activity Description WLS No: EMS/W/03 WORK LOAD DETAILS SHEET Elegant Spg Shifts A B The average time to resolve a complaint works out to be 17.57 minutes.(1125/64) The average arrival rate is 64/10 = 6.4 per shift and the average servicing rate = 8*60 /17.57 = 27.31 per shift / = 0.2343= 24 % _____________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 2F+1H Work Centre Drawframe &Simplex - - - 2F+1H PF PH PF PH A Draw Frame 1 Machine Clg. Of Cherry Hara 3 2 1 1.489 2 17.9 8.9 2 Machine Clg. Of LDO/6 2 2 1 2.978 4 47.6 23.8 3 Cots Buffing 1 1 1 2.978 6 17.9 17.9 4 Oil Change 1/4 1 1 0.5 6 0.8 0.8 5 Basic Gauge Setting 1/6 2 1 5.956 6 11.9 6.0 6 Coiler O.H 1/6 2 1 8.934 6 17.9 8.9 7 Gear Box O.H 1/12 2 1 8.934 6 8.9 4.5 B Simplex 1 M/C Cleaning 1 1/2 2 Bottom Apron Change 1 3 Top Apron Change 1 4 Gear Box Oil Change 1/4 5 Reducer Gear Box Oil Change 1/2 6 Cots Buffing 1/2 1 1 2.978 5 7.4 7.4 7 New Cots Change 1/18 1 1 5.956 5 1.7 1.7 Time (in Hours) No of Machine Monthly workload(Hours) S. No Activity Description Frequency/ Month 2 1 4.467 5 WLS No:EMS/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower 67.01 33.50 Crew Category Proposed Manpower __________________________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 2F+1H Work Centre Drawframe &Simplex - - - 2F+1H PF PH PF PH Time (in Hours) No of Machine Monthly workload(Hours) S. No Activity Description Frequency/ Month WLS No:EMS/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Crew Category Proposed Manpower 8 Top & Bottom Apron Cleaning 1/3 1 1 2.978 5 5.0 5.0 9 Spindle Truing 1/4 2 1 8.934 5 22.3 11.2 10 Bottom Roll Truing 1/6 2 1 8.934 5 14.9 7.4 11 Arbour Greasing 1/6 1 1 2.978 5 2.5 2.5 12 Bottom & Top Clearer Cloth Change 1/12 2 1 8.934 5 7.4 3.7 13 Pressure Finger Change 1/24 2 1 11.912 5 5.0 2.5 C Daily 1 Top Roller, Coiler & Clearer Cloth Cleaning- D/F 26 1 1.07 6 27.73 0.00 2 D/F Creel Cleaning 26 1 0.25 6 0.00 6.50 3 Head Stock Cleaning, Chalk powder applied - Simplex,D/F 26 1 0.42 5 0.00 10.83 4 Check both D/F,Simplex machine. Fill the log book 26 1 0.50 13.00 0.00 5 Liquimix to Cots 26 1 0.25 6.50 0.00 6 Running Problems 26 1 1 26.00 A 329.26 162.93 B 166.4 166.4 C 98.94% 97.91% D 2 1 E 98.94% 97.91% Total Workload per month ( in man hours ) Remarks Proposed Utilisation(%) Proposed Manpower Present Utilisation(%) Net Available man-hours per month(8*26*80% = 166.4 hours) __________________________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+6H Work Centre Ringframe - - - 1F+6H PF PH PF PH A Ringframe 1 M/C Cleaning 1 2 Cots Change 1/9 3 Top Apron Change 1/24 4 Separator Washing 1/9 1 6 3.00 26 8.67 52.00 5 Top Apron Washing 1/6 0 2 3.00 26 0.00 26.00 6 Spindle Oil Change 1/9 1 1 3.00 26 8.67 8.67 7 Bottom Apron Change 1/9 0 4 1.50 26 0.00 17.33 8 Suction Tube Washing 1/6 0 4 1.50 26 0.00 26.00 9 Arbour Greasing 1/9 1 1 3.00 26 8.67 8.67 10 Semi Over Hauling 1/30 3* 9** 27.00 26 0.00 138.68 B TFO 1 Machine Cleaning 1 2 Centering Disc Cleaning & Greasing 1/2 3 Thread Guide Washing 1/3 4 Main Drive Shaft Bearing Greasing 1/3 5 Spindle Oil Topping 1/3 1 1 0.32 32 3.40 3.40 6 Spindle Oil Change 1/9 1 1 0.32 32 1.13 1.13 7 Variator Assly Washing 1/6 0 2 2.55 32 0.00 27.18 C Cheesewinding 1 Machine Cleaning 1 1 6 1.91 5 9.56 57.33 Monthly workload(Hours) 1 WLS No:EMS/W/05 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower 6 S. No Activity Description Frequency/ Month Crew Category 1.5 26 Time (in Hours) No of Machine 39 234 6 40.77 1 1.274 32 244.61 __________________________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+6H Work Centre Ringframe - - - 1F+6H PF PH PF PH Monthly workload(Hours) WLS No:EMS/W/05 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower S. No Activity Description Frequency/ Month Crew Category Time (in Hours) No of Machine 2 Drum Polishing 1 1 1 2.55 5 12.74 12.74 A 132.59 857.74 B 166.4 166.4 C 79.68% 85.91% D 1 6 E 79.68% 85.91% Proposed Manpower Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) * from main gang ** two from main gang Proposed Utilisation(%) Remarks __________________________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm _________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+1 Jr.F Work Centre Ringframe - - - 1F+1Jr.F F Jr.F F Jr.F A Ringframe M/C Cleaning 1 Cots Change 1/9 Top Apron Change 1/24 Separator Washing 1/9 Top Apron Washing 1/6 Bottom Apron Change 1/9 Spindle Oil Change 1/9 Suction Tube Washing 1/6 Arbor Greasing 1/9 1 Drum Shaft Bearing Greasing 1/3 1 1 2 Variator Checking 1/3 1 0 3 C1, C2 Setting 1/3 2 0 4 Bottom Apron Setting 1/3 2 0 5 Fly Catcher setting 1/3 1 1 6 Bottom Roller Greasing 1/3 1 1 7 Delay Draft Checking 1/3 2 0 8 Drum Filter Cloth Wash 1/6 0 1 Proposed Manpower 0.800 26 WLS No:EMS/W/06 WORK LOAD DETAILS SHEET Shifts Present Manpower R/F Cleaning Gang 6.93 6.93 S. No Activity Description Frequency/ Month Crew Category Time (in Hours) No of Machine Monthly workload(Hours) ________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm _________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+1 Jr.F Work Centre Ringframe - - - 1F+1Jr.F F Jr.F F Jr.F Proposed Manpower WLS No:EMS/W/06 WORK LOAD DETAILS SHEET Shifts Present Manpower S. No Activity Description Frequency/ Month Crew Category Time (in Hours) No of Machine Monthly workload(Hours) 9 Jockey Pulley Greasing 1/9 1 1 1.60 26 5 5 10 Gear Box Oil Changing 1/6 1 1 0.80 26 3 3 11 Spindle Gauge 1/9 3 1 3.20 26 28 9 12 Ring Change 1/48 3 4.80 26 8 0 13 Lappet Hook Change 1/48 3 0.80 26 1 0 14 Spindle Tape change 1/24 2 2 3.20 26 7 7 15 Top Clearer Cloth Changing 1/24 2 2 9.60 26 21 21 16 Bottom Roller Truing 1/9 3 1 4.80 26 42 14 17 Semi Over Hauling 1/30 3 9* 14.40 26 33 22 A 154.14 87.83 B 166.4 166.4 C 92.63% 52.78% D 1 1 E 92.63% 52.78% Proposed Manpower Total Workload per month ( in man hours ) Proposed Utilisation(%) Remarks: Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) * 7 personnel from cleaning gang ________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (mins) Total Workload (mins) A 1 1 1 20.00 20.00 2 1 1 1/45 30.00 30.67 3 1 2/9 33.16 7.37 4 1 2/9 13.37 2.97 5 1 16/45 15.00 5.33 6 1 1 30.00 30.00 7 1 1 32.00 32.00 8 1 1 20.00 20.00 9 1 1 30.00 30.00 10 1 1 15.00 15.00 11 1 1 30.00 30.00 12 1 1 30.00 30.00 B 1 1 7/15 30.00 14.00 2 1 1/15 30.00 2.00 3 1 1/5 25.00 5.00 C 126.00 A 400.34 B 450.0 E 88.96% F 1 G 88.96% Remarks: Count change depend on the count. For calculation it has taken maximum time To assess the amount of time spent on attending running problems, the random samples shifts is selected from the past log books(Jan-2012). The random number is generated and number of problems attended and time spent for the problem is tabulated as follows: Attend running breakdown(28% * 450mins = 126 mins/shift) Total Workload per shift( in man mins) Net Available man-mins per shift Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) TPI Change Running Fitter Activity Description Go round to check the problem in ring frame machine. Check spindle tape, bottom apron and other idle spindle, Drum checking, Spindle speed OHTC cleaning(13 OHTC/shift) Ringframe Cots Checking(8 machines/shift) TFO Count change RT/NT Change Mechanical Check the needle bearing(8 machine/shift) Drum pulley shaft cleaning(8 machines/shift) Check the drum(26 machine/shift) Count change Ringframe&TFO Change from NT to RT Change the jockey pulley cover in reverse direction TPI Change Head Stock cleaning Draft cleaning WLS No: EMS/W/07 WORK LOAD DETAILS SHEET Elegant Spg Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (mins) Total Workload (mins) Running Fitter Activity Description Mechanical Ringframe&TFO WLS No: EMS/W/07 WORK LOAD DETAILS SHEET Elegant Spg Shifts A B C G Shift Total Time(Min s) A 170 A 110 B 155 C 200 B 80 C 165 B 205 A 115 C 50 B 100 1350 Total 13-Jan Date 06-Jan 07-Jan 08-Jan 10-Jan The average arrival rate is 74/10 = 7.4 per shift and the average servicing rate = 8*60 /17.57 = 26.31 per shift 03-Jan The average time to resolve a complaint works out to be 18.24 minutes. 11-Jan 12-Jan / = 0.2812= 28 % 11 5 8 3 04-Jan 01-Jan 10 4 8 74 No of problems 8 7 10 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm __________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 2F+2H Work Centre Autoconer& Cheese winding - - - 1F+2H PF PH PF PH A Autoconer 1 Machine Cleaning 1 2 Bearing Centre Sleeve Silicon Oiling 1 3 Impeller and Wire Mesh Cleaning & Checking 1 4 Drum Polishing 1 5 Suction Fan Bearing Greasing 1/2 6 Magazine Assly. Cleaning & Resetting 1/12 2 1 1.88 7 2.19 1.10 7 Cam Drive Shaft Bearing Greasing 1/3 1 1 1.00 7 2.33 2.33 8 Auto Doffer Cleaning & Lubrication 1/2 1 1 1.00 7 3.50 3.50 9 Over Head Unit Cleaning & Checking 1/3 1 1 1.00 7 2.33 2.33 10 Spindle Unit Opening Cleaning & Checking 1/9 1 1 4.00 7 3.11 3.11 11 Tension Assly & Shutter Cutter Opening & Clg. 1/6 3 1 4.00 7 14.00 4.67 12 Bearing Centre Greasing RH (Base) & LH (Nose) 1/10 1 1 4.00 7 2.80 2.80 13 Splicing Head Servicing 1/6 3 1 6.00 7 21.00 7.00 B Cheesewinding 1 Machine Cleaning 1 2 4 R/F Cleaning Gang 2.00 7 8.06 Time (in Hours) No of Machine Frequency/ Month Crew Category Monthly workload(Hours) 56.00 WLS No:EMS/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower S. No Activity Description ______________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm __________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 2F+2H Work Centre Autoconer& Cheese winding - - - 1F+2H PF PH PF PH Time (in Hours) No of Machine Frequency/ Month Crew Category Monthly workload(Hours) WLS No:EMS/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower S. No Activity Description 2 Drum Polishing 1 3 Pivot Bearing Oiling 1/6 1 1 0.50 5 0.42 0.42 4 Cradle Setting 1/6 1 1 2.00 5 1.67 1.67 5 Upper & Lower Guide Pulley Brg. Oiling 1/6 1 1 2.00 5 1.67 1.67 6 Upper, Lower pulley Setting 1/6 1 1 2.00 5 1.67 1.67 7 Tension Assly. & Cone Peg Setting 1/6 1 1 2.00 5 1.67 1.67 8 S.M.Ceramic Guide Setting 1/6 1 1 1.00 5 0.83 0.83 9 Tension Disc Cleaning 1/6 1 1 0.50 5 0.42 0.42 10 Over Head Blower O.H. 1/12 1 1 2.00 5 0.83 0.83 11 Gear Box Oil Change 1/12 1 1 5.00 2 0.83 0.83 Daily 12 Splicing Checking 26 1 0.0042 60 6.50 0.00 13 Cheese winding Drum Spray 4 1 0.0029 60 0.00 0.70 14 Auto Coner Bobbin Conveyor Belt Clg. 26 1 0.036 7 0.00 6.50 15 Autoconer Over Head Cleaning 16 1 Magitec 26 1 0.10 1 0.00 2.50 R/F Cleaning Gang ______________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm __________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 2F+2H Work Centre Autoconer& Cheese winding - - - 1F+2H PF PH PF PH Time (in Hours) No of Machine Frequency/ Month Crew Category Monthly workload(Hours) WLS No:EMS/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower S. No Activity Description 17 6 Pneumafil 26 1 0.06 6 0.00 9.78 18 Cheesewinding Over Head Cleaning 19 3 RJK 26 1 0.056 3 0.00 4.39 20 2 SSM 26 1 0.032 2 0.00 1.65 21 Go round and attend the idle spindle, Running 26 1 2.000 52.00 0.00 A 127.83 116.71 B 166.4 166.4 C 38.41% 35.07% D 1 2 E 76.82% 35.07% Total Workload per month ( in man hours ) In view of low utilisation of helpers(35.07%), it is recommended to provide two helpers. This has been done mainly to reduce machine down time for the scheduled maintenance activity. Two helpers involved mainly in machine cleaning, where full autoconer machine is stopped. For the fitter activities like Tension Assly & Shutter Cutter Opening & Clg (only twelve drums stops at a time), one fitter and two helpers are proposed. Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) PH- In autowinding includes Jr Fitter & helper. Cheese winding Machine cleaning&drum polishing activities are performed by Ring frame machine cleaning gang. It is considered under their workload sheet. Net Available man-hours per month(8*26*80% = 166.4 hours) ______________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+1H Work Centre TFO - - - 1F+1H PF PH PF PH Machine Cleaning 1 Centring Disc Cleaning & Greasing 1/2 Spindle Oil Topping 1/3 Spindle Oil Change 1/9 Thread Guide Washing 1/3 Variator Assly Washing 1/6 Main Drive Shaft Bearing Greasing 1/3 1 Machine Cleaning-Checking of Machine from TFO Side 1 1 0 0.69 32 21.95 0.00 2 Brake Roller Oiling 1/3 1 1 0.4262 32 4.55 4.55 3 All Gearing & Cam Box Checking 1/3 1 1 0.8524 32 9.09 9.09 4 Gear Shaft Bearing Greasing 1/4 1 1 0.8524 32 6.82 6.82 5 Take-Up & PTR Shaft Bearing Greasing 1/6 1 1 0.8524 32 4.55 4.55 6 Spindle Brg Greasing 1/6 1 1 0.8524 32 4.55 4.55 7 PTR to Pigtail Setting 1/6 1 1 1.7048 32 9.09 9.09 WLS No:EMS/W/09 WORK LOAD DETAILS SHEET Shifts Present Manpower Monthly workload(Hours) R/F Cleaning Gang Proposed Manpower S. No Activity Description Frequency/ Month Time (in Hours) No of Machin e Crew Category _______________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+1H Work Centre TFO - - - 1F+1H PF PH PF PH WLS No:EMS/W/09 WORK LOAD DETAILS SHEET Shifts Present Manpower Monthly workload(Hours) Proposed Manpower S. No Activity Description Frequency/ Month Time (in Hours) No of Machin e Crew Category 8 Cradle Setting Checking 1/6 1 1 0.8524 32 4.55 4.55 9 Thread guide setting 1/6 1 1 0.8524 32 4.55 4.55 10 CLM and Drop Wire Setting Checking 1/6 1 1 0.8524 32 4.55 4.55 11 Jockey Pulley Greasing 1/9 1 1 0.8524 32 3.03 3.03 12 Gearing OverHauling 1/18 1 1 1.7048 32 3.03 3.03 13 Gear Box Oil Change 1/18 1 1 0.8524 32 1.52 1.52 14 Over Head OverHauling 1/18 1 1 0.8524 13 0.62 0.62 Daily 15 T.F.O. Over Head Cleaning(Elgi Jacobi- 12,Nugen-1no)Remove the waste, clean with broom stick 26 1 0.06 13 0 19.25 16 Go round the all TFO machine,notedown the problem in the log book 26*2 times per day 1 0.67 32 35 0 _______________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department ELEGANT SPG A B C G Section Mechanical - - - 1F+1H Work Centre TFO - - - 1F+1H PF PH PF PH WLS No:EMS/W/09 WORK LOAD DETAILS SHEET Shifts Present Manpower Monthly workload(Hours) Proposed Manpower S. No Activity Description Frequency/ Month Time (in Hours) No of Machin e Crew Category 17 Attend th running problem identifed during intial round 26 1 1 1 1 26 26.0 18 Count Change 13 1 0.5 1 7 0 A 149.93 105.73 B 166.4 166.4 C 90.10% 31.77% D 1 1 E 90.10% 63.54% Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) Net Available man-hours per month(8*26*80% = 166.4 hours) Total Workload per month ( in man hours ) _______________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 B ELEGANT SPINNING - ELECTRICAL MAINTENANCE ________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm _________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 B 2.1 I II III G T I II III G T 1 Shift Maintenance Electrician 1 1 1 - 3 1 1 1 - 3 2 General Shift maintenance - Attending to all Electronic break down of machine & maintain the parameter. Perform PM as per the schedule Electronic Tech. - - 1 1 2 - - 1 1 2 3 Humidity plant Humidity attendant 1 1 1 - 3 1 1 1 - 3 4 General shift maintenance - Perform machine PM, Attend to the shift break down Electrician - - - 2 2 - - - 2 2 5 Motor maintenance Motor Fitter - - - 1 1 - - - 1 1 6 H.Plant & Air compressor U/Fitter - - - 1 1 - - - 1 1 7 Trench Cleaning Trench Cleaner - - - 2 2 - - - 2 2 2 2 3 7 14 2 2 3 7 14 Proposed Manpower Remarks Total ELEGANT SPINNING - ELECTRICAL MAINTENANCE Manpower Deployment S. No Section / Work area Designation Present Manpower ___________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 2.0 B 2.2 1 No changes proposed. ELEGANT SPINNING - ELECTRICAL MAINTENANCE Proposed Changes & Observations ________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 BTM SPINNING - PRODUCTION ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.1 I II III G T I II III G T 1 MIXING Mixing Man 7 7 7 - 21 6 6 6 - 18 Beater Opener 1 1 1 - 3 1 1 1 - 3 Waste Sorter - - - 1 1 - - - 1 1 2 BLOW-ROOM Tenter 4 4 4 - 12 4 4 4 - 12 3 CARDING Tenter 3 3 3 - 9 3 3 3 - 9 Lap Carrier 2 2 2 - 6 2 2 2 - 6 4 DRAWFRAME Jobber 1 1 1 - 3 1 1 1 - 3 D/F Tenter 3 3 3 - 9 3 3 3 - 9 5 SIMPLEX S/F Tenter 5 5 5 - 15 5 5 5 - 15 Doffer 3 3 3 - 9 3 3 3 - 9 Floor Cleaner 1 1 1 - 3 1 1 1 - 3 Helper / Reliever 1 1 1 - 3 1 1 1 - 3 6 RING-FRAME Doffing Reliever 3 3 3 - 9 3 3 3 - 9 Checker 1 1 1 - 3 2 2 2 - 6 Sider 13 13 13 - 39 13 13 13 - 39 Doffer 18 18 18 - 54 18 18 18 - 54 Doffer-Leader 3 3 3 - 9 3 3 3 - 9 Floor Cleaner 3 3 3 - 9 3 3 3 - 9 BTM SPINNING - PRODUCTION Manpower Deployment * S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.1 I II III G T I II III G T BTM SPINNING - PRODUCTION Manpower Deployment * S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks Runnning Fitter 1 1 1 - 3 1 1 1 - 3 7 AUTO-CONER Reliever 2 2 2 - 6 1 1 1 - 3 Material Man 2 2 2 - 6 2 2 2 - 6 Kirchi Man 2 2 2 - 6 2 2 2 - 6 Floor Cleaner 2 2 2 - 6 2 2 2 - 6 Helper in Savio No. 7 1 1 1 - 3 1 1 1 - 3 Rejection Rewinder - - - 1 1 - - - 1 1 Winder 16 16 16 - 48 8 8 8 - 24 Jam Cutting - - - 1 1 - - - 1 1 8 CHEESE WINDER Winder 10 10 10 - 30 7 7 7 - 21 Leewha Winder 1 1 1 - 3 1 1 1 - 3 9 TFO Jobber 1 1 1 - 3 1 1 1 - 3 Reliever/Helper 2 2 2 - 6 2 2 2 - 6 Sr. Checker / Jobber - - - 1 1 - - - 1 1 Tenter 12 12 12 - 36 12 12 12 - 36 10 PACKING Checker - - - 3 3 - - - 3 3 _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.1 I II III G T I II III G T BTM SPINNING - PRODUCTION Manpower Deployment * S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks Lot Final Checker - - - 2 2 - - - 1 1 Packer - - - 6 6 - - - 5 5 11 S.Q.C. Checker &Investigator3 2 - 1 6 3 2 - 1 6 127 126 124 16 393 115 114 112 14 355 * The above manpower deployment table is for 30s Count. Total _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.2 3.2.1 I a) b) c) d) M / C
N a m e P r o d u c t i o n
( k g s )
/ H o u r P a r a m e t e r s O u t p u t
Q u a n t i t i e s CARDING- LR C1/3 15.9 12 Kg/ Can D/F Breaker 78.26 10 Kg/Ca n D/F Finisher 209.17 14 kg/Can Speed frame 66.55 108 spindle/ machine 1.3 Kg/ Roving It is assumed that machines are subject to stops at random and unpredictable intervals. It is also assumed that the operator will service a machine with the minimum delay after the machine has stopped, and that if two or more are stopped at one time,he will attend to them by taking the nearest first. This method of servicing is called random tending. Thomas F.O' Connor, provided the table for calculating the machine efficiency and operators workload in this type of multimachine assignment problem in the book: Efficiency and Productivity Tables for Textile Machine Operation, Institute of Textile Technology,Virginia. Proposed Changes & Observations 62.61 119.53 409.54 BTM SPINNING - PRODUCTION o u t p u t
p e r
s h i f t
p e r
m a c h i n e 10.60 Methodology The machine efficiency and operator workload are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of machines to be alloted per personnel. Carding,Drawframe and Speedframe In Carding, Drawframe and Speed frame sections, the operator is responsible for the operation of more than one machine, if two machines stop at a time and require tenter's attention simultaneously,one of the machine must wait until he completes his work on the other. This time loss representing waiting time due to overlapping of machine stoppage is called "Interference loss". The frequency values are taken from the following tables for the repsective sections: I n p u t
p e r
s h i f t
p e r
m a c h i n e 7.71 52.17 167.34 38.03 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.2 Proposed Changes & Observations BTM SPINNING - PRODUCTION 3.2.1 II a) b) c) d) e) Methodology The working pattern of operators in Ringframe, Autconer, Cheese winding and Two-for- One(TFO) is entirely different from the preceding section.In this areas,the operator's services the machine in a cyclical manner and attends to each machines(drums) as he comes to it. The research paper "The Efficiency of N machines Uni-Directionally patrolled by single operative" by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957), is used to arrive the machines running efficiency for the different number of machines handled by the operators in the above sections considering the following working methodology: - Random breakdowns in running time @ each machine/drum N - Number of machines The operative walks round the machines in a defined order and repairs and restarts any machine which is found stopped, passing after inspecting and/or servicing any machine which is running. It is assumed that the machine stops at random with the same mean frequency and independent of each other. The difficulty in dealing with these problems lies in calculating the effect of "interference" which is the term used for incidence of simultaneous stoppages at several machines. In fact, if the optimum number of machines is being controlled by one operative, the machine efficiency required will be a marked feature. The running efficiency is arrived by the following formula provided by the research paper. = Running Efficiency, i.e the percentage of running time to total (stopped + running) time.Stopped means time lost due to interference and breaks and rectification of breaks. K- Mean walking time from one machine to next machine, includes inspection time = (b-1) / [ N{K+(b-1)C}] C - Time to repair and restart the machine Ringframe, Autoconer, Cheesewinding and Two-for-One(TFO) b = exp( NK) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.2 Proposed Changes & Observations BTM SPINNING - PRODUCTION 3.2.1 f) g) h) M / C
N a m e P r o d u c t i o n
( K g s ) /
H o u r s M a c h i n e
P a r a m e t e r s O u t p u t A v a i l a b l e
h o u r s /
S h i f t M / C
a v a i l a b l i t y
l o s t
%
* M / C
A v a i l a b i l i t y
( % ) T o t a l
T i m e
a v a i l a b l e
f o r
p r o d u c t i o n I n p u t
p e r
s h i f t
o f
r e s p
e f f i c i e n c y
p e r
m / c o u t p u t
p e r
s h i f t
o f
r e s p
e f f i c i e n c y
p e r
m / c R/F- Texmaco 8.75 440 spindle/ machine 58 gms Bobbin 8 9.50% 91.5% 7.32 49.27 1105.00 R/F-LR 10.17 432 spindle/ machine 58 gms Bobbin 8 9.50% 91.5% 7.32 57.26 1284.00 Autocone r-Espero 59.68 60 spindle/ machine 2 Kg Cone 8 30% 70.0% 5.6 5761.72 167.09 Cheese Winding- RJK 150 120 spindle/ machine 1 Kg Cheese 8 29% 71% 5.68 186.16 372.32 TFO-VJ 9.32 144 spindle/ machine 2 Kg Cone 8 4% 96.0% 7.68 71.56 35.78 TFO- PRERNA 9.32 144 spindle/ machine 2 Kg Cone 8 4% 96.0% 7.68 71.56 35.78 Methodology The frequency values are taken from the following tables for the repsective sections: The operator workload is calculated by multiplying the time taken for different activities to be performed with the frequency of the activities for the allotted number of machines. The running efficiency values and operator workload are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.2 Proposed Changes & Observations BTM SPINNING - PRODUCTION 3.2.2 I a) II a) III a) b) IV a) V a) b) VI a) VII a) It is recommended to allocate 60 drums per operator(6 machines) and 64 drums per operator in the remaining to machines. The machine efficiency would be decrease where 64 drums allocated per operator. Cheesewinding -Winder Autoconer -Winder Proposed Changes Mixing Blenders: Deploy five personnel as the packer instead of present six personnel. The proposed utilisation would be 86.74% Packing - Packers In view of low utilisation (46.43% ), it is recommended to deploy one personnel as reliever instead of the present two personnel who is presently releiveing autoconer winder in machine 2,1,5 & 6. The operator workload would be reduced as the number of winders to be relieved is become half. It is suggested to deploy two cheker per shift as checker (three units) in ringframe section instead of present one person per shift. Based on utilisation (74.47 %), it is recommended to deploy six personnel instead of the present seven personnel in a shift for three mixing blenders operation. The proposed utilisation of six personnel would be 86.88% From the analysis,it is found that the optimum number of drums to be assigned is 60 drums per operator. At present, one operator is alloted 30 drums(in two machines 32 drums/operator). Autoconer -Reliever Deploy one personnel for lot final checking activity instead of two personnel persently. The proposed utilisation would be 94.33% In BTM Spinning, the four cheese winding machines are in one section and two machines are in unit-3. Based on the above findings, two personnel is recommended for unit-3 machines(2 nos) and five personnel for four machines in the unit-1 &2. From the analysis,it is found that the optimum number of drums to be allocated is 120 drums per operator. At present, one operator is assigned 64,76,80 drums depends on the machine capacity. Packing - Lot final Checker Ringframe -Checker ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 3.0 3.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 BSP/W/09 BSP/W/07 Ringframe-Doffer BSP/W/14 Speedframe -Reliever BSP/W/11 Speedframe-Floor Cleaner BSP/W/12 Ringframe-Sider BSP/W/13 & A Speedframe Tenter BSP/W/23 BTM SPINNING - PRODUCTION Workload Sheets Summary Area of work WLS Number Mixing Man BSP/W/01 Speedframe Doffer BSP/W/10 Drawframe-Jobber Ringframe-Doffer Reliever BSP/W/16 Autoconer-Winder BSP/W/22 Ringframe-Running Fitter BSP/W/17 Ringframe-Checker BSP/W/18 Ringframe-Floor cleaner BSP/W/19 Beater Opener BSP/W/02 Blowroom Tenter BSP/W/04 Waste Sorter BSP/W/03 Carding Tenter BSP/W/05 Lap Carrier TFO- Jobber BSP/W/30 Ringframe-Doffer leader BSP/W/15 Cheesewinding-Winder(SSM) BSP/W/28 Cheesewinding-Leewha BSP/W/29 Autoconer-Reliever BSP/W/20 TFO- Tenter BSP/W/33 & A & B TFO- Sr.Jobber BSP/W/32 BSP/W/06 Drawframe Tenter BSP/W/08 BSP/W/27 BSP/W/26 Autoconer-Helper in Savio No.7 BSP/W/37 QA- Checker & Investigator Packing - Checker BSP/W/34 Packing -Lot Final Checker BSP/W/35 Packing -Packer BSP/W/36 Autoconer-Material Man BSP/W/21 Autoconer-Kirchiman Autoconer-Jam Cutting TFO- Reliever BSP/W/31 Autoconer-Floor Cleaner BSP/W/25 Autoconer-Rejection rewinder BSP/W/24 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7 7 7 - Designation Proposed Manpower 6 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 a 1 1 4.95 4.95 b 1 1 2.48 2.48 c 2 1 10.50 21.01 d 1 1 4.00 4.00 d 1 1 1.13 1.13 2 a 2 5 3.92 39.15 b 1 5 1.42 7.11 c 1 2275 0.026 59.32 d 1 2275 0.028 62.73 e 1 20 3.85 77.00 f 1 1225 0.12 144.12 g 1 41 2.07 84.87 h 1 3500 0.08 280.00 3 a b 4 a b 5 Bring the hot water in a plastic drum from geyser Mix the AS-200 & AS-400 one by one in the hot water WLS No: BSP/W/01 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Blender Mixing Boy Activity Description Spin Finish Solution preparation ( No 1 & 3)(in front of shift incharge) Bring the chemical ( AS 400) from the plastic drum in the presence of supervisor after weighing Mixing Room Bring the chemical ( AS 200) from the plastic drum in the presence of supervisor after weighing 1 3500 Keep the empty chemical cans in the respective area Layering Bring the polyester bags from respective area to near the machine Open the bales of polyester bags Take the polyester from bags and put it on the belt conveyor(feed end) Spread the blender output (inside the bin) evenly by manual Spray the spin finish solution uniformly on the layer of polyester fibre using spray pump Fill the viscose in the bag from the viscose room 0.11 385.00 Spread the blender output (inside the bin) evenly by manual Final Toppling (Mixing) Move the bags from room to mixing room Do layering by spreading polyester and viscose on the alternate layer by manually First Toppling (Mixing) Cut the material vertically in the mixing bin, lift and feed on blender belt conveyor Second Toppling (Mixing) Cut the material vertically in the mixing bin, lift and feed on blender belt conveyor 1 3500 0.11 385.00 Spread the blender output (inside the bin) evenly by manual ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7 7 7 - Designation Proposed Manpower 6 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: BSP/W/01 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Blender Mixing Boy Activity Description Mixing Room a b 6 a b c d A 2005.03 B 17 C 2345.88 D 450 E 74.47% F 6 G 86.88% Target - 2500 Kg /person * 7 persons / shift =17500 kg / shift . Each batch have 5 steps. It becomes 3500 kg batch ( 3500 * 5 steps = 17500 kg) Cut the material vertically in the mixing bin, lift and feed on blender belt conveyor 1 3500 0.11 62.17 Clean the blender & beater Clean the floor area around the machine To remove the jam of beater & blender ( if any) 1 62.17 385.00 Spread the blender output (inside the bin) evenly by manual Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Lot Change ( Shade Change) Clean the bins before starting the mixing. 1 As minimum two personnel required per mixing room, six personnel is being recommended per shift for three blowrooms. Proposed Utilisation(%) Remarks: Present Utilisation(%) Proposed Manpower per shift P/V (65/35) mixing is considered. Hence , 3500 *65% Polyester = 2275 kg / shift , 3500 * 35% Viscose =1225 kg/ shift. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 19.00 19.00 2 a 1 41 0.09 3.69 b 1 41 0.29 11.89 c 1 41 0.35 14.27 d 1 41 1.00 41.08 e 1 41 0.38 15.38 f 1 41 0.05 2.05 3 1 3 15.00 45.00 A 152.36 B 14 C 173.68 D 450 E 38.60% F 1 G 38.60% Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Viscose required per shift ( Mixing WLS sheet) = 1015 kg Number of Viscose bags to be opened = 1015/ 25 bag = 41 bag/shift Collect the empty bag, tags and keep aside Clean the beater & bin (colour change) Basic Workload per Shift ( in man minutes) Take the bags and move back to the belt conveyor Open the bag (25 Kg / Bag) Dump the viscose on the belt conveyor from bag In the middle go to room and spread the opened the viscose manually(time per bag) Net Available man-mins Total Workload ( in man minutes ) Mixing Room Viscose bag (Fibre dyeing section) Move from belt conveyor of beater to bags storage area(mean distance is considered) Rest & Relaxation Allowances ( % ) Beater Beater Opener Activity Description Clean the bow room walking path from (1-5) and area under cleaning using the broom stick(lengthy) WLS No: BSP/W/02 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 357 KG 164.22 164.22 2 1 24 bags 16.80 16.80 3 1 24 bags 120.00 120.00 4 1 4 32.00 32.00 A 333.02 B 13 C 376.31 D 480 E 78.40% F 1 G 78.40% Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Weight the waste and maintain the record in the register Put the waste in the bags and placed in the waste room category wise. Department general work. Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Sort out the waste shade wise and category wise WLS No:BSP/W/03 WORK LOAD DETAILS SHEET BTM Shifts A B C G PREPARATORY MIXING WASTE SORTER Activity Description ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 4 4 4 - Designation Proposed Manpower 4 4 4 - Sl. No Crew Size Freq/ machi ne / Shift Basic Time (Mins) Total Time (Mins) 1 a 1 1 2.00 2.00 b 1 1 5.00 5.00 2 1 828 0.076 62.93 3 1 57 0.290 16.53 4 1 57 0.096 5.47 5 1 57 0.175 9.98 6 1 57 0.510 29.07 7 1 54 0.150 8.10 8 1 3 2.310 6.93 9 1 2 5.00 10.00 10 1 0.97 120.00 116.40 A 272.41 B 15 C 313.27 D 450 E 69.61% F 1 G 69.61% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Rejection (5%) = 54.33 *5% = 2.71 laps Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Break rejected laps into small tufts and feed them equally Clean the machine area at the shift end and at intervals. Clean the machine during lot change Remarks: Machine capacity - 107.63 kg / 14.5 kg lap = 7.42 * 7.33 hours = 54.33 laps Bring the materials from mixing bin room (vertical cut)& feed on the machine lattice Keep the spindle on machine stand for next lap Keep the lap rod in the machine for new lap Remove the laprod from the machine and keep on the weighing machine and ensure that lap weight is under tolerance limit. +/-200 gms Take the polycover and tie on the lap Mixing Blowroom Tenter Activity Description Shift Changeover activities Check the machine parameters like length counter,count,batch,shade no etc Counter check weight of 5 laps of out going shift. Lot Change = 350 / month = 350 / (90 shifts*4 machine) =0.97 / shift/machine WLS No: BSP/W/04 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Keep the lap in the respective zone ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. No C l a s s i f i c a t i o n F r e q /
8
h o u r s
/
m a c h i n e
N o
o f
m a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) 1 t2 1 9 1.00 13 10.17 13 t2 7.68 9 0.24 16 19.35 14 t2 7.68 9 0.31 13 23.98 15 t2 7.68 9 0.44 15 35.22 16 t2 7.68 9 0.21 14 16.56 21 t2 10.64 9 0.63 13 68.17 22 t2 10.64 9 0.35 13 37.44 23 t 0.4256 9 1.15 13 4.98 24 t1 2 9 1.06 13 21.56 25 t2 2 9 1.50 13 30.51 26 t1 2 9 1.61 13 32.80 27 t1 2 9 2.49 13 50.65 28 t1 2 9 1.21 13 24.55 29 t1 1 2 4.36 13 9.85 31 t2 1 9 1.02 13 10.37 33 t1 1 1 0.60 13 0.68 34 t1 1 1 1.02 13 1.15 35 t1 1 1 4.10 13 4.64 36 t 0.149 9 15.00 13 22.73 WLS No: BSP/W/05 WORK LOAD DETAILS SHEET BTM Shifts A B C G Spinning Carding 3 3 Tenter 3 3 LR Load new lap rod on the machine stand from trolley/floor Activity Description Reset the machine parameter at the shift starting Front side wheel-LR Remove the lap cover from the lap Feed the lap on the machine (from machine stand to roller) Remove the empty lap rod from the machine & place on the trolley Bring the empty can and keep on the machine Move the filled can from the machine and keep in the respective area Attend the sliver cut problem Front side top-LR Thomas O Connor table Front side bottom-LR Back side bottom-LR side door-LR Clean the work area around the machines Clean the bruce wheel at the shift end and collect the waste Bring the yellow bag from blow room Move the waste collected to blow room section yellow bag Hand over the waste collected in the carding section after weighment at the shift end Clean the machine at the time of lot change T (M/C running time per cycle) = 480 mins per shift *9 machines =4320 mins t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 145.88 mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 - Designation Proposed Manpower 3 - Sl. No C l a s s i f i c a t i o n F r e q /
8
h o u r s
/
m a c h i n e
N o
o f
m a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) WLS No: BSP/W/05 WORK LOAD DETAILS SHEET BTM Shifts A B C G Spinning Carding 3 3 Tenter 3 3 Activity Description t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running ) = 251.77 mins t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 27.71 mins The machine efficiency and respective operative workload for the values above is found out from the Thomas O' Connar table and tabulated below: No of Machines Machine Efficiency(%) Operator workload(%) 9 94.31% 83.57% Lot Change = 350 / month = 350 / (90 shifts*26 machine) =0.149 / shift/machine The above values are depicted in the graph to find out the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: From the graph, the optimum number of machine can be allotted per operator is 10 nos. Remarks: 10 93.27% 91.83% 11 92.10% 99.76% 9 10 11 Machine Efficiency(%) 94.31% 93.27% 92.10% Operator Workload(%) 83.57% 91.83% 99.76% 75.00% 80.00% 85.00% 90.00% 95.00% 100.00% 105.00% E f f i c i e n c y ( % ) Carding-LR+Crossrol ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 17 per lap man 59.84 59.84 2 1 124 per lap man 97.96 97.96 3 1 17 per lap man 50.32 50.32 4 1 1 40.00 40.00 5 1 2 97.20 97.20 A 345.32 B 14 C 393.66 D 450 87.48% F 1 G 87.48% Proposed Manpower per shift Proposed Utilisation(%) Remarks: Two personnel is recommended per shift for the carding section. The above workload sheet is for single personnel Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Creel the lap to the carding machine Collect and send back the lap rod to the blowroom section. Relieve the card tenter for the lunch and tea break General cleaning of the machine and lot change Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Carry the lap from blowroom section to the carding machine. WLS No: BSP/W/06 WORK LOAD DETAILS SHEET BTM Shifts A B C G PREPARATORY CARDING LAP MAN Activity Description ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 15.83 15.83 2 1 1 30.00 30.00 3 1 1 30.00 30.00 4 1 1 10.83 10.83 5 1 14.75 % of 5.60 hrs 49.56 49.56 6 1 4 14.68 14.68 7 1 2 S/F m/c & 4 D/F m/c 8 1 1 9 1 4 41.40 41.40 A 276.31 B 13 C 312.23 D 450 E 69.38% F 1 G 69.38% CP change in case of lot change Basic Workload per Shift ( in man minutes) Help doffer & helper in lot change cleaning Wrapping of new lot & checking for defect Roller treatment 84.00 84.00 Cot belt treatment Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Proposed Manpower per shift Proposed Utilisation(%) Net Available man-mins Present Utilisation(%) Ensure the m/c are attended in case of stoppages/breakdowns WLS No: BSP/W/07 WORK LOAD DETAILS SHEET BTM Shifts A B C Drawframe &Simplex JOBBER G Drawframe &Simplex Adjust hands shortage Relieve 1 tenter for lunch Activity Description Collect cards from workers and take charge of the dept. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 Designation Proposed Manpower 3 Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s / m a c h i
n e B a s i c
T i m e
( M i n s ) N o
o f
m a c h i n e s A l l o w a n c e
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% ) T o t a l
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( M i n s ) A 1 t2 52.17 0.46 2 13 54.24 2 t2 52.17 0.40 2 13 47.16 3 t2 52.17 0.20 2 13 23.58 4 t2 62.61 0.24 2 13 33.96 5 t 4 0.98 2 13 8.86 6 t 4 0.50 2 13 4.52 7 t 3.7566 0.40 2 13 3.40 8 t 0.648 0.17 2 13 0.24 B 1 t2 167.34 0.25 1 13 47.27 2 t2 167.34 0.29 1 13 54.84 3 t2 119.53 0.26 1 13 35.12 4 t2 119.53 0.27 1 13 36.47 5 t 4 0.98 1 13 4.43 6 t 4 0.50 1 13 2.26 7 t 4.7812 0.55 1 13 2.97 8 t 4.7812 0.75 1 13 4.05 9 t 1.29 0.17 1 13 0.24 Breaker Spinning Drawframe Tenter Activity Description 3 3 3 Bring the full materials cans(Carding sliver) from carding section Replace the empty carding sliver cans with the full carding sliver can &piece the sliver in LDO/6 Return the empty cans to the carding section & keep in the area earmarked Place the empty cans in LDO/6 for doffing Change top rolls once in every two hours Clean the drafting zone and filter box once in every two hours Do the lot change cleaning Piece the ends during breakages Do the lot change cleaning Finisher Move the LDO/6 material cans to the Cherry Hara D/F(input) Replace the empty cans by the materials cans & join the sliver Place back the empty cans in Cherry Hara for doffing Remove the materials cans from cherry hara & Keep in Simplex area Change top rolls once in every two hours Clean drafting zone and filter box once in every two hrs. Piece the ends during breakages Remove the roller jam 3 BTM Spinning Shifts WLS No: BSP/W/08 WORK LOAD DETAILS SHEET A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 Designation Proposed Manpower 3 Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s / m a c h i
n e B a s i c
T i m e
( M i n s ) N o
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( M i n s ) Spinning Drawframe Tenter Activity Description 3 3 3 3 BTM Spinning Shifts WLS No: BSP/W/08 WORK LOAD DETAILS SHEET A B C G C t1 1 3.00 1 13 3.39 65.29% The machine efficiency and respective operative workload for the values above is found out from the Thomas O' Connar table and tabulated below: t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 30.98 mins No of Machines Machine Efficiency(%) Operator workload(%) Collect waste and hand over to mixing for weighment t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running ) = 332.64 mins Thomas O Connor table t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 3.39 mins T (M/C running time per cycle) = 480 mins per shift *3 machines = 1440 mins 79.41% 89.12% 95.02% 5 4 The above values are depicted in the graph to find out the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: 69.93% 62.14% 85.39% 77.89% 3 6 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 Designation Proposed Manpower 3 Sl. No C l a s s i f i c a t i o n F r e q /
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( M i n s ) Spinning Drawframe Tenter Activity Description 3 3 3 3 BTM Spinning Shifts WLS No: BSP/W/08 WORK LOAD DETAILS SHEET A B C G From the graph, Optimum number of machine to be alloted per operator is 4. But, the breaker and finisher is a group of machine and also the layout of BTM(unit1,2 &3 away from each other), it is not recommended to spilt and allocate to separate personnel. The above workload sheet is for machine in Unit-1. It has been selected for calculation ,because the capacity of machine is high in unit-1 compared to unit-2 &3. It is recommended that one operator per two breaker and one finisher machine. Lot Change = 350 / month = 350 / (90 shifts*3 machine) =0.97 / shift/machine Remarks: 3 4 5 6 Machine Efficiency(%) 85.39% 77.89% 69.93% 62.14% Operator Workload(%) 65.29% 79.41% 89.12% 95.02% 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00% E f f i c i e n c y ( % ) Drawframe-Tenter ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 5 Designation Proposed Manpower 5 Sl. No C l a s s i f i c a t i o n F r e q /
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H o u r s / m a c h i n e N o
o f
M a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e ( % ) T o t a l
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( M i n s ) 1 t2 38.03 2 0.60 13 51.57 2 t2 38.03 2 0.22 13 18.91 3 t1 4 2 2.65 13 23.96 4 t1 4 2 1.65 13 14.92 5 t1 4 2 1.00 13 9.04 6 t 4 2 5.00 13 45.20 7 t 4.095 2 0.62 13 5.74 8 t 4.095 2 1.11 13 10.27 9 t 4.095 2 0.75 13 6.94 10 a t2 0.43 2 21.60 13 20.99 b t2 0.43 2 37.80 13 36.73 c t 0.43 2 90.00 13 87.46 11 t 0.098 2 60.00 13 13.29 1 2 3 4 The machine efficiency and respective operative workload for the values above is found out from the Thomas O' Connar table and tabulated below: Idle spindle Remove the Top/Bottom Roller jam Piece the broken roving Move empty can near the D/F Move the full D/F cans from D/F can storage area to S/F machine & put the sliver on the top roller Lot change Perform Count changing activity(replace empty can with the full can, piece the sliver with the roving &start the machine) Move the full D/F cans (from D/F can storage area) to S/F machine & replace the empty cans. Clean the draft zone(green box front side) Clean the top roller clearer cloth(back side) Keep the empty cans colour wise near the D/F can storage area Activity Description Clean the fan waste Calculation of workload using Thomas O Connor table: T (M/C running time per cycle) = 480 mins per shift *2 machines = 960 mins t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 47.91 mins Machine stoppage for doffing t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running ) = 128.20 mins t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 168.90 mins Piece the ends of Finisher Sliver Piece the sliver with the roving 5 Tenter 5 5 Speed Frame 5 WLS No: BSP/W/09 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 5 Designation Proposed Manpower 5 5 Tenter 5 5 Speed Frame 5 WLS No: BSP/W/09 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning Count Change = 80 / month = 80 / (90 shifts*9 machine) = 0.098 / shift/ unit 4 65.61% 94.32% Lot Change = 350 / month = 350 / (90 shifts*9 machine) =0.43 / shift/machine The above values are depicted in the graph to find out the optimum (where running efficiency & operative workload meets) number of drums to be allotted per personnel and presented below: 2 79.29% 56.99% No of Machines Machine Efficiency(%) Remarks: From the graph, Optimum number of machine to be alloted per operator is two. 3 72.79% 78.48% Operator workload(%) Whereas in Count change, all the activity is performed, when machine is in stopped condition. Doffers helps during count change. Lot change is being performed for half of the machine and during that time the remaining half machine is in running condition. Machine gets stopped only when piecing of sliver with roving done. It is considered that all the activities for lot change has been performed only by the tenter. 2 3 4 Machine Efficiency(%) 79.29% 72.79% 65.61% Operator Workload(%) 56.99% 78.48% 94.32% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% E f f i c i e n c y ( % ) Speedframe -Tenter ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower 3 3 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 3 3600 216.00 648.00 2 3 3600 126.47 379.42 3 3 1 10.00 30.00 4 3 1 30.00 90.00 A 1147.42 B 13 C 1296.59 D 1350 E 96.04% F 1 G 96.04% To clean the simplex machine (Bobbin rail and spindle section) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Doffing of the rove bobbin at the doff of the machine Remarks: SIMPLEX Keep the doffed bobbin in the racks Sorting the simplex waste and send it to the blowroom section. G SIMPLEX DOFFER Activity Description WLS No: BSP/W/10 WORK LOAD DETAILS SHEET BTM Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 6 tenter 378.00 378.00 A 378.00 B 13 C 427.14 D 450 E 94.92% F 1 G 94.92% 6 tenter - (5 S/F & 1 D/F) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Relieve the machine tenter for lunch and tea break and do the tenter activities during that time. Remarks: SIMPLEX Basic Workload per Shift ( in man minutes) G SIMPLEX RELIEVER Activity Description WLS No: BSP/W/11 WORK LOAD DETAILS SHEET BTM Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - Designation Proposed Manpower 1 1 - Sl. No Crew Size Total Sq. meter Freq/ shift Basic Time (Mins) Total Time (Mins) 1 1 8234 4 350.00 350.00 A 350.00 B 13 C 395.50 D 450 E 87.89% F 1 G 87.89% WLS No: BSP/W/12 WORK LOAD DETAILS SHEET BTM Shifts B C G SIMPLEX SIMPLEX Floor cleaner Activity Description Clean the preparatory work area Basic Workload per Shift ( in man minutes) A 1 1 Remarks: 24702 sq.feet = 8234 sq.met per shift Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 13 - Designation Proposed Manpower 13 - Sl. No Crew Size Freq/ Shift No of Machi ne Basic Time (Mins) Allo wanc e (%) Total Time (Mins) 1 1 432 1.5 0.13 13 95.19 2 1 1 1 20.52 13 23.19 3 1 51.34 4 0.54 13 125.31 1 51.34 4 0.22 13 51.05 1 51.34 4 0.40 13 92.82 4 1 0.081 4 4.00 13 1.46 1 0.081 4 4.00 13 1.46 5 1 0.018 4 4.00 13 0.33 1 0.018 4 4.00 13 0.33 6 1 18 4 0.02 13 1.87 1 18 4 0.41 13 33.36 1 18 4 0.02 13 1.87 7 1 4 4 0.33 13 5.97 A 434.21 B 480 C 90.46% 5 13 Sider 13 13 WLS No: BSP/W/13 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning Remove the top clearer, clean and keep on the lammba Put the top clearer on the machine after the count change over Activity Description Top clearer cleaning Ringframe- LR(432 Spindle) 13 Drafting zone cleaning To attend idle spindles in his m/c Remove roller lapping using hexablade knife Piece the broken threads Roving cut join Lot change Present Utilisation(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). Count change Remove the top clearer, clean and keep on the lammba Put the top clearer on the machine after the count change over S/F Roving Change Bring the S/F roving near the machine from the S/F roving storage area Replace the empty rovings with the new rovings Place the empty rovings in the area To collect pnumafil waste and hand over it to mixing for weighment at the shift end. Basic Workload per Shift ( in man minutes) Net Available man-mins = (b-1) / [ N{K+(b-1)C}] ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 13 - Designation Proposed Manpower 13 - Sl. No Crew Size Freq/ Shift No of Machi ne Basic Time (Mins) Allo wanc e (%) Total Time (Mins) 13 Sider 13 13 WLS No: BSP/W/13 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning Activity Description Ringframe- LR(432 Spindle) 13 1944 (432*4.5) 83.40% The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Spindles Running Efficiency () (%) Operator workload(%) - 0.000499, N - 1728 (432*4), C - 0.22, K - 0.03 1728 (432*4) 84.97% 90.46% 106.91% Remarks: Lot Change = 350 / month = 350 / (90 shifts*48 machines) =0.0812 / shift The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: From the graph, the optimum number of spindle can be alloted per operator is 1728 nos Count Change = 80 / month = 80 / (90 shifts*48 machines) = 0.018 / shift Speedframe rovings is changed mainly during the lot change and Count change. As the activities are performed during lot&count change it is being considered under the doffers workload. But small percentage(30%) of S/F rovings is being changed by sider ( while running).Number of rovings to be feed per ringframe per shift equals to 58 rovings. 98.69% 2160 (432*5) 81.89% 1728 (432*4) 1944 (432*4.5) 2160 (432*5) Running Efficiency () (%) 84.97% 83.40% 81.89% Operator workload(%) 90.46% 98.69% 106.91% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) Ringframe-LR ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 13 - Designation Proposed Manpower 13 - Sl. No Crew Size Freq/ Shift No of Machi ne Basic Time (Mins) Allo wanc e (%) Total Time (Mins) 13 Sider 13 13 WLS No: BSP/W/13 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning Activity Description Ringframe- LR(432 Spindle) 13 Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle) = Machine running hours ( 8 hours * 0.915 = 7.32 hours) Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 1728 Spindle Actual machine efficiency (%) = 7.32 hours *0.8497 = 6.219 hours/shift * Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle is collected from the management ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No C r e w
S i z e F r e q /
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( % ) T o t a l
T i m e
( M i n s ) 1 1 440 1.5 0.13 13 96.95 2 1 1 1 20.52 13 23.19 3 1 44.2 4.5 0.54 13 121.37 1 44.2 4.5 0.22 13 49.45 1 44.2 4.5 0.40 13 89.90 4 1 0.081 4.5 5.00 13 2.06 1 0.081 4.5 5.00 13 2.06 5 1 0.018 4.5 5.00 13 0.46 1 0.018 4.5 5.00 13 0.46 6 1 15 4.5 0.03 13 2.29 1 15 4.5 0.43 13 32.80 1 15 4.5 0.02 13 1.75 7 1 4 4.5 0.33 13 6.71 A 429.45 B 480 C 89.47% - Sider - - - WLS No: BSP/W/13 A WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning S/F Roving Change Remove the top clearer, clean and keep on the lammba Put the top clearer on the machine after the count change over Activity Description Top clearer cleaning Ringframe- Texmaco(440spindle) Drafting zone cleaning To attend idle spindles in his m/c Remove roller lapping using hexablade knife Piece the broken threads Bring the S/F roving near the machine from the S/F roving storage area Replace the empty rovings with the new rovings Place the empty rovings in the area To collect pnumafil waste and hand over it to mixing for weighment at the shift end. Present Utilisation(%) Roving cut join Lot change Count change Remove the top clearer, clean and keep on the lammba Put the top clearer on the machine after the count change over Total Workload per Shift ( in man minutes) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No C r e w
S i z e F r e q /
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( M i n s ) - Sider - - - WLS No: BSP/W/13 A WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning Activity Description Ringframe- Texmaco(440spindle) 5 The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Spindles Running Efficiency () (%) Operator workload(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). 2200 (5*440) 81.65% 96.63% = (b-1) / [ N{K+(b-1)C}] - 0.0004981, N - 1760(440*4), C - 0.22, K - 0.03 1760 (4*440) 84.76% 82.31% 1980 (4.5*440) 83.18% 89.47% The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: 1760 (4*440) 1980 (4.5*440) 2200 (5*440) Running Efficiency () (%) 84.76% 83.18% 81.65% Operator workload(%) 82.31% 89.47% 96.63% 70.00% 75.00% 80.00% 85.00% 90.00% 95.00% 100.00% E f f i c i e n c y ( % ) Ringframe-Texmaco ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No C r e w
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T i m e
( M i n s ) - Sider - - - WLS No: BSP/W/13 A WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning Activity Description Ringframe- Texmaco(440spindle) Remarks: Speedframe rovings is changed mainly during the lot change and Count change. As the activities are performed during lot&count change it is being considered under the doffers workload. But small percentage(30%) of S/F rovings is being changed by sider ( while running).Number of rovings to be feed per ringframe per shift equals to 50 rovings. From the graph, the optimum number of spindle can be alloted per operator is 1760 nos Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle) = Machine running hours ( 8 hours * 0.915 = 7.32 hours) In BTM, there are six number of texmaco machine with 400 spindles are there. As only the number spindles are less than the 440 spindle texmaco make. The above workload sheet is applicable to that machines also. Count Change = 80 / month = 80 / (90 shifts*48 machines) = 0.018 / shift Lot Change = 350 / month = 350 / (90 shifts*48 machines) =0.0812 / shift Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 1760 Spindle Actual machine efficiency (%) = 7.32 hours *0.8476 = 6.204 hours/shift * Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle is collected from the management ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 Designation Proposed Manpower 6 6 Sl. No Crew Size Freq/ Shift No of Spindl es/mac hine Basic Time (Mins) Total Time (Mins) 1 7 1 5.00 35.00 2 a 5 63 0.48 151.20 b 5 63 440 1.81 570.90 c 5 63 440 0.88 277.20 d 5 63 1.00 315.00 3 a 1 440 0.02 8.80 b 1 440 0.03 11.88 c 1 440 0.04 18.48 d 1 1 3.58 3.58 4 a 1 1.296 440 0.02 10.69 b 1 1.296 440 0.01 7.13 c 1 1.296 440 0.08 48.33 d 1 1.296 440 0.41 233.80 e 1 1.296 440 0.12 68.43 f 1 1.296 440 0.01 7.13 5 a 1 0.296 2 side 1.98 0.59 b 1 0.296 440 0.012 1.55 c 1 0.296 440 0.078 10.13 d 1 0.296 2 side 1.98 0.59 e 1 0.296 440 0.02 2.44 f 1 0.296 440 0.01 1.63 g 1 0.296 440 0.08 10.42 h 1 0.296 440 0.41 53.40 6 G Spinning B Ringframe WLS No: BSP/W/14 WORK LOAD DETAILS SHEET BTM Spinning Shifts A C Bobbin change(Doffing) Take trays, Collect the empty R/F bobbins from storage area near entrance, Reach the machine spot Remove the filled R/F bobbin from the spindle & Put the empty R/F bobbin in the R/F spindle Keep the collected R/F bobbin trays in the R/F Sorting area Piece the roving with the bobbin Doffer Activity Description Shift Release activity 6 Open the doom Put the new count lammba on the machine Count Change Ring Travellour Change Remove the Old ring travellour Arrange S/F from racks to trolley Join the thread roving and bobbin Bring the S/F roving near the machine from the S/F roving storage area Put the S/F roving in the creel Bring the S/F roving near the machine from the S/F roving storage area(40 rovings/trolley) Put the S/F roving in the creel Join the thread roving and bobbin Remove the empty S/F bobbins from the creel and keep near the rack Move the empty trolley back to S/F rovings area Remove the lammba for the old count 1 machi ne/unit Clean the machine area after ring travellour change using magnet bar Put the new ring travellour Arrange S/F rovings from racks to trolley(40 rovings) Join the thread after inserting the new ring Lot Change Close the doom ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 Designation Proposed Manpower 6 6 Sl. No Crew Size Freq/ Shift No of Spindl es/mac hine Basic Time (Mins) Total Time (Mins) 6 G Spinning B Ringframe WLS No: BSP/W/14 WORK LOAD DETAILS SHEET BTM Spinning Shifts A C Doffer Activity Description 6 i 1 0.296 440 0.12 15.63 j 1 0.296 440 0.01 1.63 6 a 1 1 5 9.00 45.00 b 1 1 5 3.01 15.06 c 1 1 5 2.71 13.54 d 1 1 5 2.87 14.36 e 1 1 5 0.99 4.95 f 1 1 900 0.04 34.99 g 1 1 900 0.05 47.82 A 2041.25 B 8 C 2204.55 D 480 E 76.55% F 6 G 76.55% Lot Change = 350 / month = 350 / (90 shifts*3 Unit) =1.296 / shift/unit As reliever is provided, net available man mins becomes 480 mins. As the above activity frequency is for 480 mins. Clean the creel plastic cover top area for fly Spindle gap cleaning Jockey pulley cleaning Clean using the broom stick Remove the empty S/F bobbins from the creel and keep near the rack Move the empty trolley back to S/F rovings area Cleaning Clean the creels (below the cover) area for fly One Doffing team consist 6 Doffers and one Co-ordinating person.Each unit have one doffing team. Rest & Relaxation Allowances ( % )(Total-13%-5% relieved by reliever+8% added in the workload) Total Workload ( in man minutes ) Net Available man-mins No of rovings consumed per shift/unit = 900 nos ( from machine capacity) Ring travellour Change -1 machine/ shift / unit Basic Workload per Shift ( in man minutes) The doffers maximum workload is on Texmaco 440 spindle machine comapred to 400 spindle(texmaco) and LR (432 Spindle). Hence it has taken for calculation and shown above. Present Utilisation(%) Proposed Manpower per shift Clean the S/F empty rovings(using knife remove the threads) Arrange the cleaned S/F empty rovings in the racks Count Change = 80 / month = 80 / (90 shifts*3 Unit) = 0.296 / shift/ unit Proposed Utilisation(%) Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower 3 3 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.00 5.00 2 1 3 63.00 189.00 3 4 5 A 194.00 B 13 C 219.22 D 450 E 48.72% F 1 G 48.72% B C G Spinning Ringframe Doffer-Leader Activity Description Shift Release activity WLS No: BSP/W/15 WORK LOAD DETAILS SHEET BTM Spinning Shifts A The above activitiy(3,4 &5) is supervisory in nature. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Relieve the Ringframe sider in that unit(Tea,Lunch Or breaks) Co-ordinate the doffing team effectively for minimising the machine downtime for changover Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Discussing with the supervisors, siders Monitor and perform the scheduled activities like ring travellours change, machine cleaning and lot change/count change with the doffers ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower 3 3 3 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 6 63 375.00 A 375.00 B 13 C 423.75 D 450 E 94.17% F 1 G 94.17% WLS No: BSP/W/16 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Spinning Proposed Manpower per shift Proposed Utilisation(%) Remarks: Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person Activity Description Relieve the ringframe-doffers for breaks Present Utilisation(%) Ringframe Reliever-Doffers Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 96 93.12 93.12 2 1 6 120.00 120.00 3 1 1 90.00 90.00 A 303.12 B 13 C 342.53 D 360 E 95.15% F 1 G 95.15% G RINGFRAME Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) WLS No: BSP/W/17 WORK LOAD DETAILS SHEET BTM Shifts A B C RINGFRAME RUNNING FITTER Activity Description Check the ratched pawl of all the ringframe and TFO machines Change the machine particular as per the requirement Attend the ringframe & TFO idle spindle due to mechanical faults Total Workload ( in man minutes ) Net Available man-mins Proposed Manpower per shift Proposed Utilisation(%) Remarks: Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 62.50 62.50 2 1 4 20.00 20.00 3 1 1 65.00 65.00 4 1 3 22.17 66.50 5 1 3 36.00 36.00 6 1 3 15.00 45.00 7 1 1 30.00 30.00 8 1 3 31.67 95.00 9 1 2 15.00 30.00 A 450.00 B 13 C 508.50 D 450 E 113.00% F 2 G 56.50% Basic Workload per Shift ( in man minutes) Proposed Utilisation(%) Remarks: Check the finisher drawframe wrapping Give the lot information (New lot & Final Lot) to the post spinning secetion Check the lot final ringframe bobbins Check the wrapping of the new lot taken at ringframe Take the sample from carding & ringframe and paste them at the ringframe sample book Complete the sample book from mixing layering register Check material for contamination Hank Reading Net Available man-mins Present Utilisation(%) Proposed Manpower per shift RING FRAME CHECKER Activity Description Check the running shade from blowroom to ringframe Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) WLS No: BSP/W/18 WORK LOAD DETAILS SHEET BTM Shifts A B C G RING FRAME ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower 3 3 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.50 10.50 2 1 3 46.80 46.80 3 1 4 128.00 128.00 4 1 2 52.00 52.00 5 1 1 31.20 31.20 A 268.50 B 13 C 303.41 D 450 E 67.42% F 1 G 67.42% Proposed Manpower per shift Proposed Utilisation(%) Remarks: Three floor cleaner is recommended in ringframe section of BTM. The above workload sheet is for one floor cleaner. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Collect the ringframe bobbins from the auto winding colour wise Floor cleaning Help the sider in replacing the empty simplex bobbin with the full rove bobbin. (if Simplex bobbins replacement are higher than 100) Sort the ringframe waste shade wise and take the sweeping waste to the blowroom section at the end of the shift. Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Activity Description Check the cleaning of the department at the shift start WLS No: BSP/W/19 WORK LOAD DETAILS SHEET BTM Shifts A B C G RINGFRAME RINGFRAME FLOOR CLEANER ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 4 63 252.00 2 1 2 10 20.00 3 1 16 0.90 14.40 4 1 16 1.00 16.00 5 1 8 2.12 16.96 6 1 8 0.67 5.36 7 1 8 0.97 7.75 8 1 8 0.67 5.36 9 1 16 2.00 32.00 A 369.83 B 13 C 417.91 D 450 E 46.43% F 1 G 92.87% Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person No of doffs- 4 per shift per machine Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Come back to workplace Bring the empty autocone from the rack and arrange it on the machine(60 cone/time)(two machine/reliever) Move the trolley to loose packing area Arrange the cones from trolley to ground Basic Workload per Shift ( in man minutes) Maintain sample book for that particular machine(two machine/reliever) Take the full bobbins/half bobbins and put on the autoconer tenter trays Arrange the trays after&before segregation Collect the full autocone from the machine and arrange it on the trolley(60 cones/trolley)( One machine/reliever) Autoconer Reliever Activity Description Relieve - Four tenter's for breaks WLS No: BSP/W/20 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 Designation Proposed Manpower 2 2 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 62 56.42 112.84 2 1 1 60.00 120.00 A 232.84 B 13 C 263.11 D 450 E 58.47% F 2 G 58.47% Present Utilisation(%) Proposed Manpower per shift Total Workload ( in man minutes ) Net Available man-mins Proposed Utilisation(%) Remarks: To relieve 2 autowinding tenters for lunch Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) WINDING MATERIAL MAN Activity Description To feed full R/F bobbins to auto winding m/cs during the shift using trolleys ( 62 doffs per shift for one material man) WLS No:BSP/W/21 WORK LOAD DETAILS SHEET BTM Shifts A B C G POST SPG ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2* 2* 2* - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 24000 bobbins 120.00 240.00 2 1 1200 bobbins 16.20 32.40 3 1 300 bobbins 105.00 210.00 A 482.40 B 13 C 545.11 D 450 E 60.57% F 2 G 60.57% Mending of workable bottoms rejected by 3 A/C m/c and handing them to A/C operators.(300 bobbins/kirchiman) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Proposed Manpower per shift Proposed Utilisation(%) Remarks: Activity Description Sorting empty bobbins into tapas (3 A/C m/c per kirchi man)(24000 bobbins / kirchiman) Cutting kirchi of 3 A/C m/c(1200 bobbins/kirchi man) Present Utilisation(%) POST SPG B C G WINDING KIRCHI MAN WLS No: BSP/W/22 WORK LOAD DETAILS SHEET BTM Shifts A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 5 57.50 57.50 2 1 70 trolleys/ day 249.90 249.90 A 307.40 B 13 C 347.36 D 480 E 72.37% F 1 G 72.37% Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Collect trolleys from the dept. Remarks: AUTOWINDING Cutting the trolley Jam Basic Workload per Shift ( in man minutes) G AUTOWINDING JAM CUTTER Activity Description Rest & Relaxation Allowances ( % ) WLS No: BSP/W/23 WORK LOAD DETAILS SHEET BTM Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 100 cones 159.29 159.29 2 1 256 cones 24.92 24.92 3 1 100 bobbins 64.00 64.00 4 1 98 cones 53.10 53.10 5 1 20 cones 26.55 26.55 6 1 2 lots(2kg ) 17.70 17.70 7 1 15 cones 17.70 17.70 8 1 72 cones 26.55 26.55 A 389.80 B 13 C 440.48 D 480 E 91.77% F 1 G 91.77% Remarks: Proposed Manpower per shift Rewinding of SQC tested TFO cones Processing of TFO broken tape, zero TPI(at top) to 2nd quality Preparation of pair of final single cone Rewinding of single cones to remove jali, double etc Rewinding of classimate cones Present Utilisation(%) Net Available man-mins Shifting of production of 1 savio m/c to packing section Processing of defective bobbins(R/F) for 2nd quality Proposed Utilisation(%) G POST SPG Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Rewinding of packing rejection WINDING REWINDER Activity Description WLS No: BSP/W/24 WORK LOAD DETAILS SHEET BTM Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 6 rounds 127.80 127.80 2 1 1 8.85 8.85 3 1 0.33 3.30 3.30 4 1 1200 cones 14.40 14.40 5 1 20 pillers & 40 tube lights 38.80 38.80 A 193.15 B 13 C 218.26 D 450 E 48.50% F 2 G 48.50% Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) To shift sweeping of the shift to waste godown To shift hard waste of all the three shift to waste godown To clean cheese winding empty cones and place in racks colorwise To clean tube lights and pillers falling in one's floor area. POST SPG FLOOR CLEANER Activity Description To sweep area of post spg section WLS No: BSP/W/25 WORK LOAD DETAILS SHEET BTM Shifts A B C G POST SPG ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 2 63 126.00 2 1 6454 0.01200 77.45 3 1 16 0.90 14.40 4 1 16 1.00 16.00 5 1 4 2.12 8.48 6 1 4 0.67 2.68 7 1 4 0.97 3.88 8 1 4 0.67 2.68 9 1 4 2.00 8.00 10 1 4 3.00 12.00 A 271.56 B 13 C 306.87 D 450 E 68.19% F 1 G 68.19% Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person No of bobbins - 6146 Bobbins /shift + 5% rejection (308 bobbins/shift) = 6454 bobbins/shift Collect the full autocone from the machine and arrange it on the trolley(60 cones/trolley) Arrange the cones from trolley to ground Bring the empty autocone from the rack and arrange it on the machine(60 cone/time) Bring R/F bobbins from the R/F area Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Utilisation(%) Remarks: Arrange the trays after&before segregation Move the trolley to loose packing area Come back to workplace Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Relieve-Two tenter's for breaks Proposed Manpower per shift Post Spinning Sort the bobbins(only in machine 7) Take the full bobbins/half bobbins and put on the autoconer tenter trays Autconer-Savio No 7 Helper Activity Description WLS No: BSP/W/26 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 16 16 - Designation Proposed Manpower 8 8 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allow ance (%) Total Time (Mins) 1 1 30.25 0.50 13 17.09 2 1 3025 0.030 13 102.55 3 1 991.2 0.09 13 100.81 4 1 84 0.10 13 9.49 5 1 2 2.00 13 4.52 A 234.46 B 480 C 48.84% 5 Spinning Autoconer 16 Winder 8 Collect the R/F bobbins from the trolley to trays Put the R/F Bobbins in the machine drum Attend the idle drums Take the empty auto cone from the machine tray, remove the filled cone and put the empty cone on the machine and start the machine Basic Workload per Shift ( in man minutes) WLS No: BSP/W/27 WORK LOAD DETAILS SHEET BTM Shifts A B C G Activity Description Collect the waste from the machine 40 98.87% 64.81% Net Available man-mins Present Utilisation(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). = (b-1) / [ N{K+(b-1)C}] - 0.097943723, N - 30, C - 0.09, K - 0.2 30 99.96% 48.84% The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums Running Efficiency () (%) Operator workload(%) 50 97.11% 80.78% 60 94.90% 96.74% 64 93.90% 103.13% 70 92.30% 112.71% The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 16 16 - Designation Proposed Manpower 8 8 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allow ance (%) Total Time (Mins) Spinning Autoconer 16 Winder 8 WLS No: BSP/W/27 WORK LOAD DETAILS SHEET BTM Shifts A B C G Activity Description * Time lost due to general cleaning,hardwaste removal,splicing is collected from the management From the graph, the optimum number of drums can be alloted per operator is 60 nos Remarks: For 60 drums, Number of bobbins required - 5762 Bobbins/shift Rejection (5%) - 5762 * 5% = 288 bobbins.For 30 drums -(5762+288) /2 = 3025 bobbins/30 drums/shift. Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due general cleaning,hardwaste removal,splicing) = Machine running hours ( 8 hours * 77 % = 6.16 hours) Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 60 drums, Actual machine efficiency (%) = 6.16 hours *0.9490 =5.845 hours/shift 30 40 50 60 64 70 Running Efficiency () (%) 99.96% 98.87% 97.11% 94.90% 93.90% 92.30% Operator workload(%) 48.84% 64.81% 80.78% 96.74% 103.13%112.71% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) Autoconer ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 10 - Designation Proposed Manpower 7 - Sl. No Crew Size Freq/ Shift/ spindle No of spind les Basic Time (Mins) Allow ance (%) Total Time (Mins) 1 1 1.68 64 0.0663 13 8.06 2 1 1.68 64 0.1500 13 18.22 3 1 1.68 64 0.0663 13 8.06 4 1 1.68 64 0.0657 13 7.98 5 1 1.68 64 0.3650 13 44.35 6 1 3.36 64 0.0440 13 10.69 7 1 3.36 64 0.1060 13 25.76 8 1 3.36 64 0.0369 13 8.97 9 1 3.36 64 0.0500 13 12.15 10 1 3.36 64 0.0092 13 2.23 11 1 3.36 64 0.0083 13 2.02 12 1 2.688 64 0.280 13 54.43 13 1 1 1 15.000 13 16.95 A 219.87 B 480 C 45.81% 5 WLS No: BSP/W/28 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning Cheesewinding 10 10 Tenter 7 7 Basic Workload per Shift ( in man minutes) Activity Description Move the empty trolley to loose packing area Put the full autocone from ground to trolley Move the trolley to Cheesewinding section Keep the autocone from trolley to machine table Replace the empty autocone with full autocone&join Bring the empty cheese cone from the rack&keep on the machine Replace the full cheese cone with empty cheese cone Put the sticker on the cheese cone Collect full cheese cone from machine table and keep on trolley Move the trolley to weighing machine & Weigh the trolley Move the trolley to respective count running TFO machine area Attend the thread break Clean the machine Net Available man-mins Present Utilisation(%) The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums Running Efficiency () (%) Operator workload(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). = (b-1) / [ N{K+(b-1)C}] - 0.007308, N - 64, C - 0.28, K - 0.05 64 89.34% 45.81% 76 87.59% 49.77% ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 10 - Designation Proposed Manpower 7 - Sl. No Crew Size Freq/ Shift/ spindle No of spind les Basic Time (Mins) Allow ance (%) Total Time (Mins) WLS No: BSP/W/28 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning Cheesewinding 10 10 Tenter 7 7 Activity Description In BTM Spinning, the four cheese winding machines are in one section and two machines are in unit-3. Based on the above findings, two personnel is recommended for unit-3 machines(2 nos) and five personnel for four machines in the unit-1 &2. Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to doffing,worker's lunch,cleaning,Lot/Count change and idle ) = Machine running hours ( 8 hours * 77.5 % = 6.2 hours) Actual Machine efficiency (%)=Machine Running hours* Running efficiency 80 87.02% 56.38% 90 85.63% 62.98% 80.49% 89.40% 100 84.28% 69.59% 110 82.98% 76.19% The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: From the graph, the optimum number of drum can be alloted per operator is 120 nos. Remarks: 120 81.71% 82.80% 130 64 76 80 90 100 110 120 130 Running Efficiency () (%) 89.34% 87.59% 87.02% 85.63% 84.28% 82.98% 81.71% 80.49% Operator workload(%) 45.81% 49.77% 56.38% 62.98% 69.59% 76.19% 82.80% 89.40% 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00% E f f i c i e n c y ( % ) Cheesewinding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 10 - Designation Proposed Manpower 7 - Sl. No Crew Size Freq/ Shift/ spindle No of spind les Basic Time (Mins) Allow ance (%) Total Time (Mins) WLS No: BSP/W/28 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning Cheesewinding 10 10 Tenter 7 7 Activity Description 60 60 60 60 80 40 40 76 76 1 60 60 44 44 As per the breakage data provided by the company,there is no difference in breaks frequency among different makes(Textool,PSFMK and RJK) and very negligible difference in elemental times.Hence, the above workload is provided and applicable for all makes. At present, the operator's stops the machine during lunch break. Same practice is being proposed.Based on the above condition, reliever is not provided. EX: For 120 drums Actual machine efficiency (%) = 6.2 hours *0.8171 = 5.066 hours/shift Unit 1 &2 * Time lost due to doffing,worker's lunch,cleaning,Lot/Count change and idle is collected from the management Unit 3 80 Proposed manpower deployment is as follows: (each colour represents one personnel) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 25.00 25.00 2 1 1 40.00 40.00 3 1 1 20.00 20.00 4 1 1 55.83 55.83 5 1 11 55.00 55.00 6 1 1 42.40 42.40 7 1 3-4 30.00 30.00 8 1 1 30.00 30.00 A 298.23 B 13 C 337.00 D 450 E 74.89% F 1 G 74.89% Proposed Utilisation(%) Remarks: Proposed Manpower per shift To adjust savio drums according to ringframe color bobbins working in R/F section and make a record of it with the help of savio relievers. To adjust cheese winding drums as per programme decided by shift incharge with the help of cheese winders To weigh the doffs of each cheese winder on weighing scales one for Unit 1 and second for Unit 3. Record the cheese winder's production details in production register. To receive info. Regarding lot final from ring frame during his shift from shift incharge then get lot final data in sample book of that unit. Idle spindle count Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) G POST SPG Total Workload ( in man minutes ) To take shift charge Present Utilisation(%) Net Available man-mins To engage hands in the dept as per requirement To identify hands shortage section wise POST SPG JOBBER Activity Description WLS No: BSP/W/30 WORK LOAD DETAILS SHEET BTM Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq / Shift Basic Time (Mins) Total Time (Mins) 1 1 10 63 630.00 2 1 1 10.00 10.00 3 1 30 0.54 16.08 4 1 30 2.36 70.80 5 1 30 0.54 16.20 6 1 30 1.16 34.80 A 777.88 B 12 C 871.23 D 450 E 96.80% F 2 G 96.80% No of trolleys = (37.28 cones / machine / shift) * 48 machines = 1790 cones/shift = 1790 / 60 cone/trolley = 30 trolleys Proposed Utilisation(%) Remarks: Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person TFO Reliever-Tenter Activity Description Relieve-Ten TFO tenter's for breaks(5 persons each) Proposed Manpower per shift Present Utilisation(%) Total Workload ( in man minutes ) Net Available man-mins Collect the hard waste and handover & inform to supervisor Collect full TFO Cones from the machine table, keep it on the trolley(60 nos/trolley) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Move the full TFO Cones trolley back to packing room(60 nos/trolley) Bring the empty trolley from packing to respective TFO machine(mean distance) Arrange the TFO cones from trolley to ground floor WLS No: BBSP/W/31 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 80 cones 165.00 165.00 2 1 7 lots 40.00 40.00 3 1 10 lots 20.00 20.00 4 1 10 lots 38.33 38.33 5 1 7 lots 14.00 14.00 6 1 30 cones 8.20 8.20 7 1 8-10 cones 15.00 15.00 8 1 2 25.67 25.67 A 326.20 B 13 C 368.61 D 480 E 76.79% F 1 G 76.79% Proposed Utilisation(%) Remarks: Proposed Manpower per shift Lot run out from cheese winding section and record it in dept. sample book Lot final info. To packing after the lot final from TFO by writing in packing sample book Collection of defective cones from dept. for mending accordingly Baby cones of all new lots taken last day to yarn development dept. Checking for loose packing for savio final lots , shifted to cheese winding if found faulty. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) G POST SPG Total Workload ( in man minutes ) Shifting of packing rejection cones to manual winding m/c Present Utilisation(%) Net Available man-mins New lot information in packing sample book by writing lot no. shade no. Lot run out from TFO section and record it in dept. sample book POST SPG CHECKER Activity Description WLS No: BSP/W/32 WORK LOAD DETAILS SHEET BTM Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 12 - Designation Proposed Manpower 12 - Sl. No C r e w
S i z e F r e q /
S h i f t N o
o f
m a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) 1 1 78.3 4 0.0762 13 26.96 2 1 78.3 4 0.5500 13 194.73 3 1 78.3 4 0.0706 13 24.98 4 1 39.2 4 0.0235 13 4.16 5 1 39.2 4 0.0157 13 2.78 6 1 39.2 4 0.2600 13 46.02 7 1 156 4 0.0314 13 22.11 8 1 18 4 0.4000 13 32.57 9 1 1 1.5 20.0 13 30.00 A 384.32 B 480 C 80.07% 5 WLS No: BSP/W/33 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning Put the operator slip on the cone Attend the thread cut 12 12 Activity Description Bring empty TFO cone from the cone room Keep the cones on the machine Remove the full TFO cone,place on the machine holder & keep empty paper cone&join TFO-VJ(156 Spindles/ Machine) 12 12 Bring the cheese winding cone from the storage area, arrange on the machine table,keep the empty trolley aside(per cone) Replace the empty cheese cone with the full cheese cone & keep the empty cheese on the machine table& tie Collect the empty cheese cone and arrange it on the rack colourwise TENTER Clean the machine Basic Workload per Shift ( in man minutes) The running efficiency is calculated using the above formula for different number of drums and tabulated below: Net Available man-mins Present Utilisation(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). = (b-1) / [ N{K+(b-1)C}] - 0.000253326, N - 624 (156*4), C - 0.4, K - 0.07 No of Spindles Running Efficiency () (%) Operator workload(%) 624 (4 *156) 94.54% 80.07% 702 (4.5*156) 93.90% 89.72% 780 (5*156) 93.27% 98.08% ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 12 - Designation Proposed Manpower 12 - Sl. No C r e w
S i z e F r e q /
S h i f t N o
o f
m a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) WLS No: BSP/W/33 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning 12 12 Activity Description TFO-VJ(156 Spindles/ Machine) 12 12 TENTER 858 (5.5*156) 92.65% 109.19% ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 12 - Designation Proposed Manpower 12 - Sl. No C r e w
S i z e F r e q /
S h i f t N o
o f
m a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) WLS No: BSP/W/33 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning 12 12 Activity Description TFO-VJ(156 Spindles/ Machine) 12 12 TENTER 168 168 168 168 168 168 168 168 168 168 It is only suggested,actual deployment may be changed based on the machine efficiency required .As in Unit1 &2 Different shades are running, allocation of common person leads to quality problem. Hence separate personnel is being recommended, Remarks: Collection of full TFO cones from machine table to trolley is performed by doffers Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to twist contraction and idle spindle) = Machine running hours ( 8 hours * 97 % = 7.76 hours) The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: From the graph, the optimum number of drum can be alloted per operator is 624 nos Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 624 spindles, Actual machine efficiency (%) = 7.76 hours *0.9454 = 7.336 hours/shift * Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is collected from the management 624 (4 *156) 702 (4.5*156) 780 (5*156) 858 (5.5*156) Running Efficiency () (%) 94.54% 93.90% 93.27% 92.65% Operator workload(%) 80.07% 89.72% 98.08% 109.19% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) TFO-VJ (156 Spindles) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 12 - Designation Proposed Manpower 12 - Sl. No C r e w
S i z e F r e q /
S h i f t N o
o f
m a c h i n e B a s i c
T i m e
( M i n s ) A l l o w a n c e
( % ) T o t a l
T i m e
( M i n s ) WLS No: BSP/W/33 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning 12 12 Activity Description TFO-VJ(156 Spindles/ Machine) 12 12 TENTER VJ VJ VJ VJ VJ VJ VJ VJ VJ VJ 144 144 144 144 144 156 156 156 156 144 144 VJ P p p p VJ Vj VJ Vj P P 144 144 144 144 156 156 156 156 144 144 144 144 P P P P VJ VJ Vj Vj VJ VJ VJ VJ 144 144 144 144 144 144 144 144 144 144 VJ VJ VJ VJ VJ VJ VJ VJ VJ VJ 144 144 144 140 140 VJ VJ VJ VJ VJ ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No Crew Size Freq/ Shift No of machi ne Basic Time (Mins) Allow ance( %) Total Time (Mins) 1 1 83.48 4 0.0762 13 28.74 2 1 83.48 4 0.5500 13 207.53 3 1 83.48 4 0.0706 13 26.62 4 1 41.74 4 0.0235 13 4.44 5 1 41.74 4 0.0157 13 2.96 6 1 41.74 4 0.2600 13 49.05 7 1 168 4 0.0314 13 23.81 8 1 18.01 4 0.4000 13 32.57 9 1 1 1.5 20.0 13 30.00 A 405.72 B 480 C 84.53% 5 756 (4.5*168) 93.64% 840 (5*168) 92.98% 104.09% The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: 94.31% 84.53% The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). - 0.0002461, N - 672 (168*4), C - 0.4, K -0.07 672 (4 *168) The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Spindles Basic Workload per Shift ( in man minutes) Running Efficiency () (%) Operator workload(%) 94.31% Attend the thread cut Clean the machine Net Available man-mins Present Utilisation(%) Bring empty TFO cone from the cone room Keep the cones on the machine Remove the full TFO cone,place on the machine holder & keep empty paper cone&join Put the operator slip on the cone Activity Description Bring the cheese winding cone from the storage area, arrange on the machine table,keep the empty trolley aside(per cone) Replace the empty cheese cone with the full cheese cone & keep the empty cheese on the machine table& tie Collect the empty cheese cone and arrange it on the rack colourwise Post Spinning TFO-VJ(168 Spindles/ Machine) - - TENTER - - WLS No: BSP/W/33 A WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No Crew Size Freq/ Shift No of machi ne Basic Time (Mins) Allow ance( %) Total Time (Mins) Activity Description Post Spinning TFO-VJ(168 Spindles/ Machine) - - TENTER - - WLS No: BSP/W/33 A WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Collection of full TFO cones from machine table to trolley is performed by doffers Remarks: From the graph, the optimum number of drum can be alloted per operator is 672 nos Machine available hours * (Time lost due to twist contraction and idle spindle) = Machine running hours ( 8 hours * 97 % = 7.76 hours) Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 672 spindles, Actual machine efficiency (%) = 7.76 hours *0.9431 = 7.31 hours/shift Machine Efficiency: (Sample calculation) * Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is collected from the management 672 (4 *168) 756 (4.5*168) 840 (5*168) Running Efficiency () (%) 94.31% 93.64% 92.98% Operator workload(%) 84.53% 94.31% 104.09% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) TFO-VJ(168 Spindles) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No Crew Size Freq/ Shift No of machi ne Basic Time (Mins) Allowa nce (%) Total Time (Mins) 1 1 71.56 4 0.0680 13 21.99 2 1 71.56 4 0.5355 13 173.21 3 1 71.56 4 0.0690 13 22.32 4 1 35.78 4 0.0210 13 3.40 5 1 35.78 4 0.0140 13 2.26 6 1 35.78 4 0.2400 13 38.81 7 1 144 4 0.0280 13 18.22 8 1 16.46 4 0.5355 13 39.84 9 1 1 1.5 20.0 13 20.00 A 340.06 B 480 C 70.85% 5 WLS No: BSP/W/33 B WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning Remove the full TFO cone,place on the machine holder & keep empty paper cone&join Put the operator slip on the cone TFO- PRERNA(144 Spindle/Machine) - - TENTER - - Activity Description Bring the cheese winding cone from the storage area, arrange on the machine table,keep the empty trolley aside(per cone) Replace the empty cheese cone with the full cheese cone & keep the empty cheese on the machine table& tie Collect the empty cheese cone and arrange it on the rack colourwise Bring empty TFO cone from the cone room Keep the cones on the machine Net Available man-mins Present Utilisation(%) Attend the thread cut Clean the machine Basic Workload per Shift ( in man minutes) 648 (144*4.5) 92.51% 81.66% Operator workload(%) The running efficiency is arrived by the formula provided in the research paper : The Efficiency of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957). = (b-1) / [ N{K+(b-1)C}] - 0.00025, N - 576 (144*4), C - 0.535, K - 0.07 576 (144*4) 93.29% 70.85% The running efficiency is calculated using the above formula for different number of drums and tabulated below: No of Drums Running Efficiency () (%) 720 (144*5) 91.75% 90.03% ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - Designation Proposed Manpower - Sl. No Crew Size Freq/ Shift No of machi ne Basic Time (Mins) Allowa nce (%) Total Time (Mins) WLS No: BSP/W/33 B WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C G Post Spinning TFO- PRERNA(144 Spindle/Machine) - - TENTER - - Activity Description 792 (144*5.5) 91.00% 98.41% Remarks: Collection of full TFO cones from machine table to trolley is performed by relievers 864 (144*6) 90.26% 106.79% The above values are depicted in the graph to findout the optimum (where running efficiency & operative workload meets) number of drums to be alloted per personnel and presented below: From the graph, the optimum number of spindle can be alloted per operator is 720 nos Machine Efficiency: (Sample calculation) Machine available hours * (Time lost due to twist contraction and idle spindle) = Machine running hours ( 8 hours * 97 % = 7.76 hours) Actual Machine efficiency (%)=Machine Running hours* Running efficiency EX: For 720 spindles, Actual machine efficiency (%) = 7.76 hours *0.9175 = 7.119 hours/shift * Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is collected from the management 576 (144*4) 648 (144*4.5) 720 (144*5) 792 (144*5.5) 864 (144*6) Running Efficiency () (%) 93.29% 92.51% 91.75% 91.00% 90.26% Operator workload(%) 70.85% 81.66% 90.03% 98.41% 106.79% 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% 120.00% E f f i c i e n c y ( % ) TFO-PRN ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - 3 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 15.00 15.00 2 1 1 12.67 12.67 3 1 3.56 3.56 4 1 1 5.00 5.00 5 1 1020 cones 122.40 122.40 6 1 306 faulty cones 70.38 70.38 7 1 510 cones 30.60 30.60 A 259.61 B 14 C 295.96 D 450 E 65.77% F 3 G 65.77% PACKING CHECKER Activity Description Confirm lot and count detail in sample register before checking Alloted lot sticker ready by SAP before checking Checking individual cones and putting sticker In case of a faulty cone - checking time Paste a sample of new lot in sample register with Final lot cone check in all packing dept. and do separately Take charge of packing area WLS No: ESP/W/34 WORK LOAD DETAILS SHEET BTM Shifts A B C G PACKING Basic Workload per Shift ( in man minutes) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 114 1.57 178.60 2 1 114 0.82 93.10 3 1 114 1.00 114.00 4 1 1 15.00 15.00 A 400.70 B 13 C 452.79 D 480 E 47.17% F 1 G 94.33% Proposed Utilisation(%) Present Utilisation(%) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Lot final Checker B C Write the details on the log book like b.no,shade color etc Remarks: Adjust the trolley weight & number of cones by weighing At the day end ,cross check & verify the quantity packed and despatched Proposed Manpower per shift Basic Workload per Shift ( in man minutes) Write the details on the bag using marker Net Available man-mins WLS No: BSP/W/35 WORK LOAD DETAILS SHEET BTM Spinning Shifts A G Packing Activity Description Packing Room ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 6 Designation Proposed Manpower - - - 5 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 5344 0.07 356.27 2 1 167 0.13 21.43 3 1 167 0.83 139.17 4 1 167 0.13 21.43 5 1 167 1.57 261.63 6 1 167 0.07 11.13 7 1 167 0.53 87.68 8 2 167 1.43 478.73 9 1 167 0.30 50.10 10 1 167 0.82 136.94 11 1 167 0.47 77.93 12 1 167 1.10 183.70 A 1826.15 B 14 C 2081.81 D 480 E 72.28% F 5 G 86.74% Remarks: No of cones / bag - 32 nos of 2kg each Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Based on machine capacity number of bags to be packed - 167 bags Take the covered cones from ground and keep on the trolley Adjust the cones for exact weight in the weighing machine Take the white bag from area and spread it on the box Stitch the bags Prepare the needle Basic Workload per Shift ( in man minutes) Prepare the rope(take and extend) Tie the bag with rope and keep aside G Move trolley from weighing machine to bag area Put the cones from trolley into white bags Packing Room Packing Helpers Activity Description Put the individual cones in the LDPE bag Move the empty trolley from weighing machine to cone storage area Packing Move the trolley back to weighing machine After discussion, it is found that the one kg cone packing is rare,hence not considered. WLS No: BSP/W/36 WORK LOAD DETAILS SHEET BTM Spinning Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) 1 1 6 lots 2 samples/f ibre 15.57 15.57 2 1 4 shades 2 readings/ fibre 190.60 190.60 3 1 2 shades 2 readings/ fibre 40.67 81.34 4 1 1 lot 20 readings/ Lot 58.44 58.44 5 1 4 drums 6 readings/ drum 31.46 31.46 6 1 4 lots 20 readings/ Lot 29.47 29.47 7 1 1 bag 32 cones 33.60 33.60 8 1 All tested lots 5.58 5.58 9 1 22 m/c 2gm/sam ple & 4 samples/ day 31.94 31.94 11 1 4m/c 2 sample/m /c 12 1 4 m/c 5 readings/ m/c 44.13 Card sliver wrapping check, report preparation & disposal of samples Sampling of card sliver samples for wrap checking 44.13 Lab Checker& Investigator Activity Description Sampling of fibre samples from fibre dyeing deptt. & fibre godown. Autoconer single yarn splice app. & strength checking(All single pack lots), collection of spliced yarn samples, pasting them in the register, report preparation. Autoconer single yarn splice app. & strength checking(Drumwise), collection of spliced yarn samples, pasting them in the register, report preparation. Fibre moisture content% checking- Polyester & Viscose & disposal of samples. Fibre neps/gm checking- Viscose & disposal of samples. WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G Entry of all tested results of Splice & TPI in lot history & information to all concerned persons Sampling of card sliver samples for neps checking Final Yarn TPI & TPI CV% checking(All single pack & double pack) Final Yarn case checking-weighment of individual cones & yarn defects ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 13 1 2 m/c 2 samples/ m/c 14 1 2 m/c 5 readings/ m/c 15 1 1 m/c delivery 5 cans/m/c 16 1 1 m/c 20 readings/ m/c delivery 17 1 5 m/c 5 bobbins/ m/c 18 1 5 m/c 5 m/c 19 1 1 m/c 10 bobbins/ m/c 20 1 1 m/c 1 m/c 21 1 7 lots(2 times/we ek) 4 samples/ lot 22 1 1/6 5 m/c in one day 23 1 7 m/c 7 m/c 15.03 15.03 24 1 1 lot 10 coness/lo t 4.45 4.45 25 1 4 lots 6 cones/lot 26 1 1 lot 10 cones/lot 23.84 23.84 Sampling of final yarn(double) cones for yarn uster %, wrapping & TPI testing Sampling of roving bobbins for wrapping & CV% check 12.35 12.35 Simplex roving wrapping CV% check, report preparation & disposal of samples Sample preparation of roving for half lea strength testing & carry them to BTM spg. QA 10.76 10.76 Simplex roving half lea strength checking at BTM spg. QA & report preparation 7.56 7.56 Drawframe sliver wrapping checking, report preparation & Disposal of samples Sampling of Roving bobbins for wrapping check 33.35 33.35 Simplex roving wrapping check, report Sampling of drawframe sliver(finisher) samples for wrapping & CV% checking 10.26 10.26 Drawframe sliver wrapping checking, report preparation & Disposal of samples Sampling of drawframe sliver(finisher) samples for wrapping & CV% checking Autoconer Yarn cuts per 100 km checking Sampling of autoconer yarn cones for wrapping checking Sampling of final yarn(single) cones for yarn uster %, wrapping & TPI testing ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 27 1 All tested lots 19.19 19.19 28 1 52 samples 5 bobbins/s ample 29 1 26 m/c 52 samples 30 1 4 lots 10 bobbins/l ot 31 1 4 lots 20 readings/ lot 32 1 4 lots 3 samples/l ot 33 1 4 lots 3 samples/l ot 34 1 1 lot 20 readings/l ot 18.56 18.56 35 1 3 lots 20 readings/l ot 55.68 55.68 36 1 All tested lots 12.34 12.34 37 1 4 lots 10 bobbins/l ot Sampling of Ringframe yarn bobbins for RKM testing & carry them to BTM spg. QA 155.70 155.70 Final autoconer yarn wrapping check(all single pack lots) & CV% , report preparation & disposal of samples. 77.50 Ringframe yarn wrapping check, report preparation & disposal of samples. Ringframe yarn sampling of all new lots. 42.45 Ringframe yarn samples collection for checking of blend%, washing fastness &MFS checking at Lab 77.50 Entry of all card neps, card, drawframe, simplex wrapping, autoconer yarn cuts in lot history & information to all concerned persons Ringframe Yarn sampling(All m/c & all sides) 42.45 Sending & submitting the yarn samples to process lab for blend% , washing fastness & MFS checking & updating the results in lot history register Ringframe yarn wrapping & wpg. CV% checking(All new lots), report preparation & disposal of samples Final double yarn wrapping & CV% check, report preparation & disposal of samples. Entry of ringframe & final yarn wrapping, yarn blend%, washing fastness, MFS in lot history & information to all concerned. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 38 1 4 lots 30 readings/l ot 39 1 4 lots 10 bobbins/l ot 40 1 4 lots 30 readings/l ot 41 1 4 lots 5 cones/lot 42 1 4 lots 10 kg/lot 43 1 All tested lots 44 1 4 lots 6 cones/lot 45 1 4 lots 150 km/lot 46 1 All tested lots 47 1 4 lots 6 cones/lot 48 1 4 lots 150 km/lot Sampling of autoconer yarn cones for yarn classifault testing & carrying them to BTM classifault testing room 187.50 187.50 Autoconer yarn classifault testing, yarn faults collection, pasting them in report, report preparation & disposal of samples. Sampling of final yarn cones for yarn rewinding study 331.12 331.12 Final yarn rewinding study-checking on m/c , yarn faults collection, pasting of yarn faults in report, report preparation & disposal of samples. Entry of Ringframe yarn RKM, final yarn RKM & rewinding studies in lot history & information to all concerned persons. Sampling of final yarn cones for yarn classifault testing & carrying them to BTM Classifault testing room. 96.00 96.00 Final yarn classifault testing-checking on m/c, yarn faults collection, pasting of gaults & report preparation & disposal of samples. Entry of final yarn classifault test results in lot history & information to concerned persons. 155.70 155.70 Ringframe yarn RKM & RKM CV% checking, report & disposal of samples Sampling of final yarn cones for RKM testing & carry them to BTM spg. QA Final Yarn RKM & RKM CV% checking, report & disposal of samples. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 49 1 All tested lots 50 1 1/13 3 m/c in one round 51 1 1/13 3 m/c in one round 52 1 1/13 6 samples/ m/c 53 1 1/13 2 m/c in one round 54 1 1/26 All m/c 1.44 1.44 55 1 1/26 2 m/c in one round 4.04 4.04 56 1 1/26 26 m/c in one round 3.46 3.46 57 1 1/26 26 m/c in one round 9.23 9.23 58 1 1/26 26 m/c in one round 6.92 6.92 59 1 1/13 8m/c in one round 18.46 18.46 60 1 1/26 2 m/c in one round 9.23 9.23 17.31 Autoleveller function checking- wrapping,wpg. CV% & A%, report preparation & disposal of samples. Ring frame suction pressure checking & report preparation Ringframe cots checking & report preparation Ringframe spacer checking & report preparation Autoconer gauge setting checking & report preparation. Cheese winding yarn tension checking & report preparation. M/c speed checking & report preparation Simplex Top arm pressure & report preparation 187.50 Sample preparation of Autoleveler function checking 17.31 187.50 Entry of autoconer yarn classifault test results in lot history & information to all concerned persons. Blow room lap weight checking, report preparation 8.46 8.46 Blow room lap CV% check, report preparation & disposal of samples ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 61 1 1/26 2 m/c in one round 2.31 2.31 62 1 1/26 4 m/c in one round 2.31 2.31 63 1 1/26 24 in one round 12.69 12.69 64 1 1/26 8 samples/s tudy 65 1 1/26 24 samples/s tudy 66 1 1/26 8 samples/s tudy 91.90 91.90 1 1 1 1 7.45 7.45 2 1 1 1 5.00 5.00 3 1 1 0.85 0.85 1 1 0.95 0.95 1 1 1.06 1.06 1 2 2.17 4.34 1 1 0.90 0.90 4 1 1 0.30 0.30 1 3 0.54 1.62 1 3 0.30 0.90 1 3 0.33 0.99 Enter details in the UT Uster % checking & print the result Keep back the cans in carding section Collect the sample can and come back to QA Enter the details in the UT machine Cheese winding breakage study & report preparation. Carding Reach carding section from QA TFO breakage study & report preparation. Knotter's knot quality checking, pasting them in report & report preparation. Samples preparation for Cardwise sample study on same machine channel for each individual card. Cardwise study- classimat tests of RF yarn samples (Testing at Classimate room at BTM spg.) & disposal of samples. Investigator Clean the uster machine, work area , go and bring mixing register Enter the mixing composition and other details in lot register from layering register 137.85 137.85 Cardwise sample study- Uster checking of card sliver, Drawframe sliver & Ringframe yarn Drawframe(Breaker &Finisher) Come to drawframe section, collect two can(breaker) Come back to QA lab Write on the can L/L,L/R ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 1 12 1.77 21.24 1 3 0.54 1.62 1 1 0.46 0.46 1 3 0.54 1.62 1 3 0.33 0.99 1 12 1.77 21.24 1 3 0.54 1.62 5 0.00 1 9 0.54 4.86 1 9 0.15 1.35 1 9 1.51 13.59 1 36 1.47 52.92 6 1 1 1.53 1.53 1 8 8 lot*10 reading/l ot 1.13 9.04 1 1 0.67 0.67 1 8 1.22 9.76 1 8 14.10 112.80 1 8 0.50 4.00 1 1 5.00 5.00 7 1 8 0.35 2.80 1 8 0.26 2.08 Uster % checking & print the result(2 pass per can*2 cans/machine*3 machine) Move the simplex trolley to QA lab Enter the details in the UT machine Keep back the cans in the breaker section Waiting for the cans (finisher) Uster % checking & take the printout(4 readings/machine*9 machine) Ringframe Come to ringframe section, searching for the product running machine Collect the R/F bobbins(10 bobbins/machine*8 machine) Collect two cans, Come to QA lab Enter details in the UT Uster % checking & print the result(2 pass per can*2 cans/machine*3 machine) Keep back the cans in the finisher area Simplex Machine Come to simplex area from QA lab Come back to QA lab Enter the parameters in uster machine Check the uster % ( 10 bobbins)(operator workload) Take the printout of the result During the uster % machine cycle time filled the yesterday report in the log book Yarn Board Winder Take the white board and fix on the machine Fix the yarn from bobbin to board and switch on ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 1 8 0.39 3.12 1 8 0.80 6.40 8 0.00 1 2 1.04 2.08 1 20 0.15 3.00 1 20 1.00 20.00 0.00 9 1 6 6 lot*10 reading/l ot 0.35 2.10 1 6 0.26 1.56 1 6 0.39 2.34 1 6 0.80 4.80 10 1 1 4.00 4.00 11 1 1 8.00 8.00 12 1 1 3.00 3.00 13 1 1 10.00 10.00 14 Take the white board and fix on the machine Single Yarn Uster% checking(materials already brought to QA by checker) Enter details in the UT machine Fix date slip, remove the YBW board and keep near the UT machine Write details in the small slip to insert in the YBW board Enter the uster test results in lot history register & file all reports Remove the old and Connect the next single yarn cone to the UT machine Machine cycle time(2 lot*10 readings/lot) During the machine cycle time,parallely keep the old cones in the trolley) Yarn Board Winder(Final Yarn) Fix the yarn from cone to board and switch on Fix date slip, remove the YBW board and keep near the UT machine Write details in the small slip to insert in the YBW board Fill the D/F uster & spectrogram report from quality report Enter the daily production lot register data in excel sheet Send the daily QA report through mail to higher officials Sampling of Packing materials ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 2 - 1 6 Designation Proposed Manpower 3 2 - 1 6 Sl. No Crew Size Freq/ Shift Sample Size Basic Time (Mins) Total Time (Mins) Lab Checker& Investigator Activity Description WLS No: BSP/W/37 WORK LOAD DETAILS SHEET QA-BTM Shifts A B Total QA C G 1 1/13 120.00 9.23 1 1/13 120.00 9.23 1 1/13 60.00 4.62 1 1/13 60.00 4.62 A 2353.02 B 13 C 2658.92 D 2730 E 97.40% F 6 G 97.40% Present Utilisation(%) Proposed Manpower per Day Proposed Utilisation(%) Remarks: Basic Workload per shift ( in man minutes) Rest & Relaxation Allowances ( % ) Standard Workload ( in man minutes ) Net Available man-mins Sample the paper cone(embossed),Check the weight,strength,Cone length, nose dia, base dia (20 cone for 50,000 lot) Sample the HM bag, Test length,weight,gauge (10 readings for 150 kg) Sample the HDPE bag, Test length,weight,gauge (10 readings for 300 kg) Sample the paper cone(plain velvet),Check the weight,strength,Cone length, nose dia, base dia (20 cone for 50,000 lot) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A BTM SPINNING - MECHANICAL MAINTENANCE _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A 4.1 I II III G T I II III G T Fitter - - - 1 1 - - - 1 1 Helper - - - 2 2 - - - 1 1 Fitter - - - 1 1 - - - 1 1 Running Fitter - - - 1 1 - - - 1 1 Cleaner - - - 2 2 Flat Grinder - - - 1 1 Fitter - - - 1 1 - - - Running Fitter - - - 1 1 - - - Cleaner - - - 3 3 - - - 3 3 Fitter - - - 1 1 Helper - - - 1 1 Head Fitter - - - 1 1 - - - 1 1 Gauging Ftter - - - 1 1 - - - 1 1 Helper - - - 2 2 - - - 2 2 Duct Fitter - - - 1 1 - - - 1 1 Cleaner - - - 8 8 - - - 8 8 Cleaner Fitter - - - 1 1 - - - 1 1 Asst. Cleaner Fitter - - - 1 1 - - - 1 1 - 2 - 1 2 Common Cleaning gang for Ringframe & TFO Ringframe 5 Main Gang 1 - - 1 Blow Room 1 - - 1 Carding 2 Fly-Frame 3 4 Buffing BTM SPINNING - MECHANICAL MAINTENANCE Manpower Deployment S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A 4.1 I II III G T I II III G T BTM SPINNING - MECHANICAL MAINTENANCE Manpower Deployment S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks Fitter - - - 2 2 - - - 2 2 OHB Fitter - - - 1 1 - - - 0 0 Cleaner - - - 3 3 - - - 3 3 Fitter - - - 1 1 - - - 1 1 Helper - - - 1 1 - - - 1 1 0 0 0 38 38 0 0 0 33 33 Total Winding 6 TFO 7 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A 4.2 4.2.1 a) b) c) d) e) f) - - - - - - - - - - g) BTM SPINNING - MECHANICAL MAINTENANCE Proposed Changes & Observations Running maintenance data has been collected by detailed discussions with the incumbents and the supervisory personnel and compared with check studies and estimated. The manpower has been computed with a loading factor of 80 % for the maintenance personnel. The 80 % loading has been considered to take into account the following: The detailed time and motion study is recommended to arrive the standard time for the activities,whatever timings considered here,based on the group utilisation technique.And cannot taken for fixing standard times. The preventive maintenance data was collected for all the category of machines. Check studies on a sample basis were carried out to ascertain the process being followed for the preventive maintenance. The data gathered during check studies has been applied to the remaining preventive maintenance activities in that section. Methodology Breakdown maintenance (Carding, Ringframe & Autowinding) data has been obtained for a period of two months and the same has been extrapolated for a month. The sum of the preventive maintenance, breakdown maintenance(if any) and running maintenance (if any) workload for the month gives us the total workload for the mechanical personnel. Rest & Relaxation allowance is already included as a part of activity time and presented against the respective activities. PF - Permanent Fitter(Sr.Fitter,Fitter,Jr.Fitter) PH - Permanenent Helper/Cleaner Waiting for the machine for maintenance Clean the tool room daily morning Bring tools/materials from store Ex: oil,grease,waste cloth, new parts Discard the waste cloth to the waste area daily after maintenance work Change dress Prepare attendance Write logbook Unavoidable delay. EX:New activity cannot start after 4.30 pm as only 30 mins left for that day Arranging of tools & parts in tool room Efforts variation required _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A 4.2 BTM SPINNING - MECHANICAL MAINTENANCE Proposed Changes & Observations 4.2.2 I a) II a) b) III a) IV a) V a) Proposed Changes Blowroom In view of low utilisation(29.68%) of helpers in the blowroom section, it is proposed to deploy one helpers instead of the present two helper with one fitter. Cots Buffing Drawframe & Simplex(Fly-Frame) BTM-D/F & Simplex section, one separate fitter deployed for running problems & change over activities. It is suggested to follow the same practice of all members(fitter, cleaners) perform the routine checkups (for their sections) at the starting of the shift and rectify(if problem any) the same before starting the scheduled preventive maintenance activity. Incase of small running problems, the fitter can attend the problem. This will not affect the scheduled maintenance activities as the fitter involvement is less. In above that they have foreman to carryout the running problems & breakdowns. This practice is already implemented in elegant spinning. In view of low utilisation(19.69%) , it is proposed to deploy one fitter instead of the present one fitter and one helper. OHB Fitter The incumbent is incharge for the OHB in the BTM Spinning section. The major activity is collecting the dust accumulated from the OHB box & do overhauling of the OHB. As single operator walking to all the OHB and collecting waste, it takes nearly 3 hours per day. So, it is recommended that the respective section mechanical gang carryout the maintenance of their sections OHB. This practice is being followed in Elegant Spinning. No separate personnel is being recommended for this position. After the detailed discussion with the mechanical team and the management personnel, the number of running problems through out the day are very minimal compared to in elegant spinning. Hence, no personnel is deployed in shift for attending the minor/running problems. The same is being considered and manpower is suggested. Carding-Flat Grinder The utilisation of flat grinder is only 12.5%. So it is recommended that one flat grinder cum cleaner, instead of flat grinder. _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A 4.2 BTM SPINNING - MECHANICAL MAINTENANCE Proposed Changes & Observations 4.2.3 I a) b) II a) III a) Multiple Activity Chart: Multiple activity chart is used when more than one personnel is engaged for doing one job. A multiple activity chart combined with SOP gives the sequence of activity each has to perform. This reduces the idle time and increases the machine availability time. It was observed during the study that such detailed Multiple Activity Chart combined with SOP is not available as a result of which the time taken for scheduled maintenance is much higher than required. Hence it is proposed that a detailed time and motion study for regular maintenance activities has to be carried out and such Multiple Activity Chart has to be made. Instead of stopping machine two different times, the activity of cleaning gangs(S.No 1-6) could be performed, when machine stopped by gauging gang to carryout their scheduled activities. As gauging gang working on gear part (removed geared from machine and overhauling in the mechanical room), remaining part of the machine is free for cleaning. It increases the machine availability to the production. Illustration is provided in Annex-1 Ringframe - Oil Top up activity The activity of oil topping is performed by eight personnel for their allotted spindle ( 55 Spindles per person). As there is presently only one can is available, all seven are idle while one person fills his allotted spindles and made machines to be stopped. The time taken for oil topping could reduce drastically. Illustration is provided in Annex-2 Ringframe & TFO There are two different gangs performing scheduled maintenance activity in Ringframe section Called as Cleaning gang and Gauging Gang. Cleaning gang performs activities from S.No 1 6 and Gauging gang performs activities from S.No 8 16.(in the monthly Schedule For Routine/ Preventive Maintenance List) During the study and discussion, it is observed that machine is being stopped separately by cleaning gang and separately by gauging gang to perform their respective scheduled maintenance activities. Observations _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A 4.2 BTM SPINNING - MECHANICAL MAINTENANCE Proposed Changes & Observations 4.2.3 IV a) b) V a) VI a) Observations Break-hours It is observed that in elegant spinning that mechanical workers first finishes their activities and leaving for breaks , because of this the machine hours under maintenance decreases. Whereas in BTM this good practice is not observed results in the reduced hour machine availability for the production. Total Time provided for Scheduled Maintenance The time provided for scheduled maintenance activities are based on the company experience/estimation. However, it was observed during the study that the actual time required for the scheduled maintenance activities are less. So , it is recommended to go for in-depth time and motion study and fix standards for the regular maintenance activities. This will help in increasing the availability time of machine and also reduce maintenance personnel workload further. In Spinning mill, number of similar equipments are more ( 48 R/F,48 TFO) , and activity also carried out once in a month/quarter, reduction of each minutes have big impact in the machine availability to production. Illustration is provided in Annex-3 Pooling of Workforce It is observed in BTM-TFO mechanical gang (1 Fitter+1 Helper) performs the preventive maintenance activities. For example, thread guide setting and cradle drum setting which takes 2.17 hours with two crew personnel. The same activity if carried out by say four personnel, the machine down time for maintenance would be half of the time taken(2.17/2 = 1.09 hours). In the same day, morning in cheese winding section, with 3 helpers+1 fitter carried out machine cleaning activity. For that they stopped cheese winding machine for 3 hours. By pooling this two group ( TFO-2 Personnel + Cheese winding - 4 personnel) , both the activity would have been completed, but with the half of the both machine stopped presently. This type of analysis is possible only when the multiple activity chart with activity sequence(preceding/succeeding) of activity known. _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm _______________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Annex : 1 Section : BTM - Spinning - Ring Frame RING FRAME S.NO. ACTIVITY Frequency Approx Time (hrs)* Done by 1 M/C Cleaning 15D +_15D 1.25 1.25 1.25 2 Spindle Oil 4 M + 15 D Topping 3 Spdl.Oil Change 1 Y + 2 M 0.5 0.5 0.5 4 Bottom Apron 8 M + 2 M Change 6 Middle Arbour 1 Y + 2 M 0.5 0.5 Greasing 7 Draft Gear 6 M + 1 M Overhauling 8 Heart Cam As & when Overhauling required 9 J.P.Ball Brg. 1 Y + 2 M Greasing 10 Bottom Roll 1 Y + 2 M Trueing 11 Lapet Hook 2 Y + 3 M Change 12 Lifting OH 2 Y + 6 M 12 13 Spindle Gauge 8 M + 1 M 4 Requirement Prior scheduling 14 Rings Change 2 Y + 6 M This practise is being follwoed in Elegant mechanical maintenance 15 Spindle Change 10 Y + 2 Y 12 Present Method Proposed Method 0.5 P e r f o r m e d
b y
C l e a n i n g
G a n g 0.5 0.5 12 Same improvement idea holds good in TFO Section, where two gangs are involved. Performed by Gauging gang Performed by Cleaning gang 4 P e r f o r m e d
b y
G a u g i n g
G a n g 4 12 4 4 0.5 0.5 0.5 0.5 Savings per machine - 3.25 hours 2 4 Total Machine Stoppage - 1.25+0.5+0.5+0.5+0.5 + 4 = 7.25 hours Total Machine Stoppage - 4 hours __________________________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Annex : 2 Section : BTM - Spinning - Ring Frame Activity : Spindle oil Topping 24 24 21 21 18 18 15 15 12 12 9 9 6 6 3 3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Working ( Remove spindle, fill the oil & place back the spindle)* Idle Additionally cleaners avaialblity goes up Waiting for the Oil can ( Forced Idleness) Time saved per machine - 18 mins Present Method ( with One oil Can) Proposed Method ( with four oil can) T i m e
(
m i n s ) T i m e
(
m i n s ) Crew Size ( Cleaners) Crew Size ( Cleaners) Total Cycle time per machine = 24 mins Total Cycle time per machine = 6 mins _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Annex : 3 Section : BTM - Spinning - TFO T.F.O. S.NO. ACTIVITY Frequency Appro x Time Done By 11 Thread guide Setting 6 M + 1 M 12 6 M + 1 M 13 Jokey Pulley Greasing 1 Y + 2 M 2.5 Total Machine Stoppage - 3 Hours 14 1 Y + 2 M Total Crew(6 person) Utilisation - 1 hour CONE WINDING & CHEESE WINDING S.NO. ACTIVITY Frequency Appro x Done By 1 M/C Cleaning with Upper & 15 D + 4 D Lower Guide pulley Oiling 2 Drum shaft brg.&greasing 6 M + 1 M 8 Total Machine Stoppage - 3 Hours 3 Yarn Path 3 M + 15 D Setting 6 Yarn guide hook As & when required GBTL -SPG-F-08 TFO Autoconer TFO Autoconer TFO Autoconer * Given by company persons Machine Stoppag e Hours 3 3 Machine Stoppage Hours 1 2 Machine Availablity for production (extra) 2 1 Manhour s Utilised 2 crew* 3 hours= 6 manhou rs 4 crew*3 hours=12 manhours Manhours Utilised 6 crew* 1 hours= 6 manhours 6 crew*2 hours=12 manhour s - - 3 P e r f o r m e d
b y
T F O
G a u g i n g
G a n g
(
1
F i t t e r +
1
H e l p e r ) Total Crew(4 person) Utilisation - 3 hours Present Method Proposed Method Total Crew(2 person) Utilisation - 3 hours Cradle, Drum Setting Gear Overhauling 3
P e r f o r m e d
b y
A u t o c o n e r
C l e a n i n g
G a n g
(
Autoconer Gang( 1 Fitter + 3 Helpers) Total Crew(6 person) Utilisation - 2 hours 4 4 4 Total Autoconer Machine Stoppage - 2 Hours Proposed Method ( 2TFO Gang + 4 Autoconer Gang) Present Method Savings 6 Persons( 2 TFO Gang + 4 Autoconer Gang) TFO Gang ( 1 Fitter + 1 Helper) 6 Persons( 2 TFO Gang + 4 Autoconer Gang) Total TFO Machine Stoppage - 1 Hours __________________________________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 A 4.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 OHTC Fitter BSM/W/11 TFO BSM/W/12 Ring frame-Main Gang BSM/W/08 Duct Fitter BSM/W/09 Autowinding&Cheese Winding BSM/W/10 Running Fitter- BSM/W/05 Cots Buffing BSM/W/06 Cleaning Gang-R/F&TFO BSM/W/07 Carding BSM/W/02 Flat Grinder BSM/W/03 Drawframe&Simplex BSM/W/04 BTM SPINNING - MECHANICAL MAINTENANCE Workload Sheets Summary Area of work WLS Number Blow Room BSM/W/01 _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH A Blowroom & Mixing 1 Line Blender Cleaning 1 1 1 3.0876 5 15 15 a) Clear the material from the machine and stop the machine b) Dismantle the grid bar c) Cleaning the grid bar d) Mantling of the grid bar e) Cleaning of the beater and striping plate f) Cleaning of the feed lattice g) Cleaning of the inclined lattice h) Cleaning of the bottom inclined lattice i) Cleaning of the evener roller/lattice j) Cleaning of the feed roll k) Checking and greasing of the bearings l) Close the cover of the machine and start the machine WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) 2 Hopper Feeder Cleaning 1 1 1 3.0876 5 15 15 a) Clear the material from the machine and stop the machine b) Removal of the chain and belt c) Opening and cleaning of the vibrating door of the hopper feeder d) Cleaning of the inclined lattice e) Dismantling of the gears f) Cleaning & checking of the gears g) Mantling of the gears h) Cleaning of the stripper roll i) Cleaning of the evener roller/lattice l) Close the cover of the machine and start the machine 3 Condenser & Doffing Section cleaning. 1 1 1 3.0876 5 15 15 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) a) Clear the material from the machine and stop the machine b) Cleaning of the cage c) Cleaning of the striping roll d) Close the cover of the condenser e) Dismantling of the solenoid valves f) Cleaning and mantling of the solenoid valves g) Dismantling of the calendar roll gear h) Checking and cleaning of the calendar roll gears i) Cleaning & checking of the doffing arm spring and arm j) Checking and cleaning of the tire coupling _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) k) Close the cover of the machine and start the machine 4 Scutcher Cleaning 1 1 1 3.0876 5 15 15 a) Clear the material from the machine and stop the machine b) Dismantling of the paddles c) Cleaning of the paddles d) Dismantling of the grid bar e) Cleaning of the grid bars f) Mantling of the grid bars g) Mantling of the paddles h) Gauging of the paddle gauge i) Checking of the cone drum j) Opening and Checking of the PIV gear k) Checking of the calendar roll gear l) Cleaning of the beater and striping plate _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) m) Gauge of the feed roll to beater and striping plate to beater j) Close the cover of the machine and start the machine 5 Mixing Blender Cleaning ( Mixing Blender -4 nos, viscose opener-1 No) 1 1 1 2.70165 5 14 14 a) Clear the material from the machine and stop the machine b) Cleaning of the bottom lattice c) Cleaning of the feed lattice d) Cleaning of the inclined lattice e) Cleaning of the bottom inclined lattice f) Cleaning of the evener roller/lattice g) Cleaning of the feed roll h) Checking and greasing of the bearings _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) i) Close the cover of the machine and start the machine 6 Mxg. Condenser Cleaning 1 1 1 1.5438 11 17 17 a) Clear the material from the machine and stop the machine b) Cleaning of the cage c) Cleaning of the striping roll d) Cleaning of the mouth piece e) Close the cover of the condenser 7 Gear box Oil Change 1/6 1 1 0.7719 12 2 2 a) Stop the machine and open the oil box b) Removal of the old oil from the oil box c) Cleaning of the gears d) Putting of the new oil in to the oil box _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) 8 K. Beater Legs Change ( Blow Room - 2 have one leg at Front & One leg at back) 1/9 1 1 7.719 6 5 5 a) Clear the material from the machine and stop the machine b) Removal of the KB Belt c) Dismantling of the beater legs d) Marking of the holes in the new beater e) Drilling the hole in the beater legs f) Fitting the beater legs on the beater g) Balancing of the beater h) Gauge the beater to feed roll and striping to beater i) Close the cover of the machine and start the machine 9 Filter Bags Washing 1/3 1 1 0.38 21 3 3 a) Opening of the filter bags b) Washing of the filter bags c) Tight the filter bags on its position after Performed by Carpenter. _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+2 H Work Centre Blowroom & Mixing - - - 1 F+1 H PF PH PF PH WORK LOAD DETAILS SHEET Time (in Hours) No of Machine Crew Category WLS No:BSM/W/01 Present Manpower Proposed Manpower Shifts S. No Activity Description Frequency/ Month Monthly workload(Hours) 10 Running Problems(During General Shift) 26 1 1 1 26 A 127.60 101.60 B 166.4 166.4 C 76.68% 30.53% D 1 1 E 76.68% 61.06% Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+3 H Work Centre Carding - - - 1F+2H+1 Flat Grinder PF PH PF PH 1 Full setting 1 1 3 2.4 26 62 187 a) Allow to run out the machine b) Stop the machine c) Remove lap roll, lap stand, Feed plate feed roll,Lickerin,Undercasing d) Clean the machine through Air Pressure e) Clean all the Parts f) Remove jam from all the place g) Clean all the gearing d) Reset all the gauge f) Fix all the open parts in machine g) Start the machine at slow speed for checking of any abnormal sound h) Clean the machine once through Air pressure i) Start the machine j) Handover to production Deptt Frequency/ Month Crew Category WLS No:BSM/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower No of Machine Monthly workload(Hours) S. No Activity Description Time (in Hours) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+3 H Work Centre Carding - - - 1F+2H+1 Flat Grinder PF PH PF PH Frequency/ Month Crew Category WLS No:BSM/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower No of Machine Monthly workload(Hours) S. No Activity Description Time (in Hours) Overhauling Cylinder Wire Change Doffer Wire Change Flat Tops Change St.Flats ( Doffer ) change Combing Segment Change a) Allow to run out the machine b) Stop the machine c) Open the cover and Belts & whole machine d) Remove lap roll, lap stand, Feed plate feed roll,Lickerin,Undercasing e) Remove the flats & Flat bend f) Remove the old wire from Cylinder g) Remove the old wire from Doffer h) Take bare Reading of Cylinder and Doffer i) Open all the gears j) Fix mounting machine on Cylinder k) Mount The cylinder l) Fix mounting Machine on Doffer 26 2 23.227 69.68 1 3 21.44 1/24 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+3 H Work Centre Carding - - - 1F+2H+1 Flat Grinder PF PH PF PH Frequency/ Month Crew Category WLS No:BSM/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower No of Machine Monthly workload(Hours) S. No Activity Description Time (in Hours) m) Mount the doffer n) light grinding on Cylinder and doffer o) Put the new St doffer side and Combing Segment p) Assemble whole the parts and fix on machine q) Fix all the gears on machine r) Put new stationary flats on machine s) Reset all the gauge t) Start the machine at slow speed for checking of abnormal sound u) Handover the machine to Production 3 Stationary Flats ( Licker-in ) change 1/9 1 2 2.144 26 6 12 a) Remove licker in b) Open all the stationary flats c) Remove old Stationary Flats d) remove Top and bottom Plate licker in side e) Put new flats f) Fix on machine g) Fit the licker in on machine h) Reset the gauge _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+3 H Work Centre Carding - - - 1F+2H+1 Flat Grinder PF PH PF PH Frequency/ Month Crew Category WLS No:BSM/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower No of Machine Monthly workload(Hours) S. No Activity Description Time (in Hours) 4 Licker-in Wire Change 1/9 1 1 2.144 26 6 6 j) Open the licker in wire k) Mount the wire on licker in 5 Cylender,Doffer Grinding(28 in the last one year) 2 1/3 1 2 2.144 1 5 10 a) Allow to run out the machine b) Fix the grinder on doffer c) Set the gauge for grinder d) Run grinder without contact of doffer wire e) Give the contact of grinder to doffer wire f) Remove the grinder from doffer g) Stop the machine h) Open the top and bottom plate and doffer side st flats i) Reverse the direction of Cylinder j) Put grinder on cylinder k) Give the contact of grinder to cylinder l) Stop the machine m) Fix all the parts on machine n) Reset the gauge o) Start the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+3 H Work Centre Carding - - - 1F+2H+1 Flat Grinder PF PH PF PH Frequency/ Month Crew Category WLS No:BSM/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower No of Machine Monthly workload(Hours) S. No Activity Description Time (in Hours) 6 Sharprite 1/6 1 2 2.144 26 9 19 a) Allow to run out the machine b) Fix the grinder on doffer c) Set the gauge for sharpener d) Give the contact of sharpener to doffer wire e) Remove the sharpener from doffer f) Stop the machine g) Open the top and bottom plate and doffer side st flats h) Reverse the direction of Cylinder i) Put sharpener on cylinder j) Give the contact of sharpener to cylinder k) Stop the machine l) Fix all the parts on machine m) Reset the gauge n) Start the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+3 H Work Centre Carding - - - 1F+2H+1 Flat Grinder PF PH PF PH Frequency/ Month Crew Category WLS No:BSM/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower No of Machine Monthly workload(Hours) S. No Activity Description Time (in Hours) 7 Clearer roller clothing change (7 in the last one year) 3/5 1 3 1.072 1 1 2 a) Allow to run out the machine b) Stop the machine c) Remove the clearer roll d) Open the clothing e) Mount the new clothing f) Fix on machine g) Reset the gauge h) Start the machine 8 Gearbox oil change 1/8 1 1 1 26 3 3 9 Petrol Stripping 1 1 3 4.288 1 4 13 10 Developmental Machine- MMC&LR 1 1 3 4.288 1 4 13 11 Breakdown(from past record) 1 1 5.75 1 6 0 12 Running Problems 1 1 26 1 0 26 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+3 H Work Centre Carding - - - 1F+2H+1 Flat Grinder PF PH PF PH Frequency/ Month Crew Category WLS No:BSM/W/02 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower No of Machine Monthly workload(Hours) S. No Activity Description Time (in Hours) Proposed Method 13 Flat Grinding 20.8 A 130.51 360.90 B 166.4 166.4 C 78.43% 72.30% D 1 3 E 78.43% 76.52% Proposed Manpower The running fitter attends the running problem only in the general shift. The running problem between 5pm to 8 am is attended by production operator. The fitter is called whenever required depends on the problem. It also found that the running problems are very less and breakdown is very minimal. The activity of flat grinders are considered in the proposed method. Proposed Utilisation(%) Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - 1 Designation Proposed Manpower - - 0 Sl. No Crew Size Freq/ Month Basic Time (hours) No of machin es Monthly Workload (hours) 1 1 1/24 4.80 26 5.20 2 1 1/24 4.80 26 5.20 3 1 1/24 4.80 26 5.20 4 1 1/24 4.80 26 5.20 A 20.80 B 166.4 E 12.50% F 0 G 0.00% Number of carding machine - 26 Nos It is suggested that flat grinder performs the scheduled works, the operator performs the flat grinding activity. Number of stationary flats per machine - 88 nos The utilisation of flat grinder is only 12.50%. The activity of flat grinder is not time bounded like machine has to start within given hours. As all the activities are outside work, it does not affect the machine availability. Present Utilisation(%) Proposed Utilisation(%) Flat Grinding Remarks: Activity Description Remove the stationary flats from flats(88 nos) Take bare reading and leveling(88 nos) C Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) - - Grinding of all the flats(88 nos) Flat Grinder Clip all the flats(88 nos) Frequency of flat grinding - once in two years Proposed Manpower per shift WLS No:BSM/W/03 BTM Shifts A B G Mechanical WORK LOAD DETAILS SHEET _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH A Drawframe 1 M/C Cleaning 2 1 2 1.42 11 14 62 a) Allow to run out the material b) Stop the machine c) Remove all the cans from machine d) Put the Rexin and bench on machine e) Remove the top roll from machine f) Clean the top clearer cloth g) Remove the jam of bottom h) Remove the coiler cover i) Clean all the coiler j) Apply grease in bottom roll ,coiler,callender roll and delivery roll shaft&gearing k) run the machine l) Stop the machine m) remove fly and grease n) Clean All the rolls and coiler from petrol o) Apply Chalk powder in bottom roll ,coiler,callender roll and delivery roll shaft p) Check the machine for any abnormality q) Put top roll on machine WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine 2 Coiler OH 1/2 1 2 1.42 11 8 16 3 Oil Change 1/2 1 1 1.42 11 8 8 4 Bottom Roll Trueing 1/2 1 1 2.84 11 16 16 a) Allow to run out the material b) Stop the machine c) Remove all the cans from machine d) remove the oil from gear box e) Open the gearing and coiler f) Open the gear box g) Take out the all rolls h) Clan the roll and slide gearing and Gear box, coiler with brush and kerosene i) Check and roll true j) Check wire rings and balls if faulty then replace k) Apply grease in coiler l) Reset the coiler m) Clan the coiler plate from wall hold compound n) put all rolls, coiler and gears in machine o) Apply FCV powder where needed p) Start the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine B Simplex 1 M/C Cleaning 1 1 3 4.49 10 27 135 a) Allow to run out the material b) Stop the machine c) Take out all the flyer d) Raise the pateli e) Run the machine idle &apply grease in Bottom roll f) Clean the Excess grease from bottom roll g) Raise the top arm and remove the cradle h) Wash the top apron from surf i) Refix all the aprons on cradle j) Apply lubricants on weight chain, lever chain and lever bush & pateli bush k) Stop the machine l) Clean the top and bottom clearer cloth m) Remove the jam from bottom roll n) Clean all the gearing o) Check all the bearing and gears _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine p) Clean all the spindle wheel, bobbin wheel Bobbin rail and Spindle rail& apply grease on q) Close all the cover r) clean all the flyer s) Fit cradle on machine t) Reset the Arm u) Start the machine and down the petti v) Apply spindle oil in spindle w) Run the machine idle x) Stop the machine y) Then reclean all the grease and oil z) Put flyer on spindle aa) Clean the flyer with rope and petrol ab) handover the machine 2 Long Collar Cleaning 1/3 1 3 1.50 10 5 15 a) Allow to run out the material b) Stop the machine c) Open the spindle cover d) Open the spindle and take it out e) Clean the collar from bottle brush _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine f) Remove old oil from spindle housing g) Put fresh oil h) Refix the spindle in collar i) Make them free j) Set all the spindle wheel k) Apply grease on spindle and bobbin wheel l) Close the cover m) Start the machine 3 Bottom Apron Change 1/9 2 0.25 10 0 1 4 Top Apron Change 1/18 2 0.25 10 0 0.28 5 Middle Arbor Greasing 1/12 2 0.17 10 0 0.28 6 Bottom roll gauge checking & Top arm pressure setting 1/6 1 1 1.50 10 2 2 a) Allow to run out the material b) Stop the machine c) Check the Arm pressure and arm bar _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine 7 Spindle Trueing 1/6 1 1 1.50 10 2 2 a) Allow to run out the material b) Stop the machine c) Take out all the spindle d) True all the spindle e) Clean all the long collar f) Put spindle in collar g) Make them free h) Close the cover i) Apply oil in long collar in running mode j) Clean all the excess oil in stoppage mode k) Run the machine 8 Bottom Roll Trueing 1/6 1 1 2.99 10 5 5 a) Allow to run out the material b) Stop the machine c) Raise the top Arm d) Take out the bottom roll e) Clean all the bottom roll f) Check all the bearing of bottom roll g) Make all the true _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine h) Fit on the machine i) Apply grease in all rolls in running mode j) Clean all the grease with petrol k) Start the machine 9 Bottom Roll Trueing ( Front & middle) 1/24 1 1 2.99 10 1 1 a) Allow to run out the material b) Stop the machine c) Raise the top Arm d) Take out the bottom roll e) Clean all the bottom roll f) Check all the bearing of bottom roll g) Make all the true h) Fit on the machine i) Apply grease in all rolls in running mode j) Clean all the grease with petrol k) Start the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+3H Work Centre Drawframe & Simplex - - - 1F+3H PF PH PF PH WLS No:BSM/W/04 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. No Activity Description Crew Category Monthly workload(Hours) Frequency/ Month No of Machine 10 Developmental Machine(Drawframe 2 1 3 5.99 1 12 36 11 Running work(Draw frame &Simplex)Provided in the schedule ( 2 days/month) 2 1 3 5.99 1 12 36 C Proposed Method: 2 1 3 5.99 1 12 Activity of Running fitter is divided among three helpers and one fitter ( 69 hours/month = 17.5 hours fitter & 52.5 hours helpers) 17.50 52.50 A 111.91 335.21 B 166.4 166.4 C 67.25% 67.15% D 1 3 E 77.77% 77.67% In this section (Drawframe&Simplex) the fitter % utilisation is very minimal when compared to the other sections. In other section, the total time of cleaning is approx one hour. In that involvement of fitter is also around 30-40 mins. Whereas in D/F & Simplex Machine cleaning time is approx 4 hours(D/F) & 6 Hours(Simplex). In this situation, the work of fitter (40 mins) is very minimal. Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ____________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 0 Sl. No Crew Size Freq/ Month Basic Time (hours) Monthly Workload (hours) A 1 1 26 0.17 4.33 2 1 26 0.17 4.33 3 1 26 0.30 7.80 B 1 1 26 0.25 6.50 2 1 248 0.03 7.44 3 1 358 0.03 10.74 4 1 4 0.75 3.00 5 1 49 0.50 24.50 A 68.65 B 166.4 E 41.25% F 0 G 0.00% Count change = 147/3 = 49 Proposed Manpower per shift Proposed Utilisation(%) Remarks: Aprons Changed = 742/3 = 248 Cots Changed = 1072/3 = 358 Flyer ceramic bush changed = 11/3 = 4 Draw frame&Simplex Running Fitter Activity Description Count change Drawframe: Monitor the sliver @ Cherryhara & LR Check the stop motion Change the flyer ceramic bush The activity is shifted to drawframe mechanical gang and considered there. Data collected from past record (Sep'11 to Nov'11) Take the sample for uster % checking to lab, wait and collect the result Change the apron Simplex Round checkup the machine for problem Change the Cots Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) WLS No:BSM/W/05 WORK LOAD DETAILS SHEET BTM Shifts A B C G Mechanical _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - 1F+1H Designation Proposed Manpower - - 1F Sl. No Crew Size Freq/ Month Basic Time (mins) No of machine s Monthly Workload (mins) 1 1 1 5.00 2 10.00 1 1/3 0.17 21120 1173.33 2 1/3 0.17 10560 586.67 1 1 5.00 2 10.00 2 1/3 0.30 211 21.12 2 1 1/3 15.00 48 240.00 1 1/3 15.00 48 240.00 3 1 1 5.00 2 10.00 1 1/2 0.17 540 45.00 2 1/2 0.17 135 11.25 1 1 5.00 2 10.00 2 1/2 0.30 11 1.62 4 1 1/2 15.00 10 75.00 1 1/2 15.00 10 75.00 5 1 1 1/24 0.12 48 0.23 1 1/24 0.55 21120 484.00 1 1/24 0.23 48 0.47 1 1/24 0.25 48 0.50 1 1/24 0.15 21120 132.00 6 1 1 1/24 0.12 10 0.05 1 1/24 0.55 540 12.38 1 1/24 0.23 10 0.10 1 1/24 0.25 10 0.10 WLS No:BSM/W/06 WORK LOAD DETAILS SHEET BTM Shifts A B C G Mechanical - Cots Buffing-Ring Frame Bring the cots trays from the machine area Cots Buffer - Activity Description Cots Buffing Room Buff in the machine(machine cycle time).Operator work only feeding Prepare liquimix solution Apply liquimix on whole sets Grease the whole sets(50 pieces-19 mins*2crew Apply liquimix on whole sets Check the eccentricity machine(parallel done Keep back the trays to machine area Grease the whole sets(50 pieces-19 mins*2crew size) Second time buffing(25%) Check the eccentricity machine(parallel done during buffing) Remove cots Remove the bolt from machine Buff in the machine(machine cycle time).Operator work only feeding Second time buffing(25%) Keep back the trays to machine area Soak the cots in that overnight&clean Set the bolt on machine to remove cots Cots Mounting-Simplex Fix the new bolt on machine Remove the bolt from machine Fix the new bolt on machine Fix new cots Set the bolt on machine to remove cots Remove cots Prepare liquimix solution Soak the cots in that overnight&clean Cots Mounting-Ringframe Cots Buffing-Simplex Bring the cots trays from the machine area _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - 1F+1H Designation Proposed Manpower - - 1F Sl. No Crew Size Freq/ Month Basic Time (mins) No of machine s Monthly Workload (mins) WLS No:BSM/W/06 WORK LOAD DETAILS SHEET BTM Shifts A B C G Mechanical - Cots Buffer - Activity Description Cots Buffing Room 1 1/24 0.15 540 3.38 7 1 1/60 1.02 33 0.56 1 1/60 0.72 33 0.39 8 1 1/24 10.00 48 20.00 1 1/24 1.02 5280 223.67 1 1/24 2.48 5280 545.60 A 3932.41 B 9984.0 E 19.69% F 1 G 39.39% Fix new cots Fix new cots Cots Mounting -Drawframe Remove spindle Remarks: Apply fevicol, fix the new cloth & dry Total Workload per month ( in man mins ) Net Available man-mins per month(480*26*80%= 9984 mins) Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Fix the green cloth on the top roller clearer Soak the top roller clearer overnight Remove the old cloth _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+1AF+8H Work Centre Ringframe & TFO - - - 1F+1AF+8H PF PH PF PH A Ringframe 1 M/C Cleaning & Top Apron Change 2 2 8 0.99 48 189.6 758.4 a) Stop the machine b) Lift out the top roller clearer c) Lift out the top arm d) Wrap out the rove bobbins e) Cleaning of the bobbin holder caps f) Dismantling of the pnumafil pipe g) Cleaning of the front, middle & back arbor h) Cleaning of the L-Bracket, apron bridge bar and fluted roller i) Back zone cleaning j) Cleaning of the lifting, lifting pulley, lappet rod, poker rod, porker rod tube. k) Cleaning of the spindle and ring rail l) Bolster jam cleaning m) Mantling of the pnumafil pipes n) Pressing of the top arms o) Placing of the top roller clearer. p) Dismantling of the draft gear No of Machine Frequency/ Month Monthly workload(Hours) Time (in Hours) S. No Activity Description Crew Category WLS No:BSM/W/07 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+1AF+8H Work Centre Ringframe & TFO - - - 1F+1AF+8H PF PH PF PH No of Machine Frequency/ Month Monthly workload(Hours) Time (in Hours) S. No Activity Description Crew Category WLS No:BSM/W/07 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower q) Cleaning & Checking of the draft gear r) Greasing of the machine & motor pulley s) Checking of roving guide and spacer, t) Cleaning of the gutter Top Apron Change a) Stop the machine & Dismantle the cradles b) Removal of the old aprons c) Insert the new apron in the cradles d) Insert the cradle and start the machine 2 Spindle Oil Topping 1/4 8 0.083 48 0 8 a) Removal of the spindle b) Dropping of the oil in to the spindles c) Placing of the spindles on its position 3 Spindle.Oil Change 1/12 2 8 0.25 48 2 8 a) Removal of the spindle b) Replacing of the oil in to the spindles with the help of oiling machine c) Placing of the spindles on its position _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+1AF+8H Work Centre Ringframe & TFO - - - 1F+1AF+8H PF PH PF PH No of Machine Frequency/ Month Monthly workload(Hours) Time (in Hours) S. No Activity Description Crew Category WLS No:BSM/W/07 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower 4 Bottom Apron Change 1/8 0 8 0.25 48 0 12 a) Dismantling of the bridge bar b) Removal of the old aprons c) Insert the new aprons d) Mantling of the bridge bar 6 Middle Arbor Greasing 1/12 0 8 0.153 48 0 4.89 a) Open of the arbor b) Greasing of the arbor c) Petrol wash of the arbor 7 Rings Change-Texmaco Developmental 2 2 8 0.79 1 3.2 12.6 8 Rings Change-LR Developmental m/c 2 2 8 0.79 1 3.16 12.64 9 Spindle Change 1/120 0 4** 9.5 50 0 7.0 10 Lifting OH 1/24 0 3** 9.5 48 0 16.8 B TFO 1 M/C Cleaning 1 2 8 1.02 48 98.04 392.16 a) Allow to run out the material _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+1AF+8H Work Centre Ringframe & TFO - - - 1F+1AF+8H PF PH PF PH No of Machine Frequency/ Month Monthly workload(Hours) Time (in Hours) S. No Activity Description Crew Category WLS No:BSM/W/07 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower b) Stop the machine c) Clean the adaptor d) Down the cradle and clean them e) Remove jam from drum &PTR and clean them f) Clean the Pig tail, J.Pulley. g) Remove jam from J.Pulley and Drum Pulley d) Clean separator from surf and Dhoti f) Take out the pot g) Clean the pot from surf and dhoti h) Take out the spindle i) Clean the spindle from dhoti surf j) Clean the thread guide k) Clean the beam l) Clean the drum pulley m) Put spindle n) Put pot o) Reset the setting of pot p) Clean and check all the gearing and if found faulty the informed to foreman _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+1AF+8H Work Centre Ringframe & TFO - - - 1F+1AF+8H PF PH PF PH No of Machine Frequency/ Month Monthly workload(Hours) Time (in Hours) S. No Activity Description Crew Category WLS No:BSM/W/07 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower q) Apply grease on gearing r) Close the cover s) Start the machine t) Clean the break u) clean the machine v) Handover to production 2 Spindle Oil Topping 1/2 1 1 0.25 48 6 6 a) Stop the machine b) Taken out the pot c) Taken out the spindle d) Topping done e) Put Spindle f) Put Pot g) Start the machine 3 Spindle Oil Change 1/12 1 1 0.50 48 2 2 a) Stop the machine b) Taken out the pot c) Taken out the spindle _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+1AF+8H Work Centre Ringframe & TFO - - - 1F+1AF+8H PF PH PF PH No of Machine Frequency/ Month Monthly workload(Hours) Time (in Hours) S. No Activity Description Crew Category WLS No:BSM/W/07 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower d) Clean the spindle e) Remove burnt oil from bolster f) Put fresh oil g) Put Spindle h) Put Pot i) Start the machine 4 Spindle Bearing Greasing-VJ 1/12 1 1 0.25 38 0.792 0.792 a) Allow to run out the material b) Stop the machine c) Remove pot and spindle d) Clean the spindle and pot e) Apply grease in spindle bearing f) Put spindle g) Put pot h) Start the machine 5 Spindle Bearing Greasing-Prerna 1/4 1 1 0.25 10 0.625 0.625 a) Allow to run out the material b) Stop the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1F+1AF+8H Work Centre Ringframe & TFO - - - 1F+1AF+8H PF PH PF PH No of Machine Frequency/ Month Monthly workload(Hours) Time (in Hours) S. No Activity Description Crew Category WLS No:BSM/W/07 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower c) Remove pot and spindle d) Clean the spindle and pot e) Apply grease in spindle bearing f) Put spindle g) Put pot h) Start the machine A 305.38 1241.95 B 166.4 166.4 C 91.76% 93.30% D 2 8 E 91.76% 98.31% * Out of three helpers, one are from cleaning gang. ** Out of four helpers, two are from cleaning gang. Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) Total Workload per month ( in man hours ) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH 1 Draft Gear Overhauling 1/6 2 2 2.4 50 39.57 39.57 a) Stop the machine and dismantle the whole draft gear system b) Washing of the gears, bearing, stud and stud key with kerosene oil c) Mantling of the whole draft gear system d) Start the machine and checking the gear system 2 Heart Cam Overhauling(Texmaco M/c only) 1/3 1 1 1.2 32 12.66 12.66 a) Stop the machine and dismantling of the heart cam assembly b) Checking and cleaning of the heart cam, heart cam shaft, ball bearings, plate wheel, ratchet pawl & ratchet pawl stud c) Mantling of the heart cam assembly d) Start the machine and check the movement of the heart cam WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) 3 Heart Cam Overhauling-Develop-Texmaco 1/3 2 2 1.0 1 0.67 0.67 4 J.P.Ball Brg. Greasing 1/12 2 2 2.4 48 18.992 18.992 a) Stop the machine and dismantling of the jockey pulley system b) Greasing of the jockey pulley c) Mantling of the jockey pulley d) Dismantling of the cover of the pedestal e) Cleaning of the pedestal f) Greasing of the pedestal g) Mantle the cover of the pedestal h) Setting of the jockey pulley, T.R Pulley and drum pulley and tap i) Start the machine and check the machine 5 J.P.Ball Brg. Greasing-Texmaco Developmental m/c 1/12 2 2 0.5 1 0.08 0.08 6 J.P.Ball Brg. Greasing-LR Developmental m/c 1/12 2 2 1.0 1 0.17 0.17 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) 7 Bottom Roll Truing 1/12 2 2 7.1 48 56.98 56.98 a) Open of the bottom roll bearings of the reserved b) Washing of the bottom roll with petrol with the c) Fitting of the bearing in the bottom roll d) Roll to roll joining e) Truing of the bottom roll f) Stop the one side of the machine and remove the bottom roll from the machine g) Mantling of the new trued roll to the machine h) Start the that side of the machine i) Repeat the steps from a to h for other side of the machine 8 Bottom Roll Truing-Texmaco Developmental m/c 1/12 2 2 1.0 1 0.17 0.17 9 Bottom Roll Truing-LR Developmental m/c 1/12 2 2 4.0 1 0.67 0.67 10 Lappet Hook Change 1/24 2 2 2.4 1 0.20 0.20 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) a) Stop the machine and dismantling of the lappet hook b) Rough fitting of the new lappet hooks c) Lappet gauge of the lappet hook 11 Lappet Hook Change-Texmaco Developmental m/c 1/24 2 2 1.0 1 0.083 0.083 12 Lappet Hook Change-LR Developmental m/c 1/24 2 2 1.0 1 0.083 0.083 13 Lifting OH 1/24 2 3* 7.1 48 28.488 32.4 a) Stop the machine and dismantle the lappet rail b) Dismantling of the separator c) Dismantling of the ring rail d) Dismantling of Lifting pulley, lappet rod, pocket rod, pocker rod tube e) Dismantling of the ball bearing of the lifting pulley f) Washing of lappet rod, pocker rod tube, ring rail head bracket g) Mantling of the lifting pulley with new bearing _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) h) Complete assembling of the lappet rod, pocker rod tube, ring rail head bracket i) Ring rail fitting & lappet rail fitting j) Ring rail height gauge and lappet rail height gauge k) Spindle gauge and lappet gauge l) Fly catcher gauge m) Separator fitting and start the machine 14 Lifting OH-Texmaco Developmental m/c 1/24 2 2 4.0 1 0.33 0.33 15 Lifting OH-LR Developmental m/c 1/24 2 2 4.0 1 0.33 0.33 16 Spindle Gauge 1/8 2 2 2.4 48 28.488 28.488 a) Stop the machine and dismantling of the separator b) Cleaning of the poker tube and lappet rod c) Ring rail height gauge d) Lappet rail height gauge e) Spindle gauge f) Lappet gauge g) Fly catcher gauge h) Fitting of the separator and start the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) 17 Spindle Gauge-Texmaco Developmental m/c 1/8 2 2 0.5 1 0.125 0.125 18 Spindle Gauge-LR Developmental m/c 1/8 2 2 1.0 1 0.25 0.25 19 Rings Change 1/24 2 2 7.1 48 28.49 28.49 a) Stop the machine and dismantle the separator b) Remove the ring rail and cleaning of the ring rail c) Change the ring with new one d) Cleaning of the lappet rod & pocker rod tube e) Fitting of the ring rail f) Ring rail height gauge g) Lappet rail height gauge h) Rough ring gauge i) Final ring gauge j) Lappet hook gauge k) Fly catcher gauge l) Fitting of the separator m) Start the machine and check the movement 20 Rings Change-Texmaco Developmental m/c 1/24 2 2 1.0 1 0.083 0.083 21 Rings Change-LR Developmental m/c 1/24 2 2 1.5 1 0.125 0.125 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) 22 Spindle Change 1/120 2 4** 7.1 50 5.935 6.75 a) Stop the machine and dismantle the ABC Ring rail b) Dismantle the separator c) Loose the bolster d) Bolster open with spindle e) Fitted the new bolster with spindle f) Tight the bolster g) Open the spindle h) Oiling the bolster i) Fitting the spindle in to the bolster j) Ring rail height gauge k) Lappet Height gauge l) ABC ring rail height gauge and fitting m) Dismantling of the ABC rings rail n) Ring gauge o) Lappet gauge p) Fly Catcher gauge q) Fitting of the separator r) ABC ring rail fitting and start the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+ 2 H Work Centre Ringframe & TFO - - - 2 F+ 2 H PF PH PF PH WLS No:BSM/W/08 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Frequency/ Month Crew Category S. No Activity Description Time (in Hours) No of Machine Monthly workload(Hours) A 222.96 227.69 B 166.4 166.4 C 67.00% 68.42% D 2 2 E 67.00% 68.42% ** Out of four helpers, two are from cleaning gang. Proposed Manpower Proposed Utilisation(%) Present Utilisation(%) * Out of three helpers, one are from cleaning gang. Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - 1 Designation Proposed Manpower - - 1 Sl. No Crew Size Freq/ Month Basic Time (hours) No of machin es Monthly Workload (hours) 1 1 2 0.35 48 33.60 2 1 2 0.25 48 24.00 3 1 7.75 4 1 A 65.35 B 166.4 E 39.27% F 1 G 39.27% Proposed Utilisation(%) Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) Proposed Manpower per shift Remarks: - Duct Fitter G Major idle attend Ringframe Activity Description Mechanical - Assist the Foreman in attending breakdown WLS No:BSM/W/09 WORK LOAD DETAILS SHEET BTM Shifts A B C Clean the Pn pipe,Clean all the duct To check the all spindle lock _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH A Autowinding 1 M/C Cleaning & Cleaning of Base Adaptor 2 1 3 1.19 7 16.59 49.77 a) Stop the machine b) Dismantle the magazine c) Cleaning of the machine with the air pressure d) Cutting of the adopter jam e) Conveyor belt plate is removed from the machine for cleaning f) Cutting of the jam on the conveyor belt pulley g) Cleaning of the Jali d) Cleaning of the head stock f) Checking of the suction and conveyor belt g) Cutting of the jam on material trolley or repairing of the bearing in case jammed h) Checking of the machine as per the check sheet and attend if found any abnormality. 2 Winding. Head Cleaning & Oiling 1/3 1 3 0 7 0.92 2.77 Open the cover WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) Clean the Head by Air pressure Remove any abnormality if found Grease at necessary parts Close the cover 3 Suction Arm Setting Setting check 1/3 1 3 0 7 0.58 1.75 4 Gripper arm Setting 1/3 1 3 0 7 0.58 1.75 Setting check 5 Yarn Trap OH 1/4 3 3 7 0.00 16.59 Open the yarn trap Open the yarn trap assembly Clean the bracket the Gear Clean the assembly and yarn trap Silicon oil added on yarn trap assembly rod Refix the yarn trap assembly Fix the assembly on machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) Fix the yarn trap on machine 6 Splicer Servicing 1/4 3 3 7 0.00 16.59 Open the splicer Open the cover Open the introducer Clean the introducer Open the preparatory of splicer Clean the Splicer Check the chamber cover and chamber cover spring Assemble the splicer Fit on spindle 7 Magazine cover cleaning 1/6 1 3 1 7 0.81 2.42 Remove the magazine Remove the magazine cover clean the magazine cover assembly with petrol Grease on magazine cover rod and spring Clean the magazine cover _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) Fix the magazine cover Mix the magazine 8 Cradle setting 1/6 2 1 7 0.00 1.61 Stop the machine loose the bolt Put the cone Reset the gauge by 5 mm on base side Reset the gauge by 4 mm nose side Tight the bolt start the machine 9 Bobbin Peg Overhauling 1/4 3 2 7 0.00 8.30 Open the bolt Open the bobbin peg cut the jam Clean the bush of bobbin peg lever Fix the bobbin peg Tight the bolt _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) 10 Duct Cleaning 1/6 2 4 2 7 3.69 7.37 Stop the machine Remove the magazine Close the Air pressure Open the bolt of pressure pipe Lift the pressure pipe Open the duct chamber Remove the support of duct Open the joint Remove the economizer with Allen key Clean the duct Remove the pipe Clean the economizer Clean the pipe Refit the duct 11 Suction arm OH 1/12 2 4 1 7 1.61 3.23 Stop the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) Open the winding head Open the fitting Open the suction arm Open the lock of fitting taken out the shaft of fitting Clean the all the suction arm assembly Clean the fitting and suction arm with surf Added silicon oil Refix the suction arm assbly Fit it on the Suction arm and fitting Rest the setting of suction arm Start the machine 12 Clutch OH 1/12 2 4 2 7 1.84 3.69 Stop the machine open the cover remove the clutch belt Open the clutch bolt Take out the clutch _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) Clean the clutch with petrol Apply grease on clutch Clean the base of clutch Fit the clutch and Fit the Belt Reset the clutch Start the machine 13 Splicer OH 1/12 2 4 2 7 1.84 3.69 Stop the machine Open the splicer pipe Open the splicer Open the splicer cover Clean the splicer with Petrol Apply OKS 475 Hs grease on Splicer Close the cover Fix splicer on the machine & pipe 14 Tension Disc Clg ,Setting & OH 1/6 2 4 1 7 1.84 3.69 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) Open the tension assly Open the tension disc ,piston Clean the tension disc and piston Apply oil on piston Fix the disc and piston in tension assembly Clean the tension assembly Fix on machine 15 Tension Assembly Clg & Oiling 1/12 2 4 1 7 0.92 1.84 Open the tension assly Open the tension disc ,piston Clean the tension disc and piston Apply oil on piston Fix the disc and piston in tension assembly Clean the tension assembly Fix on machine 16 Adaptor Greasing 1/6 1 3 1 7 0.92 2.77 Remove the adaptor _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) Clean the spring Clean the adaptor Clean the machine arm Nose side jam removal Fix it back on machine B Cheese Winding 1 M/C Cleaning with Upper & Lower Guide pulley Oiling 2 1 3 2 7 33.71 101.12 a) Allow to run out the material b) Stop the machine c) Remove the Swing plate and Swing plate cover d) Remove the jam from Drum & Drum Shaft e) Remove jam from adaptor f) Remove the jam of stop motion shaft g) Clean the whole machine from bottle brush d) Open the upper and lower guide pulley f) Clean the upper and lower guide pulley _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) g) Apply oil and fit on the machine of both the guide pulley h) Lubrication on all the points i) Complete all the missing spare j) Fix the swing plate and swing plate cover on machine k) Check all the belts and pulley l) Start the machine and handover it to Production 2 Drum shaft brg. Greasing 1/6 1 3 6 7 7.49 22.47 a) Allow to run out the material b) Stop the machine c) Loose all the drums d) shift the drums e) Open the bearing cover f) Taken out the burnt grease g) Put fresh grease d) Check all the bearing if found faulty then replace f) Close all the bearing cover g) Set the cradle and drum _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) h) Start the machine for 5 min i) Stop the machine j) Then clean the drum and bearing cover with petrol for removing the greasing k) Start the machine and handover it to Production 3 Yarn Path Setting 1/3 2 3 7 0.00 14.98 a) Check the yarn path b) If found any problem then reset them 4 Adopter Greasing & Drum cradle setting 1/3 1 2 7 0.00 5.15 a) Allow to run out the material b) Stop the machine c) Fit the cheese in Cradle & check d) If faulty then reset e) Start the machine and handover it to Production 5 Drop Needle Change 1/10 3 3 7 0.00 6.74 _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 2 F+3 H Work Centre Autoconer & Cheesewinding - - - 2F+3 H PF PH PF PH WLS No:BSM/W/10 WORK LOAD DETAILS SHEET Shifts Present Manpower Proposed Manpower Time (in Hours) S. N o Activity Description Crew Category Frequency/ Month No of Machine Monthly workload(Hours) 6 Yarn guide hook 1/10 3 3 7 0.00 6.74 7 Developmental Machine-Cone Winding 1 1 3 6 1 6.42 19.26 8 Developmental Machine-SSM(Fibre dyeing) 1 3 6 1 0.00 19.26 9 Developmental Machine-PS Metler&Classmate 1 1 3 6 1 6.42 19.26 10 Breakdown Works 1 1 5 4.75 0.00 11 Attend idle spindle(Autoconer&Cheesse winding) 26 1 2 52.00 0.00 A 142.94 342.79 B 166.4 166.4 C 42.95% 68.67% D 2 3 E 42.95% 68.67% Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - 1 Designation Proposed Manpower - - 0 Sl. No Crew Size Freq/ Shift Basic Time (mins) No of machin es Total Workloa d (mins) 1 1 1 3.95 22 86.96 2 1 1 3.68 10 36.81 3 1 1 3.87 7 27.07 4 1 1 3.91 9 35.19 5 1 1 112.50 1 112.50 A 174.76 B 360.0 E 48.55% F 0 G 0.00% B C OHB Fitter - Activity Description Autoconer,Chee sewinding,TFO Net Available man-mins per shift(480*80% = 360 mins) Present Utilisation(%) Stop the OHTC,Clean the waste box of OHTC,remove the dust accumulated, clean the filter with emery sheet, Clean the outer surface of OHTC using cloth,brush,Check the suction of OHTC,clean the fly in the rail, check whole the waste discharge Festo Remarks: Stop the OHTC,Clean the waste box of OHTC,remove the dust accumulated, clean the filter with emery sheet, Clean the outer surface of OHTC using cloth,brush,Check the suction of OHTC,clean the fly in the rail, check whole the waste discharge system WLS No: BSM/W/11 WORK LOAD DETAILS SHEET BTM Shifts A Jacobi Stop the OHTC,Clean the waste box of OHTC,remove the dust accumulated, clean the filter with emery sheet, Clean the outer surface of OHTC using cloth,brush,Check the suction of OHTC,clean the fly in the rail, check whole the waste discharge system Autoconer Cheesewinding/Rewinding G - Mechanical Overhaul the OHTC machine(once in two month) Proposed Utilisation(%) Total Workload per shift ( in man mins) Proposed Manpower per shift Stop the OHTC,Clean the waste box of OHTC,remove the dust accumulated, clean the filter with emery sheet, Clean the outer surface of OHTC using cloth,brush,Check the suction of OHTC,clean the fly in the rail, check whole the waste discharge system _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - 1 Designation Proposed Manpower - - 0 Sl. No Crew Size Freq/ Shift Basic Time (mins) No of machin es Total Workloa d (mins) B C OHB Fitter - Activity Description Autoconer,Chee sewinding,TFO WLS No: BSM/W/11 WORK LOAD DETAILS SHEET BTM Shifts A G - Mechanical No of machines Area 4 TFO 3 Unit-3 15 R/F 1 Winding Cheese Winding - 5 nos Ring frame(unit-2) - 5 nos Ring frame(unit-1) - 7 nos 1 Festo Unit-3 R/F Instead of providing one separate personnel for OHTC maintenance with 51.06% utilisation, it is recommended that the activity could be performed by the respective section's maintenance gang. It increases the respective gang utilisation and reduces the separate manpower required. Total OHTC in BTM Savio- 8 Nos TFO (unit1 &2) - 8 nos No of machines TFO Ring frame(unit-3) - 8 nos TFO(unit-3) - 7 Nos Leewa Jacobi Area 4 1 5 _______________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+ 1 H Work Centre TFO - - - 1 F+ 1 H PF PH PF PH 1 Gear Oil Change (VJ - 38 M/cs) 1/12 1 1 1.00 38 3.17 3.17 a) Stop the machine b) Open the cover of gear box c) Remove old oil d) Clean all the gears e) Check all the gears f) Put fresh oil g) Check the oil pump d) Close the cover f) stop the machine g) Stop motion, Dropper 2 Gear Oil Change(PRN-10 M/c) 1/6 1 1 1.00 10 1.67 1.67 a) Stop the machine b) Open the cover of gear box c) Remove old oil d) Clean all the gears e) Check all the gears f) Put fresh oil g) Check the oil pump Monthly workload(Hours) Time (in Hours) Proposed Manpower Activity Description Crew Category WLS No:BSM/W/12 WORK LOAD DETAILS SHEET Shifts Present Manpower S. No Frequency/ Month No of Machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+ 1 H Work Centre TFO - - - 1 F+ 1 H PF PH PF PH Monthly workload(Hours) Time (in Hours) Proposed Manpower Activity Description Crew Category WLS No:BSM/W/12 WORK LOAD DETAILS SHEET Shifts Present Manpower S. No Frequency/ Month No of Machine d) Close the cover f) stop the machine 3 Stop motion, dropper setting, Adopter Greasing Setting 1/6 1 1 1.81 48 14.44 14.44 a) Allow to run out the material b) Stop the machine c) Take out the all adaptor d) Clean all the adoptor&Cradle e) Apply grease in cradle f) Pur adaptor in cradle g) Start the machine d) Down all the dropper wire f) Check the stop motion and reset stop motion g) Start the machine 5 T.R. & P.T.R. Greasing 1/6 1 1 0.76 48 6.06 6.06 a) Allow to run out the material b) Stop the machine c) Clean burnt grease from TR&PTR _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+ 1 H Work Centre TFO - - - 1 F+ 1 H PF PH PF PH Monthly workload(Hours) Time (in Hours) Proposed Manpower Activity Description Crew Category WLS No:BSM/W/12 WORK LOAD DETAILS SHEET Shifts Present Manpower S. No Frequency/ Month No of Machine d) Open all nipple e) Apply fresh grease from pump in TR&PTR f) Tight the nipple g) Start the machine h) Clean all the excess grease i) Handover the machine to production 6 Tin Roll Bearing Greasing(Only VJ-38 M/cs) 1/6 1 1 1.44 38 9.15 9.15 a) Stop the machine b) Open the nipple c) Apply grease d) Tight the nipple e) Start the machine f) Clean all the excess grease g) Handover the machine to production 7 Belt Guide roller Greasing(Only PRN-10 M/cs) 1/6 1 1 2.17 10 3.61 3.61 a) Stop the machine b) Allow to run out the material c) Remove the nipple from guide roller _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+ 1 H Work Centre TFO - - - 1 F+ 1 H PF PH PF PH Monthly workload(Hours) Time (in Hours) Proposed Manpower Activity Description Crew Category WLS No:BSM/W/12 WORK LOAD DETAILS SHEET Shifts Present Manpower S. No Frequency/ Month No of Machine d) Check all the duide pulley if faulty then replace e) Apply grease in all guide rolls, Tension pulley and main pulley f) Start the machine 8 Thread guide Setting, Cradle, Drum Setting 1/6 1 1 2.17 48 17.33 17.33 a) Allow to run out the material b) Stop the machine c) Insert cone in cradle d) Down the cradle on drum e) Set the cradle and drum f) Set the thread guide in middle portion of drum g) Check the setting through yarn from trum to thread guide h) Start the machine 9 Jokey Pulley Greasing 1/12 1 1 1.00 48 4.00 4.00 a) Stop the machine b) Apply grease in j.Pulley through pump and nipple c) Start the machine _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+ 1 H Work Centre TFO - - - 1 F+ 1 H PF PH PF PH Monthly workload(Hours) Time (in Hours) Proposed Manpower Activity Description Crew Category WLS No:BSM/W/12 WORK LOAD DETAILS SHEET Shifts Present Manpower S. No Frequency/ Month No of Machine 10 Gear Overhauling 1/12 1 1 2.89 48 11.55 11.55 a) Stop the machine b) Take out all the gears and bearing and stud c) Clean all the gears stud and bearings d) Check and replace all the defective gears stud and bearing e) Clean all the gear end f) Put grease in stud g) Fix all the gears d) Apply gears on all gears f) Start the machine and check for abnormal sound g) Close the cover h) Handover to production 11 Pig tail Setting 1/12 1 1 2.89 48 11.55 11.55 a) Stop the machine b) Remove the material from Pigtail c) Tie dori from off end to gear end d) Clean the pig tail _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department BTM A B C G Section Mechanical - - - 1 F+ 1 H Work Centre TFO - - - 1 F+ 1 H PF PH PF PH Monthly workload(Hours) Time (in Hours) Proposed Manpower Activity Description Crew Category WLS No:BSM/W/12 WORK LOAD DETAILS SHEET Shifts Present Manpower S. No Frequency/ Month No of Machine e) Set the Pigtail f) Cheek &set the alignment from spindle to Pigtail g) Remove the line dori d) Start the machine 12 Attend Developmental machine 1 1 1 6 1 6.00 6.00 13 Attend Idle Spindle at the shift starting 26 1 0 2 1 52.00 0.00 14 Count Change in TFO (during General Shift) 1 1 1 0.5 1 0.50 0.50 15 Repair & rectify the parts removed from the machine (in the room) 1 1 1 6 1 6.00 6.00 A 147.03 95.03 B 166.40 166.40 C 88.4% 57.1% D 1 1 E 88.4% 57.1% Total Workload per month ( in man hours ) Net Available man-hours per month(8*26*80% = 166.4 hours) Present Utilisation(%) Proposed Manpower Proposed Utilisation(%) Total Number of machine: VJ-38 Nos, PRN-10 Nos _________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 B BTM SPINNING - ELECTRICAL MAINTENANCE ________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm _________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 B 4.1 I II III G T I II III G T 1 Shift maintenance Shift Electrician 1 1 1 - 3 1 1 1 - 3 2 General shift maintenance Gen. Electrician - - - 2 2 - - - 2 2 3 Shift maintenance - Electronics Electronic 1 1 1 - 3 1 1 1 - 3 4 Humidity plant Humidity Attendant 1 1 1 - 3 1 1 1 - 3 5 General shift maintenance Gen.Fitter - - - 3 3 - - - 3 3 6 General shift maintenance Helper - - - 1 1 - - - 1 1 7 Motor maintenance Motor Winder - - - 1 1 - - - 1 1 8 Over head blower maintenance OHB Fitter - - - 1 1 - - - 1 1 9 Gutter cleaning Gutter Cleaner - - - 3 3 - - - 3 3 10 Motor maintenance Motor Fitter - - - 1 1 - - - 1 1 3 3 3 12 21 3 3 3 12 21 BTM SPINNING - ELECTRICAL MAINTENANCE Manpower Deployment S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks Total ___________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 4.0 B 4.2 1 BTM SPINNING - ELECTRICAL MAINTENANCE Proposed Changes & Observations No changes proposed. ________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5 A FIBER DYEING ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5.0 A 5.1 I II III G T I II III G T 1 HTHP Dyeing M/c -1 Operator 1 1 1 - 3 2 HTHP Dyeing M/c -2 Operator 1 1 1 - 3 3 HTHP Dyeing M/c -3 Operator 1 1 1 - 3 4 HTHP Dyeing M/c -4 Operator 1 1 1 - 3 5 25 kg Sample dyeing m/c (HTHP-5) Operator 1 1 1 - 3 6 Stemping & Hydroextractor M/C -120 & 280 Kg Helper 3 3 3 - 9 7 Stemping & Hydroextractor M/C-320 Kg Helper 1 1 1 - 3 8 Stemping & Hydroextractor M/C-700 Kg Helper 2 2 2 - 6 9 Radio Frequency dryer/Steam Dryer Operator 4 4 4 - 12 3 3 3 - 9 10 Store Man Store person 1 1 1 - 3 1 1 1 - 3 11 Yarn Preperation Operator 1 1 - - 2 1 1 - - 2 12 SSM Winding M/c Winder 1 1 1 - 3 1 1 1 - 3 13 Floor Cleaner Cleaner - - - 1 1 - - - 1 1 14 SAP Data Entry operator - - - 1 1 - - - 1 1 15 Maintenance Fitter/Helper - - 1 2 3 - - 1 2 3 18 18 18 4 58 14 14 14 4 46 S. No Section / Work area Designation Present Manpower Proposed Manpower 5 5 FIBER DYEING Manpower Deployment - 5 Remarks Total 15 3 3 3 - 9 _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5.0 A 5.2 5.2.1 I II III Deploy three personnel per shift for radio frequency drier instead of present four personnel per shift. The utilisation of individual batch of operator are less, mainly because of HTHP dyeing cycle time constraint. Hence, it is recommended to form a pool of workers to minimize the forced idleness. Based on the workload analysis, It is recommended to deploy five personnel for above machines and their combined utilisation would be 82.66% The present manpower deployment in the Stemping and Hydroextractor are as follows: Manual Stemping & Hydro (120 Kg & 280 Kg ) - 3 person/shift HTHP Dyeing Machine Operator: Radio Frequency Drier Machine Stemping (700 kg) - 2 person/shift Machine Stemping (320 kg) - 1 person/shift FIBER DYEING Proposed Changes & Observations Proposed Changes In view of low utilisation of HTHP dyeing machine operator, it is recommended to provide a group of three people for five(HTHP-1,2,3 4&5) machines. They relieve each other for lunch, tea and personal needs. Stemping & Hydroextractor: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5.0 A 5.3 S.No Area of work 1 HTHP Dyeing M/c -1 2 HTHP Dyeing M/c -2,3 & 4 3 25 Kg Sample HTHP Dyeing M/c - 5 4 Stemping & Hydroextractor M/C- 120 & 280 Kg 5 Stemping & Hydroextractor M/C- 320 Kg 6 Stemping & Hydroextractor M/C- 700 Kg 7 Propsoed Workload for Stemping &hydroextractor 8 Radio Frequency dryer/Steam Dryer -Polyester Batch 9 Radio Frequency dryer/Steam Dryer -Viscose Batch 10 Store Man 11 Yarn Preperation 12 SSM Winding M/c 13 Floor Cleaner 14 Sap Data Entry operator 15 Maintenance FD/MAINT/01 FD/W/03 FD/W/05 FD/W/12 FD/W/13 FD/W/11 FD/W/08 FD/W/09 FIBER DYEING Workload Sheets Summary WLS Number FD/W/01 FD/W/10 FD/W/04 FD/W/06 FD/W/07 FD/W/08 A FD/W/02 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 5 1.50 7.50 2 1 5 2.52 12.60 3 1 5 4.00 20.00 4 1 5 0.20 1.00 5 1 5 2.66 13.30 6 1 5 1.76 8.80 7 1 5 1.38 6.90 8 1 5 1.42 7.10 9 1 5 2.12 10.60 10 1 5 0.18 0.90 11 1 5 1.95 9.76 12 1 5 0.58 2.90 13 1 5 3.42 17.10 14 1 5 3.00 15.00 A 133.46 B 12 C 149.47 D 450 E 33.22% F 1 G 33.22% WLS No: FD/W/01 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G HTHP- M/C 1 Take color & chemical according to drug slip from the store Mix colors in the addition tank, manually open/close the water lines and mix Transfer to main vessel HTHP Machine-100 Kg Operator Activity Description Check Drugs Slips and intructutions of supervisor before start new lot Take fresh water and mix liquid chemicals and transfer to main vessel Take fresh water and again mix chemical and transfer to main vessel Collect sample to check pH, show to supervisor Fill the log book Drain water from the main vessel, Mix chemicals in main vessel and switch off once water level reaches Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Drain the solution from main vessel, open the lid Take crane, lift the carrier and keep it on the ground Write in the log book Drain water from sample port, collect sample fibre from port, dry the fibre and make sample Show to supervisor for approval Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: As this machine is semi automatic and two level system, the activities required operators involvement is more than the remaining ( HTHP-2,3 & 4) machines. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 - Designation Proposed Manpower 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allow ance (%) Total Time (mins) 1 1 1 0.84 12 0.94 2 1 1 0.87 12 0.97 3 1 1 0.22 12 0.25 4 1 1 7.08 12 7.93 5 1 1 0.94 12 1.05 6 1 1 0.67 12 0.75 7 1 1 0.80 12 0.90 8 1 1 1.20 12 1.34 9 1 1 1.37 12 1.53 10 1 1 2.33 12 2.61 11 1 1 3.00 12 3.36 12 1 5 2.00 12 11.20 13 1 1 1.50 12 1.68 14 1 1 2.52 12 2.82 WLS No: FD/W/02 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A Activity Description HTHP-2,3 & 4 B Remove the hook, close the lid of the main vessel HTHP operator attends more than one machine(in the proposed method). As the operator is responsible for the operation of more than one machine,if two machines requires operators attention simultaneously,one of them must wait until he completes his work on the other. This time loss representing waiting time due to overlapping of machine stoppage is called "Interference loss". Thomas O Connor table is used for estimating this interference loss in the textile mills. C G Lift the carrier from ground and keep inside the main vessel Collect sample fibre from sample port(at the end holding time-10 mins prior) , dry and make sample HTHP Machine Operator Check Drugs Slips and intructutions of supervisor before start new lot Add chemicals and colors based on the programme in the main vessel & wait to mix properly and maintain the water level Note down the details in the log book Take color & chemical according to drug slip from the store Handover to supervisor for checking/verification 3 1 Open the HTHP vessel, put hook, take crane and join the hook(carrier) with the crane Lift the carrier and place it on the ground Note down the parameters in the logbook Collect solution from sample port for pH checking, Show to supervisor Remove the crane joint, Put on the loaded carrier Open the stock tank water and close and operation in the panel board ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 - Designation Proposed Manpower 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Allow ance (%) Total Time (mins) WLS No: FD/W/02 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A Activity Description HTHP-2,3 & 4 B C G HTHP Machine Operator 3 1 15 1 1 2.20 12 2.46 A 39.80 B 9 C 358.24 D 1440 E 24.88% F 1 G 65.34% Basic Workload per Shift ( in man minutes) Total Workload ( in man minutes ) Remarks: Proposed Utilisation(%) From O'Conner Table Total Cycle time - 147+11.42 = 158.42 mins The lowest cycle time shade is selected, because the requirement operator involvement is more in the smallest cycle. When one operator handles more than one machine, then the activities become random in nature and interference comes into the picture. Hence , we have used the interference table to arrive the number of machine one operator can handle. Light & Medium Shade -Polyester batch ( Standard cycle time collected from company) Proposed Manpower per shift Activity sequence depends only on the Shade of batch is processing whether Light,Medium,dark,heavy dark and special shade. The activities performed by the operators(HTHP-2,3&4) are same in nature. No of batches( 3 batch per operator*3 operators=9 batch per shift) t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is running) = 27.01 mins(Sum of S.No 8 to 15) From Thomas O'Conner table , Remove the fibre of last batch from sample port and put new batch fibre in the port Net Available man-mins(480*3 =1440 mins) Machine Efficiency, E = 80.44 % Operator workload,B, as a fraction of a clock hour = 0.6534 Machine Cycle time - 147 mins Loading/unloading Time - 11.42 mins t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine stopped) = 12.79 mins (Sum of S.No 1 to 7) Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 2 1.05 2.10 2 1 2 1.62 3.24 3 1 2 2.17 4.34 4 1 2 1.23 2.46 5 1 2 1.37 2.74 6 1 2 1.23 2.46 7 1 2 1.10 2.20 8 1 2 2.55 5.10 9 1 2 3.14 6.28 10 1 2 0.26 0.52 11 1 2 0.40 0.80 12 1 2 1.47 2.94 13 1 2 0.57 1.14 14 1 2 2.02 4.05 15 1 2 0.84 1.68 16 1 2 5.46 10.92 17 1 2 1.32 2.64 18 1 2 0.41 0.82 19 1 2 1.01 2.02 20 1 2 0.50 1.00 21 1 2 3.00 6.00 22 1 2 1.05 2.10 WLS No: FD/W/03 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G HTHP - No 5 Take crane,Lift the carrier from the vessel and keep it on the ground Come down,keep the empty chemcial can,discuss with the supervisor regrding the next batch,get programme slip Take small trolley,move near to the carrier HTHP Machine-25 Kg Operator Activity Description Open the sample port cover,main vessel cover and switch on Remove the lid cover,open the lid cloth Remove the bale from the carrier and keep it on the trolley Move near the hydroextractor-1 Place the plate inside the hydroextractor and lift the bale and put it on the hydroextractor Push the bales evenly and close with the cloth and close the hydro with the lid Close the locks of the hydroextractor Keep the lid in place and trolley aside Take empty bag,weigh 25 kg of fibre Move the fibre near to the carrier Take the cloth from the table and spread around the carrier Take the carrier plate and keep inside the carrier& wet the cloth Load the bale inside the carrier and spray the water & press manually Close the cloth & tie Keep the lid tightener and tight Throw bale cover outside and clean the area Take the chemicals and colors from stores,come near to the machine Take the water in main vessel by switch on/off(open valves) Mix chemcials in the main vessel ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: FD/W/03 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G HTHP - No 5 HTHP Machine-25 Kg Operator Activity Description 23 1 2 1.41 2.82 24 1 2 0.56 1.12 25 1 2 1.02 2.04 26 1 2 1.44 2.88 27 1 2 0.20 0.40 28 1 2 0.40 0.80 29 1 2 2.00 4.00 30 72.00 31 1 2 3.25 6.50 32 1 2 2.40 4.80 33 1 2 4.00 8.00 34 2.00 35 1 2 2.04 4.08 36 1 2 5.06 10.12 37 1 2 2.32 4.64 38 1 2 2.30 4.60 39 1 2 5.00 10.00 40 1 2 5.00 10.00 41 1 2 0.48 0.96 42 1 2 1.00 2.00 43 1 2 1.13 2.26 A 149.57 B 13 C 169.01 D 450 E 37.56% F 1 G 37.56% Mix the acid solution to the main vessel Unoccupied time(waiting for holding time to complete) Take the water in the additional tank manually operating and mix the acetic acid Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Waiting for the mixing to be proper and operations in the panel board Lift the loaded carrier using crane from the ground and keep inside the main vessel Basic Workload per Shift ( in man minutes) After holding time,drain the finish solution and close the valve&operation in control panel Transfer the solution to main vessel Put the finsih solution in additional tank Fill the log book Hot wash drain Cold wash drain Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Drain hot water Remove steam,collect sample from sample port and close Dry the sample by keeping on the top of HTHp main vessel & prepare sample Remove the OH crane,tighten the lid Increase the water level by operating valves manually Close the lid of the main vessel Open & close the valve of the port and maintain water level Fill the log book Machine Cycle time(For Light & medium shade)10 mins prior to the end of holding time Show the sample to the supervisor and discussion ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: FD/W/03 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G HTHP - No 5 HTHP Machine-25 Kg Operator Activity Description The machine cycle time(heating,cooling) where the physical involvement of the worker is not considered. The HTHP-5 (25 kg smaple machine) will be operational,only when the programme is scheduled by PPC. The above incumbent performs the above activity when there is a scheduled planning. The remaining time,the incumbent acts as a reliver for HTHP-1,23, & 4 operators. Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) A 1 2 5 3.00 30.00 2 1 5 1.00 5.00 3 1 5 3.72 18.60 4 1 5 2.28 11.40 5 2 5 6.00 60.00 6 2 5 2.75 27.50 7 2 5 3.05 30.50 8 2 5 4.30 43.00 9 1 5 5.00 25.00 B 1 1 10 2.68 26.80 2 1 10 2.14 21.40 3 1 10 3.80 38.00 4 1 0.00 5 1 10 1.52 15.20 6 1 10 2.00 20.00 7 2 10 2.00 40.00 8 1 10 3.00 30.00 9 1 1 2.10 2.10 10 2 1 11.00 22.00 11 1 1 4.00 4.00 WLS NO: FD/W/04 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G Hydroextractor & Stemping Fibre denier and bale number write down into program register in Front of lot no. Stemping 120 Kg& 280 Kg Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Place the bottom Carrier plate inside the carrier Helper Activity Description Stemping - 120 Kg Batch - Manual Stemping See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Fill the fiber after hand open as per the programme( 1 person manually stemping) & wet fibre properly during filling After half loading of bale, put a plate into carrier Fill the 2nd half of bale into the carrier After bale loading, close the lid and filter cloth tightly After complete the filling work clean batching area and preparation for next lot Hydro extractor After receiving the dyed fibre carrier- open the lid ,Change the hanging from old one to new carrier Open the filter cloth Take out the first plate of fibre cake and fill into hydro extractor, close the lid and lock of hydro Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Parallel operator performs other activity) Bring the empty trolley After completetion of hydro (stop the M/C) open lock , lid and take out the extracted fibre cake Move the trolley with fibre & paste the slip of information about lot and keep aside Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water Clean the carrier drum with chemical dipped cloth and water Clean the carrier lid with chemical dipped cloth and water ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS NO: FD/W/04 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G Hydroextractor & Stemping Stemping 120 Kg& 280 Kg Helper Activity Description 12 1 1 10.00 10.00 C 1 2 3 4.81 28.86 2 1 3 1.00 3.00 3 1 3 4.41 13.23 4 1 3 2.28 6.84 5 2 3 7.21 43.26 6 2 3 1.73 10.38 7 2 3 5.37 32.22 8 2 3 3.63 21.75 9 1 3 10.00 30.00 D 1 1 6 2.68 16.08 2 1 6 2.14 12.84 3 1 6 4.00 24.00 4 1 6 5 1 6 1.52 9.12 6 1 6 4.03 24.18 7 2 6 2.00 24.00 8 1 6 3.00 18.00 9 1 1 2.10 2.10 10 2 1 11.00 22.00 Dry the cloth by putting in the Hydroextractor Stemping -280 Kg Batch - Manual Stemping See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Fibre denier and bale number write down into program register in Front of lot no. Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Place the bottom Carrier plate inside the carrier Fill the fiber after hand open as per the programme & wet fibre properly during filling (Manual Stemping) After loading half carrier, put a plate into carrier Fill the fiber after hand open as per the programme & wet fibre properly during filling (Manual Stemping) After full loading, close the lid and filter cloth tightly. After complete the filling work clean batching area and prepration for next lot Hydro extractor After receiving the dyed fibre carrier open the lid, Change the hanging from old one to new carrier Open the filter cloth Take out the first plate of fibre cake and fill into hydro extractor, close the lid and lock of hydro Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Parallel operator performs other activity) Bring the empty trolley After completetion of hydro (stop the M/C) open lock and lid and take out the extracted fibre cake into trolley Move the trolley with fibre & paste the slip of information about lot and keep aside Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water Clean the carrier drum with chemical dipped cloth and water ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS NO: FD/W/04 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G Hydroextractor & Stemping Stemping 120 Kg& 280 Kg Helper Activity Description 11 1 1 4.00 4.00 12 1 1 10.00 10.00 A 836.36 B 14 C 953.45 D 450 E 70.63% Dry the cloth by putting in the Hydroextractor Clean the carrier lid with chemical dipped cloth and water Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower - - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) A 1 2 3 4.81 28.86 2 1 3 1.00 3.00 3 1 3 4.41 13.23 4 1 3 2.28 6.84 5 1 3 5.13 15.39 6 1 3 2.32 6.96 7 1 3 6.34 19.02 8 1 3 3.63 10.88 9 1 3 10.00 30.00 B 0.00 1 1 6 2.14 12.84 2 1 6 2.14 12.84 3 1 6 3.56 21.36 4 5 1 6 1.52 9.12 6 1 6 4.03 24.18 7 2 6 2.00 24.00 8 1 6 3.00 18.00 Open the filter cloth Move the trolley with fibre & paste the slip of information about lot and keep aside Bring the empty trolley Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Paralley operator performs other activity) After completetion of hydro (stop the M/C) open lock and lid and take out the extracted fibre cake into trolley Clean hydro extracting area with water and broom stick Take out the first plate of fibre cake and fill into hydro extractor,close the lid and lock of hydro Place the bottom Carrier plate inside the carrier,Turn the stemping machine & start Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After loading half carrier, put a plate into carrier Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After full loading, close the lid and filter cloth tightly. After complete the filling work clean batching area and prepration for next lot Stemping 320 kg Hydroextractor&Stemping Hydro extractor After receiving the dyed fibre carrier open the lid and filter cloth,Change the hanging from old one to new carrier Helper Activity Description See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Fibre denier and bale number write down into program register in Front of lot no. Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Stemping - 320 Kg Batch - Mechanical Stemping WLS No: FD/W/05 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower - - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Stemping 320 kg Hydroextractor&Stemping Helper Activity Description WLS No: FD/W/05 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G 9 1 1 2.10 2.10 10 2 1 11.00 22.00 11 1 1 4.00 4.00 12 1 1 10.00 10.00 A 160.44 B 13 C 181.30 D 450 E 40.29% Remarks: Clean the Carrier plates with chemcial cloth and water Basic Workload per Shift ( in man minutes) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Rest & Relaxation Allowances ( % ) Clean the carrier lid with chemcial dipped cloth and water Clean the carrier drum with chemcial dipped cloth and water Dry the cloth by putting in the hydroextractor ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) A 1 2 3 5.84 35.01 2 2 3 1.00 6.00 3 2 3 7.00 42.00 4 2 3 4.18 25.08 5 2 3 7.50 45.00 6 2 3 2.01 12.06 7 2 3 10.15 60.90 8 2 3 3.01 18.06 9 2 3 5.00 30.00 B 0.00 1 2 6 2.68 32.16 2 1 6 2.14 12.84 3 1 6 3.56 21.36 4 6 0.00 5 1 6 1.52 9.12 6 2 6 5.15 61.80 7 2 6 2.00 24.00 8 1 6 3.00 18.00 9 1 1 2.10 2.10 Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water After loading half carrier, put a plate into carrier Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After full loading, close the lid and filter cloth tightly. After complete the filling work clean batching area and prepration for next lot Move the trolley with fibre & paste the slip of information about lot and keep aside Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Parallel operator performs other activity) See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Fibre denier and bale number write down into program register in Front of lot no. Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After completetion of hydro (stop the M/C) open lock and lid and take out the extracted fibre cake & put in the trolley WLS No: FD/W/06 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C Hydroextractor&Stemping G Helper Open the filter cloth Bring the empty trolley Activity Description Stemping - 700 Kg Batch - Mechanical Stemping Stemping 700Kg Place the bottom Carrier plate inside the carrier, Turn the stemping machine & start Hydro extractor After receiving the dyed fibre carrier open the lid ,Change the hanging from old one to new carrier Take out the first plate of fibre cake and fill into hydro extractor, close the lid and lock of hydro ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: FD/W/06 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C Hydroextractor&Stemping G Helper Activity Description Stemping 700Kg 10 2 1 15.00 30.00 11 1 1 5.00 5.00 12 1 1 10.00 10.00 A 226.38 B 13 C 255.81 D 450 E 28.42% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Remarks: Clean the carrier lid with chemical dipped cloth and water Dry the cloth by putting in the hydroextractor Clean the carrier drum with chemical dipped cloth and water ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 6 - Designation Proposed Manpower 5 5 5 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) A 1 2 5 3.00 30.00 2 1 5 1.00 5.00 3 1 5 3.72 18.60 4 1 5 2.28 11.40 5 2 5 6.00 60.00 6 2 5 2.75 27.50 7 2 5 3.05 30.50 8 2 5 4.30 43.00 9 1 5 5.00 25.00 B 1 1 10 2.68 26.80 2 1 10 2.14 21.40 3 1 10 3.80 38.00 4 1 0.00 5 1 10 1.52 15.20 6 1 10 2.00 20.00 7 2 10 2.00 40.00 8 1 10 3.00 30.00 9 1 1 2.10 2.10 Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Parallel operator performs other activity) Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Place the bottom Carrier plate inside the carrier Fill the fiber after hand open as per the programme( 1 person manually stemping) & wet fibre properly during filling After half loading of bale, put a plate into carrier Fill the 2nd half of bale into the carrier After bale loading, close the lid and filter cloth tightly Bring the empty trolley Take out the first plate of fibre cake and fill into hydro extractor, close the lid and lock of hydro Stemping - 120 Kg Batch - Manual Stemping B C After completetion of hydro (stop the M/C) open lock , lid and take out the extracted fibre cake Move the trolley with fibre & paste the slip of information about lot and keep aside Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water WLS NO: FD/W/07 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A G Open the filter cloth FD See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Fibre denier and bale number write down into program register in Front of lot no. Hydro extractor After receiving the dyed fibre carrier- open the lid ,Change the hanging from old one to new carrier Hydroextractor & Stemping Helper Activity Description After complete the filling work clean batching area and prepration for next lot ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 6 - Designation Proposed Manpower 5 5 5 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) B C WLS NO: FD/W/07 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A G FD Hydroextractor & Stemping Helper Activity Description 10 2 1 11.00 22.00 11 1 1 4.00 4.00 12 1 1 10.00 10.00 C 1 2 3 4.81 28.86 2 1 3 1.00 3.00 3 1 3 4.41 13.23 4 1 3 2.28 6.84 5 2 3 7.21 43.26 6 2 3 1.73 10.38 7 2 3 5.37 32.22 8 2 3 3.63 21.75 9 1 3 10.00 30.00 D 1 1 6 2.68 16.08 2 1 6 2.14 12.84 3 1 6 4.00 24.00 4 1 6 5 1 6 1.52 9.12 6 1 6 4.03 24.18 Fill the fiber after hand open as per the programme & wet fibre properly during filling (Manual Stemping) Take out the first plate of fibre cake and fill into hydro extractor, close the lid and lock of hydro Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Parallel operator performs other activity) Bring the empty trolley After completetion of hydro (stop the M/C) open lock and lid and take out the extracted fibre cake into trolley Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Place the bottom Carrier plate inside the carrier Fill the fiber after hand open as per the programme & wet fibre properly during filling (Manual Stemping) After loading half carrier, put a plate into carrier Dry the cloth by putting in the hydroextractor After full loading, close the lid and filter cloth tightly. After complete the filling work clean batching area and prepration for next lot Hydro extractor After receiving the dyed fibre carrier open the lid, Change the hanging from old one to new carrier Open the filter cloth Fibre denier and bale number write down into program register in Front of lot no. See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Stemping -280 Kg Batch - Manual Stemping Clean the carrier drum with chemical dipped cloth and water Clean the carrier lid with chemical dipped cloth and water ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 6 - Designation Proposed Manpower 5 5 5 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) B C WLS NO: FD/W/07 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A G FD Hydroextractor & Stemping Helper Activity Description 7 2 6 2.00 24.00 8 1 6 3.00 18.00 9 1 1 2.10 2.10 10 2 1 11.00 22.00 11 1 1 4.00 4.00 12 1 1 10.00 10.00 E 1 2 3 4.81 28.86 2 1 3 1.00 3.00 3 1 3 4.41 13.23 4 1 3 2.28 6.84 5 1 3 5.13 15.39 6 1 3 2.32 6.96 7 1 3 6.34 19.02 8 1 3 3.63 10.88 9 1 3 10.00 30.00 F 1 1 6 2.14 12.84 2 1 6 2.14 12.84 3 1 6 3.56 21.36 Take out the first plate of fibre cake and fill into hydro extractor, close the lid and lock of hydro Fibre denier and bale number write down into program register in Front of lot no. Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Place the bottom Carrier plate inside the carrier, Turn the stemping machine & start Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After loading half carrier, put a plate into carrier Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After full loading, close the lid and filter cloth tightly. After complete the filling work clean batching area and prepration for next lot Hydro extractor Clean the carrier drum with chemical dipped cloth and water Clean the carrier lid with chemical dipped cloth and water Dry the cloth by putting in the hydroextractor Open the filter cloth After receiving the dyed fibre carrier open the lid and filter cloth, Change the hanging from old one to new carrier Stemping - 320 Kg Batch - Mechanical Stemping See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Move the trolley with fibre & paste the slip of information about lot and keep aside Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 6 - Designation Proposed Manpower 5 5 5 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) B C WLS NO: FD/W/07 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A G FD Hydroextractor & Stemping Helper Activity Description 4 5 1 6 1.52 9.12 6 1 6 4.03 24.18 7 2 6 2.00 24.00 8 1 6 3.00 18.00 9 1 1 2.10 2.10 10 2 1 11.00 22.00 11 1 1 4.00 4.00 12 1 1 10.00 10.00 G 0.00 1 2 3 5.84 35.01 2 2 3 1.00 6.00 3 2 3 7.00 42.00 4 2 3 4.18 25.08 5 2 3 7.50 45.00 6 2 3 2.01 12.06 7 2 3 10.15 60.90 8 2 3 3.01 18.06 9 2 3 5.00 30.00 Dry the cloth by putting in the hydroextractor Stemping - 700 Kg Batch - Mechanical Stemping See the Noted prog. from prog. register and take instructions from supervisor to fill fibre in dyeing carrier ,Bring the fibre and Weight according to program (check denier and bale number) Fibre denier and bale number write down into program register in Front of lot no. Clean the filter cloth and set into dyeing carrier as per shade color (dark or light) Place the bottom Carrier plate inside the carrier, Turn the stemping machine & start Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After loading half carrier, put a plate into carrier Fill the fiber after hand open as per the programme & wet fibre properly during filling (Machine Stemping) After full loading, close the lid and filter cloth tightly. After complete the filling work clean batching area and prepration for next lot Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Parallel operator performs other activity) Bring the empty trolley After completetion of hydro (stop the M/C) open lock and lid and take out the extracted fibre cake into trolley Move the trolley with fibre & paste the slip of information about lot and keep aside Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water Clean the carrier drum with chemical dipped cloth and water Clean the carrier lid with chemical dipped cloth and water ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 6 - Designation Proposed Manpower 5 5 5 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) B C WLS NO: FD/W/07 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A G FD Hydroextractor & Stemping Helper Activity Description H 0.00 1 2 6 2.68 32.16 2 1 6 2.14 12.84 3 1 6 3.56 21.36 4 6 0.00 5 1 6 1.52 9.12 6 2 6 5.15 61.80 7 2 6 2.00 24.00 8 1 6 3.00 18.00 9 1 1 2.10 2.10 10 2 1 15.00 30.00 11 1 1 5.00 5.00 12 1 1 10.00 10.00 A 1631.47 B 14 C 1859.87 D 450 E 68.88% F 5 G 82.66% Clean the carrier lid with chemical dipped cloth and water Dry the cloth by putting in the hydroextractor Run the hydro according to type of fibre and instructions of supervisor ( Machine Cycle time)( Parallel operator performs other activity) Bring the empty trolley After completetion of hydro (stop the M/C) open lock and lid and take out the extracted fibre cake & put in the trolley Move the trolley with fibre & paste the slip of information about lot and keep aside Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water After receiving the dyed fibre carrier open the lid ,Change the hanging from old one to new carrier Open the filter cloth Take out the first plate of fibre cake and fill into hydro extractor, close the lid and lock of hydro Clean the carrier drum with chemical dipped cloth and water Hydro extractor Proposed Utilisation(%) Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 4 4 4 - Designation Proposed Manpower 3 3 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) A 1 2 15 3.00 90.00 2 2 15 1.10 33.00 3 2 15 0.60 18.00 4 1 15 1.00 15.00 5 1 4400 0.055 242.00 6 198.00 7 1 15 0.91 13.70 8 1 4400 0.06 242.00 9 1 180 0.62 111.60 10 1 15 3.00 45.00 A 810.30 B 14 C 1121.74 D 450 E 62.32% F 3 G 83.09% Helper Activity Description For polyester batch, the materials are directly fed into R/F drier belt conveyor. Waiting between the loading(Due to machine speed limit) For Polyester Fibre in R/F Drier Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ( 923.74+198 = 1121.74 mins) Net Available man-mins Take trolley, weigh on weighing balance and write down on slips gross weight and trolley weight as per priority of drying based on fibre type co-ordination with supervisor Move the trolley from weighing machine to R/F drier area WLS No: FD/W/08 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A R/F Drier-Polyester Batch B C G Drier Note: As per discussion with the management personnel, only R/F drier going to be used. So they workload sheet prepared only for the R/F drier operation. Proposed Utilisation(%) Remarks: Average weight of batch/ trolley - 300 Kg Target per operator /shift - 1100 Kg * 4 operator = 4400/300 = 15 trolleys (Polyester batch) Load the Fibre(S.No 5 ) is the actual workload of the operator. Because of belt speed , the operator has to wait in between loading activity for few seconds/minutes which is called as unavoidable delay. But operator presence is required. So, the total cycle time = 242 +198 =440 mins/shift. But Relaxation allowance only provided to activity. R/F drier capacity(Polyester batch) - 600 kg/hr. Proposed Manpower per shift Move the trolley near the R/F drier inlet point Tie the bag with information card/tag as per lot qty ( 25 kg/ bag = 4400/25=180 Bags) Move the empty trolley back to respective place Basic Workload per Shift ( in man minutes) Present Utilisation(%) Take instructions from supervisor to dry the lot and set the speed of conveyer belt according to moisture Fill fiber in bags after drying (Take the bag, fill &keep aside) Load the fibre from trolley to belt conveyor of drier ( kg) Clean the spillage area around the machine after one batch dried. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 3* 3 3 - Designation Proposed Manpower 2* 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 4 6.10 48.80 2 1 4 0.07 0.28 3 1 4 0.07 0.28 4 1 4 1.95 7.80 5 1 4 1.00 4.00 6 1 1100 0.070 77.00 7 1 363.00 8 1 4 0.91 3.65 9 1 1100 0.06 60.50 10 1 44 0.62 27.28 11 1 4 3.00 12.00 A 547.43 B 14 C 624.07 D 450 E 46.23% F 2 G 69.34% Average weight of batch/ trolley - 300 Kg,R/F drier capacity(Viscose batch) - 150 kg/hr. Target per operate/shift - 1100 Kg for 3 operators = 1100/300 = 4 trolleys (Viscose batch) Waiting between the loading(Due to machine speed Move the empty trolley back to respective place Tie the bag with information card/tag as per lot qty ( 25 kg/ bag = 4400/25=180 Bags) Net Available man-mins For Viscose batch, the fibre is first passed through Viscose opener and then fed into belt conveyor. The moisture content for the viscose batch is in the range of 60-70% Load the Fibre(S.No 6 ) is the actual workload of the operator. Because of belt speed , the operator has to wait in between loading activity for few seconds/minutes which is called as unavoidable delay. But operator presence is required. So, the total cycle time = 77+363=440 mins/shift. Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Activity Description Discuss with the shift incharge, weigh the trolley to be dried and move to R/F drier area Collect the opened fibre from viscose opener outlet and keep aside(load it on the R/F drier belt conveyor) Take instructions from supervisor to dry the lot and set the speed of conveyer belt according to moisture Load the fibre from viscose opener outlet to belt Clean the spillage around the trolley and move the empty trolley back to Weigh machine area Viscose Fibre in R/F Drier Basic Workload per Shift ( in man minutes) WLS No: FD/W/08 A WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A Drier * There is no separate manpower for Viscose batch R/F drier. The above workload sheet is prepared to show the utilisation of drying operator ,when they perform viscose batch drying. Viscose Opener B C G Tie the bag with information card/tag as per lot qty Clean the spillage area around the machine after one batch is over Open the Viscose fibre and put on the viscose opener R/F Drier-Viscose Batch Helper ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.00 5.00 2 1 17 3.00 51.00 3 1 17 2.50 42.50 4 1 17 1.00 17.00 5 1 1 3.00 3.00 6 a 1 2 1.51 3.02 b 1 2 3.18 6.36 c 1 2 0.97 1.94 d 1 2 2.73 5.46 e 1 2 1.06 2.12 7 1 1/5 5.00 1.00 8 1 1 30.00 30.00 9 1 1 20.00 20.00 10 1 1/30 420.00 14.00 A 202.40 B 12 C 226.69 D 450 E 50.38% F 1 G 50.38% Colour&Chemical Store Helper Activity Description Check stock availability in stock register WLS No: FD/W/09 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G Store room Physical stock verification Take the empty trolley to store from fibre dyeing Discussion with the storepersonnel,Load the materials(Cans,bags,etc) in the trolley as per slip Tie the thread around the trolley after loading unload the materials from trolley to storeroom Weigh the chemicals as per drug slip given by supervisor(considered 3 chemicals per batch) Take samples for washing fastness checking to SPH lab & bring testing report ( Only in A or B Shift) End of shift note down the color & chemical consumed in their shift in the register After completion of work, clean the Colour & Chemical rooms. Clean the cans surface and chemical spillage around the cans Weigh the colors as per drug slip given by supervisor(considered 3 colours per batch) After weighing color less that particular dyes and chemicals in register and upto date the stock Bring the color & Chemical from store as instructed in issue slip(Only in A or B shift) ** Net Available man-mins Total Workload ( in man minutes ) Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: if any dyes have change the lot no. inform to supervisor for lab testing and handover samples to the lab Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Move the trolley back to fibre dyeing section store ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Colour&Chemical Store Helper Activity Description WLS No: FD/W/09 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G Store room Total - 17 batch/shift ** Shifting of colurs & chemicals from stores, floor cleaner in the fibre dyeing dept assist the store personnel. So crew size for shifting activity is two. Same practice is recommended. In view of low utilisation of storeman in B shift and C shift (Only 32.32% Activities from 1- 5),personnel is being recommended keeping in mind the follwing: As the operator has to wait every time for the supervisor before weighinh chemicals and colours,which is impratical. As the supervisor is already engaged in other activity. The weighment operational is critical and store personnel is fully responsible. HTHP 2,3,4 & 5 - 12 batch/shift HTHP 1- 5 batch /Shift Number of Batch ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - - Designation Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 1.07 1.07 2 1 1 5.00 5.00 3 1 1 10.00 10.00 4 1 1 2.83 2.83 5 1 21 1.00 21.00 1 21 0.08 1.68 1 21 0.42 8.82 6 1 21 2.85 59.85 7 1 21 2.91 61.11 1 1 1.67 1.67 1 21 0.60 12.60 1 1 9.50 9.50 1 21 0.56 11.76 1 1 1.77 1.77 8 1 21 1.49 31.29 9 1 21 0.73 15.39 1 1 0.30 0.30 1 1 6.44 6.44 WLS No: FD/W/10 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G FD Pilot Plant Operator Activity Description Clean the machine after one shade is over Breaker & Finisher Collect the output sliver and cut into pieces Cheese Winding Machine Make the cheese cone from the R/F bobbins in the sample cheese winding machine Put the carding sliver in machine, pass through the breaker, collect the breaker sliver output, cut into pieces again pass through the machine. Collect the finisher sliver and put it in the cover Put the finisher silver in the speed frame and make the s/f roving, Clean the speed frame. Reach the texmaco ring frame in the unit-2 Insert the rovings in the ring frame and make the R/F bobbins(2 R/F bobbins per roving) Machine cycle time TFO Take the cheese cone and empty paper cone, reach the TFO, Put the cones in the respective count machine Remove the R/F bobbins from the machine and clean the machine Come back to yard development room Speed frame Check the machine Machine cycle time ( In the mean time come to Yarn developmental room, select the sample card from the cupboard) Collect fibre sample from shift incharge and keep on lab Keep the sample in the oven Take the dried sample from oven, put in cover and write identification slip Come from fibre dyeing to pilot plant Carding Machine Put the samples at the inlet of carding machine ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - - Designation Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: FD/W/10 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C G FD Pilot Plant Operator Activity Description 1 1 2.16 2.16 10 1 21 1.28 26.88 11 1 21 0.18 3.76 12 1 1 2.83 2.83 13 1 21 0.17 3.65 14 1 21 1.51 31.73 15 1 21 1.26 26.46 A 359.54 B 12 C 402.68 D 450 E 89.48% F 1 G 89.48% Come to TFO section and remove the TFO cone from the machine Come back to yard development room and put the cones in the warp machine and make sample yarn ( batch wise) Clean the R/F bobbins Come back to fibre dyeing machine HTHP 1 - 5 batch/shift * 3 Shift = 15 Batch HTHP 2-4 - 3 batch/shift * 3 Shift * 3 Machine = 27 batch Total = 42 batch/ day Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift So per shift - 21 batch / shift Proposed Utilisation(%) Remarks: From the past record , 518 batches was prepared in the HTHP and number of tickets made 515 Nos. The above workload sheet, was calculated Cut the blue card to prepare ticket Paste the yarn prepared in the blue card to prepare the ticket Check the ticket in the machine, take the printout and staple the report ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 8.00 8.00 2 1 1 53.33 53.33 3 1 1 14.80 14.80 4 1 1 15.83 15.83 5 1 72 138.00 138.00 6 1 1 6.00 6.00 7 1 36 11.88 11.88 8 1 36 11.88 11.88 9 1 1 10.08 10.08 10 1 1 15.00 15.00 11 1 36 4.68 4.68 13 1 1 29.20 29.20 14 1 1 2.40 2.40 15 1 1 6.32 6.32 16 1 1 4.32 4.32 A 331.72 B 13 C 374.85 D 450 E 83.30% F 1 G 83.30% Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Hand over charge to next shift Hydro extraction of received dyed filament lot Rewinding the dyed & grey filament according to supervisor instruction(72 cones means 6 doffs and the helper's time attending the m/c is 40% of m/c time for 6 doffs) During rewind of dyed filament check the conning oil in every spindle Check the weight and length of every rewind grey cone and write into the register and set into rack Checking every rewind dyed filament cone (shade varriation and rewinding quality ) Write down the production grey and dyed filament in production register Taking cones to SQC for quality checking and write down sqc register Put packing slip on each dyed filament cone Packing the dyed filament cones in cartons with slip( assuming 1 carton carries 18 cones , so timings are for 5 cartons) After complete the work of winding clean the winding area Check weight of every packed carton and write down on packing slip WINDING Do the cleaning of M/C as per check list Checking the weight of received grey filament and write down into grey received register SSM WINDING HELPER Activity Description Take charge at shift start WLS No: FD/W/11 WORK LOAD DETAILS SHEET FIBRE DYEING Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 2 91.52 91.52 2 1 100 42.00 42.00 3 1 200 bags 226.00 226.00 4 1 2 18.90 18.90 A 378.42 B 13 C 427.61 D 450 E 95.03% F 1 G 95.03% Assist the store man in bringing the required material Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: FIBRE DYEING Cleaning of empty bags Stitching Of dyed fiber filled bags FIBRE DYEING FLOOR CLEANER Activity Description Floor cleaning with swab WLS No: FD/W/12 WORK LOAD DETAILS SHEET FIBRE DYEING Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - Designation Proposed Manpower - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) 1 1 1 25.00 2 1 1 25.00 3 1 1 20.00 4 1 1 20.00 5 1 11 15.00 6 1 11 15.00 7 1 1 10.00 8 1 11 77.00 9 1 1 5.00 A B C D E F G Rest & Relaxation Allowances ( % ) Feeding Daily Production in excel Net Available man-mins Confirm pending lots in sap Proposed Utilisation(%) Remarks: Maintain dyeing Cards Make Production Order in sap for dyeing fibre Basic Workload per Shift ( in man minutes) B Total Workload ( in man minutes ) Present Utilisation(%) Proposed Manpower per shift Make Card For Dyeing Daily mail for filament dispatch and transfer it into sap FIBRE DYEING OFFICE SAP OPERATOR Activity Description C Match Sap production to actual production FIBRE DYEING OFFICE Transfer Daily Fibre to Btm & Elg in sap Make Ready Daily Advice Slips WLS No: FD/W/13 WORK LOAD DETAILS SHEET FIBRE DYEING Shifts A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 1 1 Total Time (Mins) 25.00 25.00 20.00 20.00 15.00 15.00 10.00 77.00 5.00 212.00 13 239.56 450 53.24% 1 53.24% Remarks: G WLS No: FD/W/13 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - 1 2 Designation Proposed Manpower - - 1 2 Sl. No Crew Size Total Time (man mins) 1 1.1 2 86.54 1.2 2 44.77 1.3 2 63.46 1.4 2 80.77 1.5 2 112.15 1.6 2 111.35 1.7 2 16.73 1.8 2 48.92 1.9 2 32.77 2 2 36.15 A 633.61 B 15 C 728.65 D 384 E 94.88% F 2 G 94.88% 1/26 Freq/ Shift 1/26 1/26 1/26 One person in the night shift is provided based on discussion with the incumbent and detailed discussion with the maintenance personnel. The personnel mainly provided to attend the running problems occurred in the night shift.It is provided based on the allocation. 1/26 1/26 1/26 1/26 Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) SSM Winding Machine - 1 no Monga Hydro - 1 no Wet Opener - 2 nos Remarks: Hydro Extractor - 5 nos 1/26 HTHP Dyeing Vessel - 5 nos Electric Hoist - 5 nos Rest & Relaxation Allowances ( % ) Steam Drier - 2 nos Net Available man-mins per shift Total Workload 85 KW RF Drier - 1 no G FD&YD Fitter/Helper Activity Description Preventive Maintenance Stamping Machine - 5 nos Breakdown Basic Workload per Shift ( in man minutes) WLS No: FD/MECH/01 WORK LOAD DETAILS SHEET Fibre Dyeing Shifts A B C Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5 B YARN DEVELOPMENT ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5.0 B 5.1 I II III G T I II III G T 1 3 kg Sample Dyeing M/C & Fibro Mixer Helper 1 1 - - 2 1 1 - - 2 2 Beaker Dyeing M/C's Helper 1 1 - - 2 1 1 - - 2 3 Yardage Sample Making Weaver/sider/ Winder 2 2 2 - 6 2 2 2 - 6 4 Handloom Sample Making Weaver/winde r/sider 2 2 - - 4 2 2 - - 4 5 Checker Monitor - - - 1 1 - - - 1 1 6 Dope Dyed & Yarn Checking Helper - - - 1 1 - - - 1 1 6 6 2 2 16 6 6 2 2 16 Total YARN DEVELOPMENT Manpower Deployment S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5.0 B 5.2 1 YARN DEVELOPMENT Proposed Changes & Observations No changes proposed. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 5.0 B 5.2 S.No Area of work 1 3 kg Sample Dyeing M/C & Fibro Mixer 2 Beaker Dyeing M/C's 3 Yardage Sample Making 4 Checker -Monitor 5 Dope Dyed & Yarn Checking -Helper YD/W/05 YD/W/03 & A YD/W/04 YARN DEVELOPMENT Workload Sheets Summary WLS Number YD/W/01 YD/W/02 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - - Designation Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 15.00 15.00 2 1 3 60.00 60.00 3 1 3 30.00 30.00 A 105.00 B 13 C 118.65 D 450 E 26.37% F 1 G 26.37% Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) HTHP DYEING VESSEL 3KG HELPER-CONTRACT EMPLOYEE Activity Description Take charge of his duty Weighing grey fibre, dye & chemical as per 3kg dyeing program Hyrdro extracting of dyed material to remove excess water then dry the fibre on RF dryer, put in bags add tags having info about lot no., shade no., qty. & fineness WLS No: YD/W/01 WORK LOAD DETAILS SHEET YDD Shifts A B C G YARN DEV. LAB ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - - Designation Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.50 10.50 2 1 2.5 93.75 93.75 3 1 2 90.00 90.00 4 1 1 20.00 20.00 5 1 12.00 6 1 1 15.00 15.00 7 1 1 90.00 90.00 A 331.25 B 13 C 374.31 D 450 E 83.18% F 1 G 83.18% **Taking an average of twice in a month Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Bring the dope dyed fibre from godown for mixing Dyeing 50gm filament yarn sample on multiprecise-TC sample dyeing m/c ** Weighment of the fibre for 100gm to make yarn sample cone. Drying of fibre in hot air oven Basic Workload per Shift ( in man minutes) BEAKER DYEING HELPER(HTHP DYEING VESSEL 3KG) Activity Description Taking charge at the starting of the shift According to mixing & matching color soln. m pippete color as per recipes, weighment of fibre & start dyeing. Open beaker dyeing m/c , drying fibre samples, stick the fibre sample in record register & mention mixing details from mixing register. WLS No: YD/W/02 WORK LOAD DETAILS SHEET YARN DEV. DEPT. Shifts A B C G YARN DEV. LAB ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.00 10.00 2 1 1 15.00 15.00 3 1 1 10.00 10.00 4 1 1 15.00 15.00 5 1 1 45.00 45.00 7 1 1 30.00 30.00 8 1 1 5.00 5.00 A 130.00 B 13 C 146.90 D 450 E 32.64% F 1 G 32.64% Running 15 kgs of lap sample on LR C 1/3 Card Three passages at drawframe, sliver received from carding. Run Drawframe sliver on speed frame to form roving Remarks: The above workload is the operator's manual workload. But the operator has to wait during the machine cycle time. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) B C Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Take charge of his duty Running the R/F machine till the doff is due To give the charge at the end of the shift to reliever to proceed working in next shift. Receiving 15 kgs of lap from blowroom dept & bringing it to pilot plant G YARDAGE SAMPLE CARDING, DRAWFRAME, SPEEDFRAME,RING FRAME WEAVER/SIDER Activity Description WLS No: YD/W/03 WORK LOAD DETAILS SHEET YDD Shifts A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.00 10.00 2 1 1 10.00 10.00 3 1 1 45.00 45.00 4 1 1 15.00 15.00 5 1 1 45.00 45.00 6 1 1 15.00 15.00 7 1 1 5.00 5.00 A 145.00 B 13 C 163.85 D 450 E 36.41% F 1 G 36.41% Remarks: The above workload is the operator's manual workload. But the operator has to wait during the machine cycle time. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Look after the 24 drums TFO m/c which will be running throughout the shift Run the new material on TFO before discharging his duties Carrying the final yarn from pilot plant to packing To give the charge at the end of shift to reliever to proceed working in next shift. Basic Workload per Shift ( in man minutes) SAVIO, CHEESE WINDING,TFO WEAVER/SIDER Activity Description Take charge of his duty Take out the doff and make cones at winding Simultaneously make cheeses of the winded cones WLS No: YD/W/03 A WORK LOAD DETAILS SHEET YDD Shifts A B C G YARDAGE SAMPLE ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 4.72 4.72 2 1 1 40.00 40.00 3 1 1 12.00 12.00 4 1 1 35.00 35.00 5 1 1 30.00 30.00 6 1 1 20.00 20.00 7 1 1 15.00 15.00 8 1 5.00 A 161.72 B 13 C 182.74 D 480 E 38.07% F 1 G 38.07% Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Checking wrapping at R/F stage & provide final yarn sample to SQC for quality checking. Send final yarn to packing dept. yarn sample of each lot made in pilot plant to ydd lab for shade checking. Keep 1/2 kg of new shade in library Random checking of m/c's parameter as per requirement Sending material for conditioning if required. YARDAGE SAMPLE MONITOR Activity Description To check lap weight coming from blow room line. To change gauge of card, set drawframe wrapping & speed frame according to count. To set the R/F program according to count WLS No: YD/W/04 WORK LOAD DETAILS SHEET YDD Shifts A B C G PILOT PLANT ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 15 cones 45.00 45.00 2 1 1 90.00 90.00 3 1 15 cards 75.00 75.00 4 1 1 36.00 36.00 5 1 1 100.00 100.00 6 1 1 8.00 8.00 7 1 1 45.00 45.00 A 399.00 B 13 C 450.87 D 480 E 93.93% F 1 G 93.93% Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Preparation of yarn shade ticket of each & every final yarn lot & out sourced yarn for export quality to check data values through CCMS(5-6 outside yarn avg.) Making tuffts of dope dyed viscose & polyster to check delta values through CCMS & keep record in sample register (8-10 tuffts) House keeping of dark room Filling the shade consistency card after shade checking Basic Workload per Shift ( in man minutes) SHADE CHECKING HELPER Activity Description Bring the yarn sample cones from BTM for shade checking Noting down mixing details of Elegant and BTM. Preparation of shade consistency card for shade checking. WLS No: YD/W/05 WORK LOAD DETAILS SHEET YDD Shifts A B C G YD LAB ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 6. WEAVING - PREPARATORY ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 6.0 6.1 I II III G T I II III G T 1 Warping Warper 5 5 5 - 15 5 5 5 - 15 Creel Boy 5 5 5 - 15 3 3 3 - 9 Fitter 1 1 1 - 3 - - - 1 1 Rewinder 6 6 6 - 18 5 5 5 - 15 Cleaner 1 1 1 - 3 1 1 1 - 3 Loose Packer 2 2 - - 4 1 1 - - 2 Godown Man 2 2 - - 4 2 2 - - 4 2 Drawing Reed man - - - 1 1 - - - - - Cleaner - - - 1 1 - - - - - Pinner 4 4 4 - 12 2 2 2 - 6 Drawer & Reacher 16 10 6 5 37 10 10 10 - 30 Beam Colie 3 3 3 - 9 2 2 2 - 6 Total 45 39 31 7 122 31 31 28 1 91 WEAVING - PREPARATORY Manpower Deployment S. No Section / Work area Designation Present Manpower Proposed Manpower Remarks _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 6.0 6.2 6.2.1 a) b) c) d) e) f) g) h) i) WEAVING - PREPARATORY Proposed Changes & Observations A deployment of 5 personnel in the rewinding section is recommended instead of the present deployment of 6 per shift. For the 4 personnel recommended in the viscose area the utilization works out to be 50.72 % per person per shift and for the one person recommended in the polyester area, the utilization works out to be 82 % per shift. The 5 member crew has to manage the rewinding machines. The personnel may interchange positions so that the workload evens out for all the personnel. Proposed Changes One maintenance fitter per shift is not being recommended. Instead one Fitter in the general shift is being recommended. This is subject to certain activities to be performed by the production personnel. Deploy three creel boys per shift instead of the present deployment of 5 per shift. Two creel boys are for machines 1,2 and 3 and two creel boys are for machines 4,5. Beam colie- deploy two personnel in general shift instead of the present deployment of three, based on workload Position of Reed man in the general shift is not being recommended. These activities may in the future be performed by the shift cleaner. The combined workload is detailed in the workload sheet WGP/08 Position of cleaner in the general shift for the drawing area is not being recommended. These activities may in the future be performed by the shift cleaner. The combined workload is detailed in the workload sheet WGP/08 For pinning 8000 ends per shift a crew of two personnel is sufficient. Utilization for each person works out to be 21.45 % per shift. Drawer & Reacher - Deploy 10 personnel per shift for the processing of 5 beams, based on workload Deploy one loose packer per shift instead of the present deployment of two per shift based on workload. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 6.0 6.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Drawer and Reacher WGP/14 Beam Colie WGP/15 Workload Sheets Summary WLS Number Area of work Loose packer WGP/09 Godown man WGP/10 Rewinders - polyester WGP/07 Shift Cleaner WGP/08 Shift fitter WGP/05 WGP/06 Pinner WGP/13 Reed man WGP/11 General shift cleaner WGP/12 WEAVING - PREPARATORY Rewinders - viscose Warper - machine 1,2,3 WGP/01 Warper - machine 4,5 WGP/02 Creel Boy - machine 1,2,3 WGP/03 Creel Boy - machine 4,5 WGP/04 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 3 3 3 - Proposed Manpower 3 3 3 - S. No Crew Size Freq/ beam Basic Time (mins) Total Time (min) 1 2 1/1 20.35 20.35 2 2 1/1 8.41 8.41 3 2 1/1 6.48 6.48 4 2 1/1 1.08 1.08 5 1 1/1 1.27 1.27 6 1 1/1 1.67 1.67 7 1 29/1 0.96 27.82 8 1 1/1 1.64 1.64 9 1 1/1 5.49 5.49 10 2 1/1 13.64 13.64 11 - 1/1 2.00 WLS No:WGP/01 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section Pass thread from V-reed to be tied them to the Roller Preparatory Work Centre Warping Designation Warper Set the Count,warp length and No of ends in the electronic display Make Long rope to insert Leese in the sections required Tie the combined ends(after passing them through V-reed) to the drum and insert leesing;same step being repeated for every section Activity Description Manual Element Take the cone out of the packet and load on to the creel(iron bars) i.e. 148 cones Take the cone out of the packet and load on the other side of the creel(for selvedge purpose) Setting stop motion pin and check tension in the threads and tie them upto the leese reed Attend to thread cuts(1 per 29 sections) Make adjustments i.e. tie bolts ,adjust drums,unhook all sections onto the iron bar ,place them onto the beam and tie the ends onto the beam Take out remaining cones as the full beam has been prepared and place them in a bag;Both from creel and selvedge Machine Elements Rotate @550 meters/min(actual 450 meters/min)i.e for 1 section of 1020 meters ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 3 3 3 - Proposed Manpower 3 3 3 - S. No Crew Size Freq/ beam Basic Time (mins) Total Time (min) WLS No:WGP/01 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section Preparatory Work Centre Warping Designation Warper Activity Description 12 - 1/1 10.33 A 87.85 B 6 C 527.10 D 13 E 595.62 F 1350 G 44.12% H 3 I 44.12% Roll onto the beam@100 meters/min;Total warping length=1020 metres Basic Workload per Beam ( in man minutes) Frequency per Shift;No of beams to make Basic Workload per Shift ( in man minutes) Proposed Manpower per shift Proposed Utilisation(%) Remarks:1) Number of beams to make has been taken as per data provided by the management i.e. 30000 mtrs of the fabric is to be warped per day or 2000 mtrs per m/c.In one time average 1000 mtrs being warped on an average therefore warping is being done 2 times per m/c per shift Rest & Relaxation Allowances ( % ) Total Workload per Shift( in man minutes ) Net Available man-mins per shift Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 2 2 2 - Proposed Manpower 2 2 2 - S. No Crew Size Freq/ beam Basic Time Total Time (min) 1 2 1/1 16.47 16.47 2 2 1/1 8.83 8.83 3 2 1/1 4.81 4.81 4 2 1/1 1.99 1.99 5 1 1/1 1.26 1.26 6 1 1/1 0.87 0.87 7 1 44/1 39.23 39.23 8 1 1/1 1.04 1.04 9 1 1/1 7.73 7.73 10 2 1/1 11.61 11.61 11 - 1/1 1.84 12 - 1/1 8.29 A 93.82 B 4 C 375.30 D 13 E 424.09 F 900 G 47.12% H 2 I 47.12% WLS No:WGP/02 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section Pass thread from V-reed to be tied them to the Roller Preparatory Work Centre Warping Designation Warper Set the Count,warp length and No of ends in the electronic display Make Long rope to insert Leese in the sections required Tie the combined ends(after passing them through V- reed) to the drum and insert leesing;same step being repeated for every section Activity Description Manual Element Take the cone out of the packet and load on the other side of the creel(for selvedge purpose) Setting stop motion pin and check tension in the threads and tie them upto the leese reed Roll onto the beam@100 meters/min;Total warping length=829 metres Basic Workload per Beam ( in man minutes) Frequency per Shift;No of beams to make Basic Workload per Shift ( in man minutes) Attend to thread cuts(1 per 44 sections) Make adjustments i.e. tie bolts ,adjust drums,unhook all sections onto the iron bar ,place them onto the beam and tie the ends onto the beam Take out remaining cones as the full beam has been prepared and place them in a bag;Both from creel and selvedge Machine Elements Rotate @550 meters/min(actual 450 meters/min)i.e for 1 section of 829 meters Proposed Manpower per shift Proposed Utilisation(%) Rest & Relaxation Allowances ( % ) Total Workload per Shift( in man minutes ) Net Available man-mins per shift Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 3 3 3 - Proposed Manpower 2 2 2 - S. No Crew Size Freq/ beam Basic Time Total Time (mins) 1 2 1/1 20.34 20.34 2 2 1/1 8.41 8.41 3 2 1/1 6.48 6.48 4 2 1/1 1.08 1.08 5 1 1/1 5.34 5.34 6 2 1/1 9.44 9.44 7 1 1/1 28.00 28.00 8 1 1/1 6.34 6.34 A 85.43 B 6 C 90 D 602.55 E 13 F 680.88 G 1350 H 50.44% I 2 J 75.65% WLS No:WGP/03 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section Activity Description Manual Element Take the cone out of the packet and load on to the creel(iron bars) i.e. 148 cones Take the cone out of the packet and load on the other side of the creel(for selvedge purpose) Setting stop motion pin and check tension in the threads and tie them upto the leese reed Preparatory Work Centre Warping Designation Creel Boy Put oil in the m/c oiling tank from storage tank Basic Workload per Beam ( in man minutes) Frequency per Shift;No of beams to make Relieve Warper for lunch Pass thread from V-reed to be tied them to the Roller Bring empty beam from empty beam space and fit bolts Take out remaining cones as the full beam has been prepared and place them in a bag;Both from creel and selvedge Airing of workplace with air-pipe Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload per Shift( in man minutes ) Net Available man-mins per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 2 2 2 - Proposed Manpower 1 1 1 - S. No Crew Size Freq/ beam Basic Time Total Time (mins) 1 2 1/1 16.47 16.47 2 2 1/1 8.83 8.83 3 2 1/1 4.81 4.81 4 2 1/1 1.99 1.99 5 1 1/1 5.51 5.51 6 2 1/1 11.61 11.61 7 1 1/1 28.00 28.00 8 1 1/1 6.23 6.23 A 83.43 B 4 C 60 D 393.73 E 13 F 444.91 G 900 H 49.43% I 1 J 98.87% WLS No:WGP/04 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section Activity Description Manual Element Take the cone out of the packet and load on to the creel(iron bars) i.e. 120 cones Take the cone out of the packet and load on the other side of the creel(for selvedge purpose) Setting stop motion pin and check tension in the threads and tie them upto the leese reed Preparatory Work Centre Warping Designation Creel boy Put oil in the m/c oiling tank from storage tank Basic Workload per Beam ( in man minutes) Frequency per Shift;No of beams to make Relieve Warper for lunch ( in man minutes) Pass thread from V-reed to be tied them to the Roller Bring empty beam from empty beam space and fit bolts Take out remaining cones as the full beam has been prepared and place them in a bag;Both from creel and selvedge Airing of workplace with air-pipe Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload per Shift( in man minutes ) Net Available man-mins per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1 1 1 - Proposed Manpower - - - 1 S. No Crew Size Freq/ Shift Basic Time (mins) Total Time (mins) 1 1 10 2.00 20.00 2 1 4 0.50 2.00 3 3.1 1 1/3 5.00 1.67 3.2 1 1/3 10.00 3.33 3.3 1 1 3.75 3.75 4 1 5 0.69 3.47 5 1 5 2.00 10.00 6 1 1/18 424.78 23.60 7 1 15.00 15.00 A 82.82 B 13 C 93.58 D 450 E 20.80% F 1 G 19.50% Oil lubrication (rewinding - 20 spindles / shift) Activity Description Attend to the breakdowns in the various machines Set the beam flange after warping Start the idle spindle running on the rewinding machine Check the tightness of the bolts in the individual beams, tighten if required Unload the beam after warping from the warping machine Perform preventive maintenance of the machines in the presence of the supervisor Perform the oiling and greasing for all the warping machines and the rewinding machines Oil lubrication (warping ) G Section Greasing (warping machines) Preparatory Work Warping and Rewinding Designation Fitter Proposed Manpower per day Proposed Utilisation(%) WLS No:WGP/05 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C 3. Keeping the above points in mind, this position is being recommended to be manned only in the general shift. 4. Some of the rewinders will have to be trained in the performance of the activity 2 in the shifts B and C respectively. 1 It is observed that the utilization per shift is only 20 %. Activities 1,3 and 5 may be shifted to the warper / warper helper as these do not require any complex routines to be performed. 2. No data regarding the breakown attendance and the preventive maintenace performed has been furnished. The details provided here are based on discussions with the Maintenace In Charge and the Fitter. During my study for a shift no breakdown attendance has been observed. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 4 4 4 - Proposed Manpower 4 4 4 - S. No Crew Size Freq/ Shift Basic Time (mins) man mins Total Time (mins) 1 4 733.91 733.91 2 3 4 5 6 7 8 9 10 11 60.00 60.00 A 793.91 B 15 C 913.00 D 450 E 50.72% F 4 G 50.72% Remarks: 1. The rewinding section is to be manned by a crew of 5 personnel. During the shift itself the personnel may interchange positions to even out the workloads for the individuals. Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Place the unused cones in the storage area and back Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Others - discussions with the supervisors etc Place the big poly bag aside and back Attend to problems such as thread cuts, changing the small input rolls etc., Pull the big poly bag from near to the weighing machine to the working area Place cones from the big poly bag onto the machine Connect the thread to the empty cone, wind and start the cones Place the completed big rolls into a big poly bag WLS No:WGP/06 WORK LOAD DETAILS SHEET Department Weaving Shifts A B Preparatory C G Section Place completed roll in the poly cover and place the same on the machine top Prepare slips and paste on the inside of the cone Get cones, place cones on the machine Work Warping and Rewinding Designation Rewinders viscose Activity Description ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 2 2 2 - Proposed Manpower 1 1 1 - S. No Crew Size Freq/ Shift Basic Time (mins) man mins Total Time (mins) 1 2 305.99 305.99 2 3 4 5 6 7 8 9 10 11 15.00 15.00 A 320.99 B 15 C 369.14 D 450 E 41.02% F 1 G 82.03% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins 1. The rewinding section is to be manned by a crew of 5 personnel. During the shift itself the personnel may interchange positions to even out the workloads for the individuals. Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Connect the thread to the empty cone, wind and start the cones Place the completed big rolls into a big poly bag Place the big poly bag aside and back Attend to problems such as thread cuts, changing the small input rolls etc., Others - discussions with the supervisors etc Basic Workload per Shift ( in man minutes) Place completed roll in the poly cover and place the same on the machine top Prepare slips and paste on the inside of the cone Get cones, place cones on the machine Place the unused cones in the storage area and back Pull the big poly bag from near to the weighing machine to the working area Place cones from the big poly bag onto the machine Preparatory Work Warping and Rewinding Designatio n Rewinder - polyester Activity Description WLS No:WGP/07 WORK LOAD DETAILS SHEET Departmen Weaving Shifts A B C G Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1 1 1 - Proposed Manpower 1 1 1 - S. No Crew Size Freq/ Shift Basic Time (mins) man mins Total Time (mins) 1 2 3 4 1 99.20 99.20 5 1 115.70 115.70 A 577.51 B 13 C 652.58 D 450 E 48.34% F 3 G 48.34% Total Workload ( in man minutes ) Net Available man-mins per day 362.61 362.61 Proposed Utilisation(%) General shift cleaning works Present Utilisation(%) 1 Basic Workload per Shift ( in man minutes) B Shift : (362.61/3 + 99.20/2 + 115.70/2) * 1.13 = 258 minutes and utilization = 57.33 % C Shift : (362.61 /3)*1.13= 137 minutes and utilization = 30.35 % Remarks: 1. The utilization for this position holder in the three shifts will be as follows: Proposed Manpower per day A shift : (362.61/3 + 99.20/2 + 115.70/2) * 1.13 = 258 minutes and utilization = 57.33 % Rest & Relaxation Allowances ( % ) Clean the warping area (collect waste, collect the creel covers, waste cones etc., collect in a poly cover and dispose in the disposal area). Clean by both the broom stick and the long handled broom Clean rewinding area by broomstick, collect wastes in the polycover and dispose in the disposal area Reed man activities Clean godown area by broomstick, collect wastes in the polycover and dispose in the disposal area Preparatory Work Warping and Rewinding Designation Cleaner Activity Description WLS No:WGP/08 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Weaving Preparatory Preparatory Present Manpower 2 2 - - Loose Packer Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 5 18.07 90.33 2 1 5 0.85 4.24 3 1 5 0.53 2.65 4 1 1 5.21 5.21 5 1 1 2.11 2.11 6 1 1 4.31 4.31 7 1 1 2.21 2.21 8 1 20 2.61 52.27 9 1 20 1.78 35.51 10 1 20 0.83 16.66 11 1 20 0.46 9.23 12 1 20 0.28 5.56 13 1 2 0.95 1.91 14 1 2 0.35 0.71 15 1 20 0.88 17.59 16 1 1 0.35 0.35 A 250.85 B 13 C 283.47 D 900 E 31.50% F 1 G 62.99% Section Activity Description Packing empty cones coming from Loom Shed and shift to godown Shift 400 empty cones in a separate bag coming from the Loom Shed;segregation is done according to color of the cones Department WLS No:WGP/09 WORK LOAD DETAILS SHEET Shifts A B C G Shift the bags after weighing to be sent for reuse Load 10 bags on trolley Carry 5 bags upto yarn godown entry and unload Return with empty trolley For transferring extra bags to upwrad godown for external sales and use Open the stitch of the bags Transfer cones from 1 bag to another(28 cones) Prepare,stitch and put a sample cone outside the bag Put details on the bag viz lot no and number of cones with a marker Bring trolley to load bags for transfer Load 5 bags on to the trolley Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Work Centre Designation Proposed Manpower per shift Carry upto weighing m/c Weigh the bags (deduce 200 gm of bag wt and 350 gms of card board of cone and note in the register) and put aside Return for next set Basic Workload per Shift ( in man minutes) Stitich the new bag and put sample cone outside new bag Note the count lot,no and shade no in register Put new count no on the register ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 2 2 - - Proposed Manpower 2 2 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 7 1.26 17.64 2 2 7 2.31 32.36 3 2 6 1.01 12.11 4 2 5 1.31 13.12 5 2 5 2.16 21.58 6 2 5 0.35 3.55 7 2 5 1.07 10.65 8 2 5 0.35 3.53 9 2 4 1.62 12.99 10 2 2 1.23 4.92 11 2 2 5.81 23.23 12 2 2 2.74 10.96 13 1 5 3.87 19.36 14 1 5 0.97 4.85 15 1 5 0.54 2.72 16 1 2 1.17 2.35 17 1 1 0.75 0.75 Activity Description Arrange the yarn on warping m/c Destack and load 6 bags(at a time) of 64 kg each on two trolley Designation WLS No:WGP/10 WORK LOAD DETAILS SHEET Shifts A B C G Unload all 3 bags to the place Return and carrying the bags to Weft godown 2(for another set of 70 looms) Unload all 3 bags to the place Return with empty trolley for next load Carrying upto warping m/c and dump Return with empty trolley for next load Put the yarn from main godown to weft godown Destack and load 6 bags(at a time) of 64 kg each on trolley Carrying the bags to Weft godown 1(for 1 set of 70 looms) Carry bag to yarn godown or rewinding Return empty handed for next bag From Weft Godown to Loose Section Loading 6 bags(containing semi used cones) on to the trolley Carrying the trolley upto rewinding and place after weighing Return to take next load Packing cones left after Warping to be transferred either to rewinding or to godown Shifting cones from 1 bag(48 cones in 1 bag) to another according to their destination Prepare and stitch the bag Write lot no,count and no of cones on the bag Weaving Preparatory Preparatory Godown Man Department Section Work Centre ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 2 2 - - Proposed Manpower 2 2 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Activity Description Designation WLS No:WGP/10 WORK LOAD DETAILS SHEET Shifts A B C G Weaving Preparatory Preparatory Godown Man Department Section Work Centre 18 1 1 95.84 95.84 A 292.51 B 13 C 330.53 D 900 E 36.73% F 2 G 36.73% Proposed Utilisation(%) Remarks:Since 6000 mtrs have to be given to warping m/c i.e. per shift 31.2 bags.Since at a time 6 bags can be taken to warping by two persons therefore they will deliver all the bags in 7 trips Check the loose yarn available for next day program Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower - - - 1 Proposed Manpower - - - - S. No Crew Size Freq/ Shift Basic Time (mins) Total Time (mins) 1 1 1 5 5 2 2.1 1 7 0.27 1.89 2.2 1 14 0.71 9.98 2.3 1 7 1.57 10.99 2.4 1 14 3.05 42.63 2.5 1 7 2.02 14.12 2.6 1 14 0.25 3.52 2.7 1 14 0.16 2.26 3 3.1 1 1 0.42 0.42 3.2 1 2 0.83 1.65 3.3 1 2 1.05 2.10 3.4 1 2 0.47 0.93 3.5 1 2 0.11 0.23 4 4.1 4.2 4.3 A 115.70 B 13 C 130.75 D 480 E 27.24% F - G - Stack reed Clean the reed using the cotton waste Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Basic Workload per Shift ( in man minutes) Activity Description Cut damaged reeds to smaller sizes, using a saw Clean the reed using the polishing piece Adjust the gap in the reed using the plier Place reed on the work table, clean with compressed air Clean reed with wire brush Clean reed with cotton waste Other miscellaneous works Pick reed, place on the work table, clean using the wire Clean the reed using emery paper -both sides Proposed Utilisation(%) Remarks: 20 In case the reeds are damaged, provide the information to the supervisor who will make the necessary entries in the computer Go the machine area, using the plier adjust the reed gap At the beginning of the shift - switch on the bulb, adjust, clean the work area, collect tools and place on the work table Sultex, Dornier reeds Transport reeds from the ground floor to the first floor Net Available man-mins Present Utilisation(%) Preparatory Work Drawing Designation Reed Man 1. The position of the Reed man is not being recommended and this activity is shifted to shift cleaner Keep the reed in the rack and back to workplace Airjet Walk to the airjet area Proposed Manpower per shift WLS No:WGP/11 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower - - - 1 Proposed Manpower - - - - S. No Crew Size Freq/ Shift Basic Time (mins) man mins Total Time (mins) 1 1.1 1 1 3.57 3.57 1.2 1 1 73.51 83.84 1.3 1 1 1.79 1.79 1.4 1 1 10.00 10.00 A 99.20 B 13 C 112.10 D 450 E 24.91% F - G - Remarks: 1. The position of the general shift cleaner in the drawing area is not being recommended and this activity is shifted to shift cleaner Office Collect the wastes in the poly cover and dispose Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Activity Description Clean Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Weft godown Drawing work area WLS No:WGP/12 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section Preparatory Work Centre Warping and Rewinding Designation Cleaner ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 4 4 4 - Proposed Manpower 2 2 2 - S. No Crew Size Freq/ Shift Basic Time (mins) man mins Total Time (mins) 1 2 2 2.48 9.90 2 1 2 1.32 2.64 3 3.1 1 2 0.68 1.35 3.2 1 2 0.45 0.90 3.3 1 2 0.30 0.60 3.4 2 2 0.89 3.54 3.5 1 2 1.58 3.15 3.6 1 2 0.79 1.58 4 2 8000 0.01 128.99 5 1 2 1.39 2.78 6 1 2 4.36 8.71 7 1 2 0.45 0.90 A 165.03 B 17 C 193.09 D 450 E 21.45% F 2 G 21.45% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Check, segregate sections Make preparation for the pinning Perform pinning Proposed Utilisation(%) Remarks: 1. For pinning 8000 ends one crew of two personnel is sufficient. Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Work Centre Warping and Rewinding Designation Pinner Activity Description Position 2 rods, adjust WLS No:WGP/13 WORK LOAD DETAILS SHEET Department Weaving Shifts Bring 6 non serrated rods to the machine Bring 2 small reeds, gunny bag to sit on, gunny bag to put on the loom Place the gunny bags on the loom A B C G Section Keep the extra pins in the storage area Insert 6 serrated rods into the pins stack, remove the non serrated rods Bring pins along with the serrated rods - 6 numbers Fix the 6 non serrated rods to the 2 small reeds Set tightness of gear After pinning, clean up, collect the dropped pins, check for the missing pins in the work performed and insert whereever required Preparatory ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Work Centre Present Manpower 16 10 6 5 Designation Proposed Manpower 10 10 10 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 1 43.05 86.10 2 1 1 5.04 5.04 3 1 1 2.57 2.57 4 2 1 1.29 2.57 5 1 1 2.47 2.47 6 1 1 5.48 5.48 7 1 1 3.47 3.47 8 1 1 4.48 4.48 9 1 1 3.87 3.87 10 2 1 8.64 17.28 11 2 1 386.50 400.00 A 533.33 B 13 C 602.67 D 900 E 66.96% F 2 G 66.96% Process Make drawing and reaching process for making monograms and tape(212 ends for both start and end of the beam) Drawing and reaching process for rest of the ends;4000 ends in this case Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Proposed Utilisation(%) Remarks:Assumed that per shift 5 beams goes for gaiting so per shift 10 persons can do the required work Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Setting the frame on drawn beam and adjust heald wire Take 9 rods and insert in b/w frames Tie all frames with threads and adjust iron rods Take out the sheet cover from the beam and adjust the beam ;Take all the knots on an iron bar and put the bar above frame so that it suspends before frame Tie reed on one side of the frame Adjust threads on other side of the frame Preparatory Drawer & Reacher Activity Description Preparatory Activities Prepare and adjust old frames coming from loom sheds to be used for drawing and reaching purpose;10 frames+2 selvedge frames Carrying the frame upto the drawn beam Return for next frame WLS No:WGP/14 WORK LOAD DETAILS SHEET Weaving Shifts A B C G Preparatory Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 5 1.14 5.71 2 1 5 1.01 5.05 3 1 5 1.80 8.98 4 1 5 0.72 3.58 5 2 5 5.61 56.09 6 2 5 4.75 47.50 7 2 5 3.59 35.90 8 1 8 0.37 2.95 9 1 8 2.19 17.49 10 1 5 2.04 10.20 11 1 5 2.27 11.36 12 1 5 2.10 10.52 13 2 10 2.22 44.40 A 259.71 B 13 C 293.48 D 1350 E 21.74% F 2 G 32.61% Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Knotting Beam from Warping Section to Loom Shed Take out the beam after knotting and load the beam on to the Beam Loader Carry the knotted beam to the respective section in Loom Shed Return to warping section for next transfer Placing the warp beam in its proper place Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Return to warping section for next transfer Beam transfer from Drawing Section to Loom Shed Setting Drawn Beam m/c on the drawn beam,setting lever to insert beam and take out the beam loaded on m/c Carry the Drawn Beam m/c to the Loom Shed and place at the required position Return with another emptied Drawn Beam m/c to load next beam from Drawing section Empty beam from Loom Shed to Warping Section Load empty beam on to the trolley Carry the beam to empty beam section near Warping Preparatory Beam Colie Activity Description Beam transfer from Warping Section to Drawing Unhook the beam after warping and take out the beam Adjust the Beam Loader m/c beneath the beam and lift the beam Carry the beam to the Drawing section and release the beam at its proper place WLS No:WGP/15 WORK LOAD DETAILS SHEET Weaving Shifts A B C G Preparatory Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 7. WEAVING - LOOMSHED ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 7.0 7.1 I II III G T I II III G T 1 Khata 1 Weaver 7 7 7 - 21 7 7 7 - 21 Weaver Helper 3 3 3 - 9 3 3 3 - 9 Fitter 1.5 1.5 1.5 - 4.5 1.5 1.5 1.5 - 4.5 Jobber 1 1 1 - 3 1 1 1 - 3 Roll Doffer 1.5 1.5 1.5 - 4.5 1 1 1 - 3 Charkhi Man 1 1 - - 2 - - - 1 1 Fancy Jobber - - - 1 1 - - - 1 1 Position combined with the Fancy Jobber of khata 2 Beam Gaitor 3 3 3 - 9 3 3 3 - 9 Weft Distributor 1 1 1 - 3 1 1 1 - 3 - - 2 Khata 2 Weaver 7 7 7 - 21 7 7 7 - 21 Weaver Helper 3 3 3 - 9 3 3 3 - 9 Fitter 1.5 1.5 1.5 - 4.5 1.5 1.5 1.5 - 4.5 Jobber 1 1 1 - 3 1 1 1 - 3 Roll Doffer 1.5 1.5 1.5 - 4.5 1 1 1 - 3 Fancy Jobber - - - 1 1 - - - - 0 Beam Gaitor 3 3 3 - 9 3 3 3 - 9 Weft Distributor 1 1 1 - 3 1 1 1 - 3 3 Both Khata 1 and Khata 2 Waste Picker - - - 6 6 - - - 4 4 Cleaners - Shift 2 2 2 - 6 2 2 2 - 6 Cleaners - General - - - 2 2 - - - 2 2 Total 39 39 38 10 126 37 37 37 8 119 Manpower Deployment WEAVING - LOOMSHED Proposed Manpower Remarks S. No Section / Work area Designation Present Manpower _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 7.0 7.2 7.2.1 a) b) c) d) Deploy 4 waste pickers instead of 6 waste pickers in the general shift, based on worklaod WEAVING - LOOMSHED Proposed Changes & Observations Combine the positions of the two fancy jobbers (one in khata 1 and the other in khata 2). The combined utilization will be 75.38 %. Deployment of one fancy jobber per day is recommended. Proposed Changes Deploy one roll doffer per khata instead of the present deployment of 3 for two khatas. The workload for the two roll doffers per shift is 84.22 %. Deploy one Charkhi man for both the khatas and in general shift. The utilization is 48 % for this position holder in each shift. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 7.0 7.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 WEAVING - LOOMSHED Weaver Helper Workload Sheets Summary WLS Number Fitter WGL/04 Area of work Weaver WGL/01 WGL/03 Roll Doffer WGL/06 Charkhi Man WGL/07 Weaver WGL/02 Jobber WGL/05 Beam Gator - Airjet WGL/10 Beam Gator - Sultex WGL/11 Fancy Jobber - 1 WGL/08 Fancy Jobber - 2 WGL/09 Waste Picker WGL/14 Cleaner WGL/15 Beam Gator - Dornier WGL/12 Weft Distributor WGL/13 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1 1 1 - Proposed Manpower 1 1 1 - S. No Crew Size Freq/ Shift Basic Time (mins) Total Time (mins) A 1 1 1 2.11 2.11 2 1 90 1.31 117.90 3 1 120 1.08 130.08 4 1 55 0.58 32.08 5 1 2 5.28 10.55 6 1 27.93 27.93 7 1 10.00 10.00 A 330.65 B 17 C 386.86 D 450 E 85.97% F 1 G 85.97% To check the fabric of all 10 looms for quality, every two hours Activity Description At the time of shift starting put sign on all 10 looms fabric. Indicating the shift change and date. To attend (mend) filling (weft breakage). Designation Weaver WLS No:WGL/01 WORK LOAD DETAILS SHEET Department Weaving Shifts Work Centre Khata 1 A B C G Weaving Basic Workload per Shift ( in man minutes) To attend (mend) broken warp end Dornier Patrolling behind the looms to see if there is any crossing or entanglement at the beam, and do the correction if required. Report any abnormality in terms of quality or working to the supervisor Section To change weft cones when finished.and tie the tails of the reserve cone Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1* 1 1 - Proposed Manpower 1 1 1 - * 1 2 N F X 1-X Number of machines Factor derived from finite queuing tables 8 0.975 0.052 0.948 9 0.969 0.052 0.948 10 0.963 0.052 0.948 11 0.957 0.052 0.948 12 0.95 0.052 0.948 13 0.941 0.052 0.948 14 0.932 0.052 0.948 2.1 a b c 0.69 0.41 0.45 0.50 0.55 C G One weaver for every 10 looms 0.60 0.64 Work Centre Khata 1 Designation Weaver Operator workload 0.92 WLS No:WGL/02 Department Weaving Shifts A B WORK LOAD DETAILS SHEET Section Weaving 0.92 0.91 0.91 0.91 0.90 0.89 ME Machine efficiency For the computation of the number of machines to be allocated to each weaver, we have analyzed the machine efficiency and operator workload for different machine assignments. The same is depicted in the table below: Looms Calculation for X value: Time study was carried out to determine quantum of time spent on mending broken warp, broken weft and other activities carried out in the shift by the weaver. For the mending of the broken warp the weaver takes 1.31 minutes (including walking time) and for mending weft breakages the weaver takes 1.08 minutes (including walking and taking 25 % breakage before the thread enters the accumulator and 75 % after the thread has passed through the accumulator). OW Multiplying these values with the respective frequencies per shift (90 per 10 machines per shift for warp breakages and 120 per 10 machines per shift for weft breakages) we obtain the total external work to be carried out by the weaver. This is determined to be 247.98 minutes per 10 machines per shift. Per machine it is 24.80 minutes per shift. That is for getting output from the machine for 480-24.80 = 455.20 minutes per shift, the machine has to be serviced for 24.80 minutes, giving a value of X = 24.80/480 = 0.052 For X = 0.052 the different values of the machine efficiency and operator workload has been computed and they are depicted in the table above. Based on the formulae provided in the finite queuing tables the values of the machine efficiency and the operator workload are derived. The same are plotted in a graph and it is observed that for N=10 machines we reach a ideal combination of the machine efficiency and the operator workload. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1* 1 1 - Proposed Manpower 1 1 1 - C G Work Centre Khata 1 Designation Weaver WLS No:WGL/02 Department Weaving Shifts A B WORK LOAD DETAILS SHEET Section Weaving d The ideal combination is to allot 11 machines to each weaver, but as the layout is such that there are 10 machines in one line, we recommend that the same to be continued. 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.87 0.88 0.89 0.90 0.91 0.92 0.93 1 2 3 4 5 6 7 ME Machine efficiency OW Operator workload ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1 1 1 - Proposed Manpower 1 1 1 S. No Crew Size Freq/ Shift Basic Time (mins) man mins Total Time (mins) 1 2 1 5.6 4.00 22.40 3 1 135.00 135.00 4 1 6 5.28 31.66 5 1 5/6 25.64 21.28 6 1 10.00 10.00 7 1 10.00 10.00 A 230.34 B 17 C 269.50 D 450 E 59.89% F 1 G 59.89% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Remarks: 1 This activity is alrady performed by the Weaver himself, hence this need not be performed again by the Weaver Helper also. Hence no time has been allocated for this activity here. Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Activity Description To help in passing the knotting of newly knotted beams To attend to machine whenever there is multiple breaks or smash Report any abnormality in terms of quality or working to the supervisor To check the fabric of all looms of his lines (2 lines in sultex and dornier & 3 lines in airjet) for quality at resumption *1 To change catch selvedge spool, when finished To relieve the weaver for lunch (30 min) and tea (15 min) of three lines in loomshed *2 To take quality round of his respective lines twice a shift and sign G Section Weaving Work Centre Khata 1 Designation Weaver Helper 2. The workload has been computed based on the sum of the activities 2,3,4 and 6 detailed in the weaver workload sheet. These are the activities that the weaver helper is supposed to perform when he is relieving the weavers. This works out to be 86.62 min 3. One weaver helper for three lines in the loomshed is recommended. As seen in the workload sheet, the workload per shift for any of the weaver helpers is 59.89 %. WLS No:WGL/03 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 3 3 3 - Proposed Manpower 3 3 3 - S. No Crew Size Freq/ Shift Basic Time (mins) Total Time (mins) 1 1 3 10.00 30.00 2 3 4 1 3 20.00 60.00 5 1 1 6.26 6.26 6 1 1 6.09 6.09 7 1 1 9.34 9.34 A 231.69 B 15 C 266.44 D 450 E 59.21% F 1 G 59.21% To remove the heald frames,empty beam & droppins of finished beam. To take the round for selvedge,oil leakage,abnormal sound or any abnormality related to machine. At the time of beam gaiting adjust the reed space according to fabric width. To do the oiling & greasing of new gaited or knotted looms. Rest & Relaxation Allowances ( % ) 120.00 To do the oiling of cutter scissor & rapier head. To attend the weft breakage & selvedge problem. 1 1 Proposed Utilisation(%) Remarks: 120.00 Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift To take the reading of (warp breakage, weft breakage & efficiency) at the time of shift end. Basic Workload per Shift ( in man minutes) Activity Description Weaving Work Centre Khata 1 & 2 Designation Fitter WLS No:WGL/04 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1 1 1 - Proposed Manpower 1 1 1 - S. No Crew Size Freq/ Shift Basic Time (man mins) Total Time (mins) 1 1 1 15.00 15.00 2 1 1 35.00 35.00 3 1 2.43 30.00 72.90 4 1 15.00 15.00 5 1 15.00 15.00 6 1 15.00 15.00 7 A 167.90 B 15 C 193.09 D 450 E 42.91% F 1 G 42.91% Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins per day Present Utilisation(%) Proposed Manpower per day Proposed Utilisation(%) Activity Description To allocate workmen in the department, if any shortage then he has to arrange workers accordingly. To take round of the department to ascertain the number of beam gaiting expected in the shift and plan the man power accordingly. To start the new beam with the shift incharge. To attend the machines for warp & weft breakages, selvedge problems etc. To report and attend (help to attend) any abnormal machine in terms of quality or productivity to the concerned shift incharge. To attend minor breakdowns To organise for warp or weft shortage if any G Section Weaving Work Centre Khata 1 Designation Jobber 1. Activity 4 and 5 are primarily the responsibility of the weaver and weaver helper. 2. This role is a Team Leader role wherein the position holder is a link between the workmen and the first level of management. WLS No:WGL/05 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 3 3 3 - Proposed Manpower 2 2 2 - S. No Crew Size Freq/ Shift Basic Time (mins) Total Time (mins) 1 1.1 1 120 0.63 75.08 1.2 1 120 0.48 57.84 1.3 1 120 0.29 34.78 1.4 1 120 1.39 167.14 1.5 1 120 2.39 286.20 2 1 3 0.80 2.39 3 1 1 30.00 30.00 3.1 3.2 3.3 A 653.43 B 16 C 757.97 D 450 E 56.15% F 2 G 84.22% Load empty spindle, lock, roll some fabric Write details on completed roll by chalk Transport completed roll to grey checking area To cut the first one meter fabric from every new gaited or knotted looms & keep that fabric in the bucket for checking. Others Roll doffing Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) To fix one small sample of the newly started quality on loom for reference. Discussion with operator, supervisor etc., B Basic Workload per Shift ( in man minutes) G Load empty spindle onto trolley, return back to the weaving section, check machine panel, unload empty near machine Activity Description Weaving Work Centre Khata 1 & 2 Designation Roll Doffer C Tear cloth, load completed roll onto trolley, keep trolley aside Section To wrap the light shade qualities in polythene. WLS No:WGL/06 WORK LOAD DETAILS SHEET Department Weaving Shifts A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower 1 1 - - Proposed Manpower - - - 1 S. No Crew Size Freq/ Shift Basic Time (mins) man mins Total Time (mins) 1 1 20.00 20.00 2 2.1 1 10 0.69 6.93 2.2 1 10 0.38 3.80 2.3 1 10 12.23 122.27 2.4 1 10 0.24 2.41 2.5 1 10 0.41 4.12 2.6 1 4 1.16 4.64 3 3.1 1 2 0.69 1.39 3.2 1 2 0.38 0.76 3.3 1 2 7.00 14.00 3.4 1 2 0.24 0.48 3.5 1 2 0.41 0.82 3.6 1 2 1.16 2.32 4 1 1 5.03 5.03 5 1 1 2.55 2.55 A 191.51 B 13 C 216.41 D 450 E 48.09% F 1 G 48.09% Lock the machine and adjust Remarks: 1. As the utilization of this position holder is 48 %, possibility of deploying only one person in the general shift has to be explored. The recommended manpower is one in the general shift. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Wind new thread Remove lock and keep completed spool in rack Place new thread roll, connect Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Pass through the pins, reeds and connect Total Workload ( in man minutes ) Lock the machine and adjust Wind new thread Pass through the pins, reeds and connect Go to yarn godown, search for materials, get thread spools, place them in the stand Cut the selvedge (20 threads), knot, go to stand and connect for monogram threads Prepare the spools for monogram bobbin Pick new spool, place in machine, remove old thread and dispose into the dust bin Remove lock and keep completed spool in rack Place new thread roll, connect Activity Description Pick new spool, place in machine, remove old thread and dispose into the dust bin Weaving Work Centre Khata 1 & 2 Designation Charkhi Man To collect all the empty bobbins from the looms. Prepare the spools for catch selvedge waste for Dornier, Sultex and Picanol. WLS No:WGL/07 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower - - - 1 Proposed Manpower - - - 1 S. No Crew Size Freq/ Shift Basic Time (mins) Total Time (mins) 1 1.1 1 6 10.00 60.00 1.2 1 6 6.00 36.00 1.3 1 6 1.00 6.00 2 2.1 1 3 22.25 66.75 2.2 1 2/25 66.75 5.34 2.2 1 3 11.36 34.08 2.3 1 3 1.00 3.00 A 211.17 B 13 C 238.62 D 450 E 53.03% F 1 G 53.03% Proposed Manpower per shift Monogram Punch holes of the required pattern on the sheet (done by copying the existing pattern on the pattern being created) Cut sheet to size, check visually, paste by fevibond and scrape by emery, using a rod remove the glue from the holes Go to the loomshed and hang in the hanger Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Present Utilisation(%) Activity Description Punch holes of the required pattern on the sheet (partly punching done manually, major portion done by copying the existing pattern on the pattern being created) Cut sheet to size, check visually, paste by fevibond and scrape by emery, using a rod remove the glue from the holes Go to the loomshed and hang in the hanger Total Workload ( in man minutes ) Net Available man-mins Proposed Utilisation(%) Remarks: Weaving Work Centre Khata 1 Designation Fancy Jobber Punch holes of the required pattern on the sheet (done by manual punching) Body WLS No:WGL/08 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Present Manpower - - - 1 Proposed Manpower - - - - S. No Crew Size Freq/ Shift Basic Time (mins) Total Time (mins) 1 1 1 16.36 16.36 2 1 5 15.00 75.00 3 1 13/100 105.17 14.02 A 89.02 B 13 C 100.59 D 450 E 22.35% F 1 G 22.35% Remarks: 1. The utilization of this incumbent is 22.35 %. One person may be deployed for the Fancy Jobber activity for both the khatas. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Take a round of the dornier section and check for the quality of the monograms. Incase of any non-conformity found then correct the same Prepare the monogram for the jacquard machines in the dornier section Perform preventive maintenance works on jacquard in the dornier section Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Weaving Work Centre Khata 1 Designation Fancy Jobber Activity Description WLS No:WGL/09 WORK LOAD DETAILS SHEET Department Weaving Shifts A B C G Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1.28 10.25 13.12 2 1 1.28 7.34 3 1 1.28 6.22 4 2 1.28 9.34 23.91 5 1 1.28 1.68 2.15 6 1 1.28 8.54 10.93 7 2 1.28 34.67 88.76 8 2 1.28 18.21 46.62 9 1 1.28 5.35 6.85 10 2 2 57.50 230.00 A 422.33 B 13 C 477.24 D 900 E 53.03% F 2 G 53.03% C G Weaving Airjet looms Beam Gaitor Activity Description Preparatory Activities To remove the heald frames,empty beam & droppins of finished beam WLS No:WGL/10 WORK LOAD DETAILS SHEET Weaving Shifts A B To change the leno bobbin in airjet at the time of beam change Fitting and passing threads through the reed (Work is done on both side i.e. on one side tyeing the ends of previous beam to the new beam,fixing the reed and on the other side adjusting bolts,run contrast patti to check for weaving damages ,placing roller Final adjustment and make 1 meter fresh fabric of new gaited loom & rectify all cross ends. Call the shift incharge for final,checking and hand over the machine for production. To get the machine clean with the help of loom cleaner. To get the machines lubricated with the help of Fitters Gait the new beam on loom. Arrange and adjust the beam carrying m/c on to the Airjet m/c Put the correct weft yarn as per design on the loom card, and run the machine with fresh fabric. Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) To pass the knots of knotted beam either of warping knotting or loom knotting. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1.71 13.41 22.93 2 1 1.71 8.19 3 1 1.71 7.22 4 2 1.71 21.56 73.74 5 1 1.71 1.68 2.87 6 2 1.71 41.44 141.72 7 2 1.71 25.78 88.17 8 1 1.71 12.45 21.29 9 2 2 57.50 230.00 A 580.72 B 13 C 656.21 D 900 E 72.91% F 2 G 72.91% WLS No:WGL/11 WORK LOAD DETAILS SHEET Weaving Shifts A B G Weaving To pass the knots of knotted beam either of warping knotting or loom knotting. To get the machine clean with the help of loom cleaner. To get the machines lubricated with the help of Fitters Gait the new beam on loom. Arrange and adjust the beam carrying m/c on to the Sultex m/c Put the correct weft yarn as per design on the loom card, and run the machine with fresh fabric. Sultex looms Beam Gaitor Activity Description Fitting and passing threads through the reed (Work is done on both side i.e. on one side tyeing the ends of previous beam to the new beam,fixing the reed and on the other side adjusting bolts,run contrast patti to check for weaving damages ,placing roller Drawing the ends in correct order and final adjustment and make 1 meter fresh fabric of new gaited loom & rectify all cross ends. Call the shift incharge for final,checking and hand over the machine for production. Proposed Manpower per shift Proposed Utilisation(%) C Preparatory Activities To remove the heald frames,empty beam & droppins of finished beam Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1.71 21.11 36.10 2 1 1.71 11.12 3 1 1.71 6.47 4 2 1.71 16.46 56.29 5 1 1.71 1.82 3.11 6 2 1.71 75.22 257.25 7 2 1.71 32.43 110.91 8 1 1.71 19.45 33.26 9 2 2 57.50 230.00 A 726.93 B 13 C 821.43 D 900 E 91.27% F 2 G 91.27% Dornier looms Beam Gaitor Activity Description Preparatory Activities To remove the heald frames,empty beam & droppins of finished beam WLS No:WGL/12 WORK LOAD DETAILS SHEET Weaving Shifts A B Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: C G Weaving Fitting and passing threads through the reed and fix the correct Dobby card on the machine(Work is done on both side and i.e.on one side tyeing the ends of previous beam to the new beam,fixing the reed and on the other side adjusting bolts,run contrast patti to check for weaving damages ,placing roller etc) Drawing the ends in correct order and final adjustment and make 1 meter fresh fabric of new gaited loom & rectify all cross ends. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins To pass the knots of knotted beam either of warping knotting or loom knotting. To get the machine clean with the help of loom cleaner. To get the machines lubricated with the help of Fitters Gait the new beam on loom. Arrange and adjust the beam carrying m/c on to the Dornier m/c Put the correct weft yarn as per design on the loom card, and run the machine with fresh fabric. Call the shift incharge for final,checking and hand over the machine for production. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 21 4.72 99.12 2 1 4 20.68 82.72 3 1 21 13.28 278.88 4 1 21 7.10 149.08 5 1 21 2.18 45.68 6 1 2 31.32 62.64 7 1 2 9.60 19.20 8 1 2 2.74 5.48 A 742.81 B 13 C 839.37 D 900 E 93.26% F 2 G 93.26% Activity Description Open the bags and put the yarn in the racks as per loom no wise(for 1 bag of 64 kg carrying 32 cones on an average) WLS No:WGL/13 WORK LOAD DETAILS SHEET Weaving Shifts A B C G Weaving Basic Workload per Shift ( in man minutes) From Weft Godown to Loom shed Inspecting and checking the requirements for each m/c(total 140 m/c) and note on the paper Fill the trolley (65-70 kg in a trolley) according to requirement i.e as per beam ticket count, shade , lot number Carry the trolley to the respective m/cs and place in the respective boxes(1 trolley can fulfil the requirement of 3 m/cs ) Return to take next load Loomshed Weft Distributor Proposed Manpower per shift From Looms shed to Weft Godown Collecting semi used cones into trolley from 140 m/c Carrying the trolley to weft godown and place in bags to be taken to rewinding m/c Return to take next load Proposed Utilisation(%) Remarks:30000 mtr=10000 kgs; by 60/40 rule,60 percent will go to warping and 40 percent to the weft godown.So 4000 mtrs i.e.21 bags will be transferred to the weft godown and same will be distributed in the loom per shift Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 6 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 6 108.54 651.24 2 1 3 105.76 317.28 3 1 3 75.45 226.35 4 1 3 72.58 217.74 5 1 1 90.54 90.54 A 1503.15 B 13 C 1698.56 D 2880 E 58.98% F 4 G 88.47% WLS No:WGL/14 WORK LOAD DETAILS SHEET Weaving Shifts A B C G Weaving Clean the m/c with the help of cleaner Collect waste(empty bags,polythene waste,gatta) from each m/c and pack it separately To segregate all types of yarn waste,length wise and pack it To segregate all types of fabric waste and pack it Loom Shed Waste Picker Activity Description Collect empty polythene,paper cones and plastic cones in 3 separate bags Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 2 2 2 Designation Proposed Manpower 2 2 2 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 9 22.89 206.01 2 1 6 66.78 400.68 3 1 3 31.11 93.33 4 1 3 4.34 13.02 5 1 3 14.67 44.01 6 1 9 24.33 218.97 7 1 6 25.44 152.64 A 1128.66 B 13 C 1275.39 D 1860 E 68.57% F 4 G 70.85% Activity Description To remove the catch selvedge waste from waste box with work divided among 3 workmen each having 40(sultex and picanol),48(Donear) and 40(Airjet) m/c WLS No:WGL/15 WORK LOAD DETAILS SHEET Weaving Shifts A B C G AirJet/sultex/ dornier Rest & Relaxation Allowances ( % ) To clean the running machines with air pressure . Help the fitter in removing the old heald frame set, drop pins and reed from the machines where the beam has finished. Take the old set of drop pins, reed and frames to the drawing in section carefully To do the thorough cleaning of new gaited looms with air pressure & cloth. Loom Shed Cleaner Proposed Utilisation(%) To keep the loom shed neat & clean. To collect the paper cones & polyethene, and transfer it to bardana godown Basic Workload per Shift ( in man minutes) Remarks: The above worload sheets reflects the activity of two personnel in general shift and two personnel in shift Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 A. WEAVING MAINTENANCE - MECHANICAL MAINTENANCE ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 A 8.1 A I II III G T I II III G T 1 AIRJET FITTER - - - 1 1 - - - 2 2 2 DORNIER FITTER - - - 2 2 - - - 2 2 3 SULTEX FITTER - - - 2 2 - - - 2 2 Total 0 0 0 5 5 0 0 0 6 6 Manpower Deployment WEAVING MAINTENANCE - MECHANICAL MAINTENANCE Proposed Manpower Remarks S. No Section / Work area Designation Present Manpower _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 A 8.2 A 8.2.1 A a) 8.2.2 a) b) c) - - - - d) Two fitters in each area are being proposed keeping in mind the importance of getting the equipment up and running in the least possible time and to increase the production output. The utilization for the two fitters in the sultex section works out to be 77 % whereas in the dornier and the airjet sections the utilization is 42.82 % and 38.56 %, after allowing for a loading factor of 80 %. Observations Technically if we proceed only as per workload, it is possible to combine both the airjet and the dornier sections and a common crew of two fitters may man the combined sections. However analyzing the data of breakdown maintenance for a period of two months it is observed that in the span of two months there has been one occurence of a simultaneous occurence in the airjet and the dornier areas. There has also been two breakdowns in the airjet area on one day and in the dornier areas for two days. Keeping in mind the possibility of simultaneous occurence of breakdowns inside the sections and between the sections, two seperate crews are being recommended for each of the above mentioned areas. It is furthur recommeded that the company analyze the occurence of the breakdowns in the two sections for a period of 2-3 years to obtain a reasonable estimate of the simultaneous occurences. If the simultaneous occurences are not many then a common crew of two fitters may be deployed to take care of both the sections. WEAVING MAINTENANCE - MECHANICAL Proposed Changes & Observations Deploy two fitters in the general shift in the airjet area instead of the present deployment of one in the general shift Proposed Changes The following need improvements to make the maintenance function more effective Records keeping The start and end times for both the preventive maintenance and the breakdown maintenance to be maintained. This would help in the analysis of the breakdowns and in maintenance planning The manpower has been computed with a loading factor of 80 % for the maintenance personnel. The 80 % loading has been considered to take into account the following Variation in machine availability Collection & deposit of tools, dress change Effort variation Getting consumables from the sub store etc, ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 A 8.2 A WEAVING MAINTENANCE - MECHANICAL Proposed Changes & Observations 8.2.2 Use of standard operating procedures Observations For the preventive maintenance activities the personnel should use SOP's which will also detail the time element of the activities to be carried out. Presently checklists are used, but SOP's will reduce the variations and also act as benchmarks Effective supervision It is observed that the breaks (tea and lunch) taken by the maintenance personnel are not synchronized and the allowed time / more than the allowed time for the same is utilized. The maintenance personnel to be trained and educated that during the preventive maintenance / breakdown maintenance the times for the breaks can be kept at minimum so that the crew is able to focus better on the maintenance aspects Coordination Coordination between the mechanical and electrical maintenance sections is poor leading to less effective maintenance levels. On two of the days when the preventive maintenance activities in the mechanical section were studied it has been observed that the electrical section did not perform the electrical side of the preventive maintenance activities. Stopping a particular equipment again only for electrical maintenance would lead to loss of time and effort ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 A 8.3 A S.No 1 2 3 AIRJET WGM/MECH/03 WEAVING MAINTENANCE - MECHANICAL DORNIER SULTEX AND PICANOL WGM/MECH/01 WGM/MECH/02 Workload Sheets Summary WLS Number Area of work ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 1.1 2 1040 1.87 1943.26 1.2 2 40 2.22 88.70 1.3 370.59 2 1.1 2 72 2.46 177.32 1.2 2 6 4.63 27.76 A 2607.63 B 15 C 2943.18 D 3840 E 76.65% F 2 G 76.65% Activity Description 1. Available man hours per year has been calculated @ 25 working days per month Yearly maintenance Net Available man-hrs per year Present Utilisation(%) Proposed Manpower per shift B C G Mechanical Sultex (number of machines - 40) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) WLS No: WGM/MECH/01 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A Half yearly maintenance Sultex and Picanol Fitter Remarks: Proposed Utilisation(%) Breakdown maintenance 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity Picanol (number of machines - 6) Monthly maintenance Yearly maintenance Basic Workload per Shift ( in man minutes) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 1.1 2 48 11.68 560.56 1.2 2 999.79 A 1560.35 B 15 C 1644.43 D 3840 E 42.82% F 2 G 42.82% 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) Net Available man-hrs per year 1. Available man hours per year has been calculated @ 25 working days per month Yearly maintenance Breakdown maintenance Dornier Fitter Activity Description Dornier (number of machines - 48) WLS No: WGM/MECH/02 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Mechanical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - Total Time (Hrs) 1 1.1 1 52 4.73 245.98 1.2 2 80 4.97 397.83 1.3 2 40 10.05 402.09 1.4 277.86 A 1323.76 B 15 C 1480.64 D 1920 E 77.12% F 2 G 38.56% 1. Available man hours per year has been calculated @ 25 working days per month Weekly greasing 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) Airjet Fitter Activity Description Airjet (number of machines - 40) Net Available man-hrs per year Half Yearly maintenance Yearly maintenance Breakdown maintenance WLS No: WGM/MECH/03 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Mechanical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 B. WEAVING MAINTENANCE - ELECTRICAL MAINTENANCE ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8.0 B 8.1 B I II III G T I II III G T 1 Shift maintenance Electrician 1 1 1 - 3 1 1 1 - 3 2 General shift maintenance - attending to major breakdowns and preventive maintenance Electrician - - - 3 3 - - - 2 2 3 Humidity plant Humidity attendant 1 1 1 - 3 1 1 1 - 3 4 Engineering Workshop Fitter / Turner - - - 2 2 - - - 1 1 5 Motor maintenance Motor Fitter - - - 1 1 - - - 1 1 6 Motor winding Motor winder - - - 1 1 - - - 1 1 7 Lighting and outside works Wireman - - - 2 2 - - - 2 2 8 Cleaning of return air grills, ducts and RA wire mesh Cleaners - - - 3 3 1 1 1 - 3 Total 2 2 2 12 18 3 3 3 7 16 S. No Section / Work area Designation Present Manpower Manpower Deployment WEAVING MAINTENANCE - ELECTRICAL MAINTENANCE Proposed Manpower Remarks _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 B 8.2 B 8.2.1 B a) b) 8.2.2 B The start and end times for both the preventive maintenance and the breakdown maintenance to be maintained. This would help in the analysis of the breakdowns and in maintenance planning Use of standard operating procedures For the preventive maintenance activities the personnel should use SOP's which will also detail the time element of the activities to be carried out. Presently checklists are used, but SOP's will reduce the variations and also act as benchmarks. It has also been observed that the crew use the mobile torch during the maintenance activities which is not a healthy practice. Effective supervision It is observed that the breaks (tea and lunch) taken by the maintenance personnel are not synchronized and the allowed time / more than the allowed time for the same is utilized. The maintenance personnel to be trained and educated that during the preventive maintenance / breakdown maintenance the times for the breaks can be kept at minimum so that the crew is able to focus better on the maintenance aspects Coordination Coordination between the mechanical and electrical maintenance sections is poor leading to less effective maintenance levels. On two of the days when the preventive maintenance activities in the mechanical section were studied it has been observed that the electrical section did not perform the electrical side of the preventive maintenance activities. Stopping a particular equipment again only for electrical maintenance would lead to loss of time and effort WEAVING MAINTENANCE - ELECTRICAL Proposed Changes & Observations Deploy two electricians in the general shift for the attending of the preventive maintenance and breakdown maintenance works instead of the present deployment of three personnel in the general shift. The utilization is 48 % at 80 % loading factor. Proposed Changes Records keeping Observations Deploy one person in the workshop instead of the present deployment of two personnel. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 B 8.2 B WEAVING MAINTENANCE - ELECTRICAL Proposed Changes & Observations 8.2.2 B The activities to be so planned and peformed that the time taken is minimized. Activites that can be carried out in parallel have to be planned. For example, when the production personnel are shutting down the machine and handing over for production, the maintenance personnel can start their activities such as keeping the grease gun ready, bring all the tools, arrange in the workplace, bring the bearings and other consumables which are likely to be changed and keep ready in the workplace. It is observed that the personnel keep making rounds to the workshop often to get tools, bearings etc,. Planning Observations ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 8 B 8.3 B S.No 1 2 3 4 5 6 7 8 WLS Number Area of work Humidity plant operator WGM/ELE/08 Workshop fitter and turner WGM/ELE/07 Cleaners WGM/ELE/05 Lighting electricians WGM/ELE/06 Motor Fitter WGM/ELE/03 Motor winder WGM/ELE/04 WEAVING MAINTENANCE General shift electricians Shift Electricians WGM/ELE/01 WGM/ELE/02 Workload Sheets Summary ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - 1 2 Date Total time 1-Dec 345 2-Dec 525 3-Dec 445 4-Dec 490 5-Dec 300 6-Dec 395 7-Dec 495 2995 3 4 5 6 / = 0.2976 ~ 0.30 For / = 0.30 we find that the utilization of the shift electrician is 30 % only per shift. Hence it is recommended that the deployment of one per shift may be continued and additional works as deemed fit may be allocated to the incumbent whenever required The average time to resolve a complaint works out to be 50 minutes and as per the time distribution also the modal value is 45 minutes. 9 7 8 11 Number of complaints 7 Loomshed Electrician Data provided for the period december 1-7 (7 days) Number of complaints attended on each day and the total time spent for the same is 60 The average arrival rate is 60/7 = 8.57 per day and the average servicing rate = 24*60/50 = 28.8 per day 9 9 WLS No: WGM/ELE/01 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - 2 1 2 3 4 5 PF CE PH CH SULTEX 75.8 221.0 0.0 1.2 PF CE AIR JET 67.8 247.8 0.0 2.2 PH CH DORNIER 44.0 140.0 48.0 24.0 PICNOL 126.0 258.0 0.0 0.0 WARPING 27.0 224.0 0.0 17.0 H PLANT 120 * 0.0 0.0 360** STABILIZER 3.2 9.0 0.0 0.0 TRANSFORMER 1.6 4.0 0.0 0.5 COMPRESSOR 153.5 36.5 0.0 307 ** BREAKDOWN MAINTENANCE 128.0 702.0 0.0 38.5 TOTAL 506.9 1842.3 48.0 82.2 * ** Loomshed Electrician Contract Electrician Permanent The yearly workload section wise is detailed below: The preventive maintenance data was collected for all the category of machines. Check studies on a sample basis were carried out to ascertain the process being followed for the preventive maintenance. Detailed discussions were held with the incumbents and the supervisory personnel. Breakdown maintenance data has been obtained for a period of two months and the same has been extrapolated for a year. The sum of the preventive maintenance and the breakdown maintenance workload for the year gives us the total workload for the general shift electricians. The works performed by the Motor Fitter, humidity plant operator and the cleaning personnel are refle WLS No: WGM/ELE/02 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical Section Included in the Motor Fitter workload and given in the separate workload sheet The cleaning personnel workload sheet detailes these activities. Hence the total not considered here Yearly Workload of Crew Category Involved (In hrs) Permanent Fitter Contract ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - 2 Loomshed Electrician WLS No: WGM/ELE/02 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical 6 - - - - Collection & deposit of tools, dress change Effort variation For the two personnel recommended, the workload percentage appears to be 48 %. Two personnel are recommended as the base crew size for this kind of maintenance activity is two personnel The yearly workload for the personnel works out to be 1842.3 hrs. The manpower has been computed with a loading factor of 80 % for the maintenance personnel. The 80 % loading has been considered to take into account the following Variation in machine availability Getting consumables from the sub store etc, ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 1 2 3 4 5 S.No 1 2 6 WLS No: WGM/ELE/03 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical Breakdown maintenance data has been obtained for a period of two months and the same has been extrapolated for a year. The sum of the preventive maintenance and the breakdown maintenance workload for the year gives us the total workload for the general shift electricians. The works performed by the Motor Fitter are reflected in this worklaod sheet. The yearly workload for the Motor Fitter, section wise is detailed below: Loomshed Motor Fitter The preventive maintenance data was collected for all the category of machines. Check studies on a sample basis were carried out to ascertain the process being followed for the preventive maintenance. Detailed discussions were held with the incumbents and the supervisory personnel. Description For the one person recommended, the workload percentage appears to be 53.48 % (at 80 % loading) Workload per year (Hrs) The yearly workload for the personnel works out to be 1026.9 hrs. 626.9 Preventive and breakdown maintenance Check all the motors in the loomshed, clean, check earthing points, leakage etc., Total workload per year 400 1026.9 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Year Basic Time - man hrs Total Time (Hrs) 1 1 40 2.0 80.00 1 4 4.0 16.00 1 28 12.0 336.00 A 432.00 B 15 C 496.80 D 2400 E 20.70% F 1 G 20.70% Activity Description Rewind the motors of the following categories, check its performance WLS No: WGM/ELE/04 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical Net Available man-hrs per year 1 HP and Less Between 1 HP to 7.5 HP Above 7.5 HP Motor Rewinding Motor Rewinder 1. Man hours per year has been calculated @ 25 working days per month Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) 2. The number of the motors serviced and rewinded have been obtained from the present incumbent. 3. The utilization per year is 20.70 %. As this position has been filled recently, the company will have to decide the continuity of this position based on the work which will be performed by this position holder in the next one year. Also the pros and cons of sending the motors for outside servicing and the advantages of an in house facility for this activity will have to be taken into consideration by the company. Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower 1 1 1 - Sl. No C r e w
S i z e F r e q /
Y e a r B a s i c
T i m e
-
m a n
m i n s T o t a l
T i m e
( H r s ) 1 a) 1 300 22.10 110.50 b) 1 1095 22.95 418.84 c) 1 300 3.83 19.13 d) 1 1095 38.25 698.06 e) 1 1095 2.55 46.54 f) 1 300 17.14 85.72 g) 1 300 14.03 70.13 h) 2 1095 25.50 930.75 i) 2 1095 51.00 1861.50 j) 1 1095 14.80 270.10 k) 1 1095 26.40 481.80 2 307 ** 3 360** 4 82.17 A 5075.23 B 14 C 5785.76 D 8760 E 66.05% F 1 G 66.05% Half Trenches inside the loomshed (two numbers - sultex and picanol area) Galleries and rooms (3 numbers) above warping Galleries and rooms (2 numbers) near the electrical manager's room Compressors (three numbers) H plant Trenches inside the loomshed (two numbers - dornier area) Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) Net Available man-hrs per year Battery room (inside grey checking) Preventive and breakdown maintenance Main Trenches below the weaving loomshed (7 channels) Transfer the waste to the waste yard Weaving power house by broomstick, equipments and control panel by weaving waste Work shop Loomshed Helpers Activity Description Clean the Manager's room, steps in the department, weft godown, humidity room near warping, electrical panel room in warping, yarn godown no 2, collect waste in poly cover and dispose in the dust bin Humidity room adjacent to the sultex area WLS No: WGM/ELE/05 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower 1 1 1 - Sl. No C r e w
S i z e F r e q /
Y e a r B a s i c
T i m e
-
m a n
m i n s T o t a l
T i m e
( H r s ) Loomshed Helpers Activity Description WLS No: WGM/ELE/05 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical 1. Man hours per year has been calculated @ 25 working days per month 2. Presently three personnel are working in the general shift, but discussions with the manager has revealed that they would be deployed in the shifts after the training period 3. The time taken for the activities will be less than what is reflected here as the cleaning will be taking place in all the shifts and not in general shift as at present. This will impact activites g,h,i,j,k Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Day Basic Time - man mins Total Time (mins) 1 1 1 30.00 30.00 2 1 1 60.00 60.00 3 2 5 48.00 480.00 A 510.00 B 15 C 586.50 D 960 E 61.09% F 2 G 61.09% WLS No: WGM/ELE/06 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Daily check the tubelights in mending, loom shed,warping and drawing * 2 Attend to complaints in the various departments Loomshed & outside Electricians Activity Description KWH meter reading 3. This crew has attended 31 complaints in 7 days (29th dec - jan 4th), the data for which was provided. The average number of complaints handled is ranging between 4 -5 per day with an average handling time of 48 minutes. Proposed Utilisation(%) Remarks: 1. Man hours per year has been calculated @ 25 working days per month 2. During the studies in the various departments this activity by the electrical staff has not been observed regularly and this actiivty does not add value. Hence this activity time is not included in the total. Whenever there is a complaint then the same may be resolved by the deployed crew. Total Workload ( in man hours per day) Net Available man-hrs per day Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 1 1 2 3 4 5 During the observations carried out, it has been observed that the primary work is performed by the personnel who need the work to be carried out (various maintenance departments). The workshop personnel only perform secondary works such as providing technical assistance in the completion of the works. The works being carried out in this department is not very complex and the equipment is very old and not very high precision type. Keeping in mind the above points, it is recommended that the workshop be manned by one person. Workshop Fitter / Turner The following equipment are present in the workshop: 2 lathes, 1 shaper, 1 planer, and 1 power hacksaw. All the equipment are very old and the planer in fact is 1899 make model. Detailed discussions were held with the incumbents and the supervisory personnel. WLS No: WGM/ELE/07 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time - man mins Total Time (mins) 1 1 1 30.00 30.00 2 a) 1 1 15.00 15.00 b) 1 1 30.00 30.00 c) 1 1 90.00 90.00 d) 1 1 10.00 10.00 e) 1 1/18 90.00 5.00 f) 1 1/60 300.00 5.00 3 1 4 10.00 40.00 4 1 2/3 45.00 30.00 A 255.00 B 15 C 293.25 D 450 E 65.17% F 1 G 65.17% Once in two hours record readings from the 6 thermometers Operate valves, perform back wash Operate the softner plant Perform flashing Operate the RO plant Clean plant premises Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Nozzle cleaning (performed only during the A and B Clean the nozzles: during summer one hour spent on this activity (about 4 in sultex and 3 in others) and during winter 30 minutes spent on this activity (about 2 in sultex and 2 in others). Hence taken 50 % @ 1 hour and 50 % @ 30 minutes Net Available man-hrs per day Present Utilisation(%) Humidity plant H plant operator Activity Description Check all the supply air fans ( 19 numbers) and return air fans (13 numbers) and pumps (12 numbers) for the 7 plants daily Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per day) Clean the 6 filters in RO plant once in a week Change salt every 20 days (70 Kg) WLS No: WGM/ELE/08 WORK LOAD DETAILS SHEET Weaving Maintenance Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 9. WEAVING - QA ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 9.0 9.1 I II III G T I II III G T 1 Greige fabric checking Investigator / Checker - - - 1 1 - - - 1 1 Helper - - - 1 1 - - - 1 1 2 Weaving QA Investigator 1 1 1* - 2 1 1 - - 2 * Staff category and the rest are contract employees 3 QA - Process Lab Investigator 1 1 1 - 3 1 1 1 - 3 Total 2 2 1 2 7 2 2 1 2 7 S. No Section / Work area Designation Present Manpower Manpower Deployment WEAVING - QA Proposed Manpower Remarks _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 9.0 9.2 9.2.1 a) WEAVING - QA Proposed Changes & Observations Proposed Changes No changes proposed. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 9.0 9.3 S.No 1 2 3 WEAVING - QA Quality rounds and report preparation Process lab WGQA/03 Checking of fabric received from the outside vendors WGQA/01 WGQA/02 Workload Sheets Summary WLS Number Area of work ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 14 0.64 18.02 2 1 18 7.12 128.16 3 1 18 0.63 11.25 4 1 36 0.48 17.28 5 2 18 0.27 9.60 6 1 18 0.27 4.80 7 1 9 0.45 4.05 8 2 4 7.32 58.56 9 2 4 3.30 26.40 10 2 4 1.71 13.65 11 2 1 30.00 60.00 12 1 4 8.20 32.80 13 1 18 1.50 27.00 A 411.58 B 17 C 481.54 D 960 E 50.16% F 2 G 50.16% 2. The inspection will be carried out in cycles of 20 minutes followed by a break of 17 % X 20 minutes = 3.4 minutes. The two personnel will be carrying out the inspection in turns. When one person avails tea break, the other can continue the inspection . Write details of completed roll in the record, open new page, write details of the new roll, set counter to zero Entry of greige fabric checking in SAP Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Checking of Ends & Picks of the all inspected fabric pieces Collect the rolls to be processed from the respective storage areas, weigh and stack near the machine Transport completed rolls to the big batching machine Others such as discussion with the superiors, getting instructions etc,. Write quality details on the fabric - twice Untie knots, keep the completed roll in the designated area Load new empty spindle, roll certain length of cloth Cut cloth piece at the end 1. The average length is considered as 100 meters Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Place new roll on the stand, pull some cloth, tie two ends to the previous fabric Inspect fabric till the fabric roll is completed Greige Fabric Checking Investigator, Helper Activity Description Load new roll in the machine, pass through the rollers, pull fabric till the inspection table WLS No: WGQA/01 WORK LOAD DETAILS SHEET Weaving Shifts A B C G Quality Assurance ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1* - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1.1 1 1 70.71 70.71 1.2 1 3 3.00 9.00 1.3 1 3 1.00 3.00 1.4 1 4 5.00 20.00 2 1 1 25.00 25.00 A 127.71 B 15 C 146.86 D 450 E 32.64% F 1 G 32.64% * - Staff category Rest & Relaxation Allowances ( % ) Ascertain the defects being noticed in the grey checking machines, note down the quality number and the defect meters Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: WLS No: WGQA/02 WORK LOAD DETAILS SHEET Weaving Shifts A Basic Workload per Shift ( in man minutes) Quality Assurance Investigator Activity Description Quality round of the loom shed - 134 looms B C G Quality Assurance Net Available man-mins Input data into the computer, file documents Check for the quality of the fabric being woven in the looms, mark defects by chalk In case of non conformities, discuss with the production supevisor Prepare slips for the non-conformity observed and place one slip in the roll being processed Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1.1 1 1 26.32 26.32 1.2 1 3 10.23 30.70 1.3 1 1 105.26 105.26 1.4 1 1 21.93 21.93 1.5 1 1 31.14 31.14 1.6 1 1 24.92 24.92 1.7 1 1 62.30 62.30 1.8 1 1 5.00 5.00 2 2.1 1 1 42.10 42.10 2.2 1 3 10.23 30.70 2.3 1 1 31.14 31.14 2.4 1 1 62.30 62.30 2.5 1 1 5.00 5.00 2.6 1 1/9 60.00 6.67 2.7 1 1/6 60.00 10.00 Samples submission to despatch department, bills collection from HOD office and forwarding to accounts department Yarn testing (Blend % & Colour fastness to washing) - 8 samples (1 reading) Fabric sample collection from Process House - 14 samples Development fabric testing (Width, GSM, Colour fastness to washing, water & rubbing, Blend composition & Pilling) - 5 samples (1 reading) Outsourced fabric testing-bulk (Colour fastness to washing & rubbing & Pilling) - 10 samples (1 reading) Folding of the roll strips for grouping and returning back to folding department - 60 strips Material collection from stores (Chemical & stationary for lab use) Fibres testing (Colour fastness to washing) - 20 samples (1 reading) Sample preparation for CSV checking - 18 samples (1 reading) Shift B Development fabric testing (Width, GSM, Colour fastness to washing, water & rubbing, Blend composition & Pilling) - 5 samples (1 reading) Outsourced fabric testing-preshipment (Width, GSM, Colour fastness to washing & rubbing, Blend composition, Pilling) - 4 samples (1 reading) Outsourced fabric testing-bulk (Colour fastness to washing & rubbing & Pilling) - 10 samples (1 reading) Folding of the roll strips for grouping and returning back to folding department - 60 strips Process lab Investigator Activity Description Shift A Instrument & Lab Cleaning Fabric sample collection from Process House - 14 samples WLS No: WGQA/03 WORK LOAD DETAILS SHEET Weaving Shifts A B C G Quality Assurance ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Process lab Investigator Activity Description WLS No: WGQA/03 WORK LOAD DETAILS SHEET Weaving Shifts A B C G Quality Assurance 3 3.1 1 3 10.23 30.70 3.2 1 1 18.69 18.69 3.3 1 1 124.60 124.60 A 669.47 B 14 C 763.20 D 1350 E 56.53% F 3 G 56.53% Fabric sample collection from Process House Shift C Bulk fabric sample testing-Domestic fabric (Width, Colour fastness to washing & rubbing & Pilling) - 20 samples (1 reading) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per day Proposed Utilisation(%) Basic Workload per day ( in man minutes) Bulk fabric sample testing-RMG fabric (Width, GSM, Colour fastness to washing, water & rubbing, Blend composition & Pilling, CSV stitching) - 3 samples (1 reading) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 10. CHECKING, MENDING AND FINISHING ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 10.0 10.1 I II III G T I II III G T 1 Grey checking Checker 4 4 3 - 11 4 4 3 - 11 Loader 6 6 4 - 16 4 4 3 - 11 Segregator cum Loader 2 3 - - 5 - - - - - 2 Mending Damage reporter - - - 1 1 - - - 1 1 Menders - - - 45 45 - - - 28 28 Mended fabric checker - - - 3 3 - - - 4 4 Loaders - - - 3 3 - - - - - Cleaner - - - 1 1 - - - 1 1 Computer operator 2 - - 1 3 2 - - 1 3 3 Kitty mending Kitty Menders - - - 17 17 - - - 8 8 Totally 20 are there, 17 are in mending and 3 in finish folding 4 Finish folding Finish Checker - - - 1 1 - - - 1 1 5 Perching Checker 4 4 4 - 12 2 2 2 - 6 6 Fold machine Operator - - - 3 3 - - - 2 2 Helper - - - 3 3 - - - 2 2 7 Grading section Monitor - - - 1 1 - - - 1 1 Sample man - - - 2 2 - - - 2 2 Loader - - - 2 2 - - - 2 2 Grader - - - 25 25 - - - 18 18 THAN loader - - - 2 2 - - - 2 2 S. No Section / Work area Designation Present Manpower Manpower Deployment CHECKING, MENDING AND FINISHING Proposed Manpower Remarks _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 10.0 10.1 I II III G T I II III G T S. No Section / Work area Designation Present Manpower Manpower Deployment CHECKING, MENDING AND FINISHING Proposed Manpower Remarks Cut piece grader - - - 9 9 - - - 7 7 Kitty Menders - - - 3 3 - - - 2 2 8 THAN packing Bar code sticker operator - - - 1 1 - - - 1 1 Manpower deployment given per line Helper - - - 3 3 - - - 3 3 THAN folder - - - 2 2 - - - 2 2 Per line THAN screening - - - 1 1 - - - 1 1 Per line THAN stamper - - - 1 1 - - - 1 1 Per line Wrapper man - - - 1 1 - - - 1 1 Per line Poly bag man - - - 1 1 - - - 1 1 Per line THAN segregator - - - 3 3 - - - 3 3 9 PL Packing section PL Packers - - - 16 16 - - - 16 16 FRC Sorter - - - 2 2 - - - 1 1 10 B & R Inspection Finish Checker - - - 1 1 - - - 1 1 Inspector 8 8 8 - 24 7 7 7 - 21 Packers 6 6 4 - 16 4 4 4 - 12 Sample man - - - 1 1 - - - 1 1 11 Finish folding Helper - - - 4 4 - - - 4 4 Computer operator - - - 2 2 - - - 2 2 Cleaner - - - 2 2 - - - 1 1 Total 32 31 23 163 249 23 21 19 121 184 _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 10.0 10.2 10.2.1 a) b) c) d) e) f) g) h) i) j) k) l) Fold machines - operate two machines per day to fulfill the production requirements of 26500 per day, hence deploy 4 personnel instead of the present deployment of 6 personnel THAN grader - deploy eighteen personnel instead of the present deployment of twenty five per day based on workload CP grader - deploy seven personnel instead of the present deployment of nine per day based on workload Kitty mender in grading - Deploy 2 personnel instead of the present deployment of 3 personnel, based on workload. The graders may be trained in this activity also so that this position may be eliminated in the long run. FRC sorter - Deploy 1 person instead of the present deployment of 2 personnel, based on workload. CHECKING, MENDING AND FINISHING Proposed Changes & Observations Proposed Changes Mending checker helper - Deploy none as mender helper inspead of the present deployment os one along with each checker. The utilization amounts to 14.69 % and these activities may be performed by the mender who takes his fabric for re-inspection. Kitty mender - Deploy 8 personnel instead of the present deployment of 17 personnel, based on workload. Perching - deploy two operators per shift instead of the present deployment of 4 per shift. The organization needs to operate only two machines per shift Deploy one personnel for two machine as loaders in the grey checking area instead of the present deployment of three personnel for two machines. The workload works out to be 15.28 % per shift per machine. Also the activities of the segregator cum loader are also to be performed by these loaders. During the inspection of the rolls adequate time is available to carry out the segregator cum loaders's activities also. At the outset it is recommended that one person per machine be deployed and thereafter this may be rationalized to the above staffing pattern after some period of working. Segregator cum loader - deploy none per shift instead of the present deployment of 2 in A shift and 3 in the B shift. The activiites will henceforth be performed by the grey checking loaders. The utilization per shift is 10.29 % for each of the two personnel deployed. Menders - Deploy 28 menders in general shift instead of the present deployment of 45 in general shift. An allowance of 17 % has been provided and the personnel may avail these allowances after the time specified in the workload sheets. Mender checkers - Deploy 4 personnel in general shift inatead of the present deployment of three personnel, if all the 9000 meters have to be checked. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 10.0 10.2 10.2.1 CHECKING, MENDING AND FINISHING Proposed Changes & Observations Proposed Changes m) n) o) B & R inspection - packers - deploy 4 personnel per shift instead of the present deployment of 6 personnel. The breakup of the activities are explained in detail in the workload sheet Finish folding - cleaner - deploy one person in the general shift instead of the present deployment of two per day based on workload Rolling cum inspection - Checkers - Operate 7 machines per shift instead of the present operation of eight machines, hence deploy 7 personnel as checkers instead of the present deployment of 8 personnel per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 10.0 10.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Cleaner - finish folding Monitor Finish checker - B & R section Bale helpers Sample man - B & R section Bar code operator - B & R section Computer operator - B & R section THAN segregator PL packer - bar code operator PL packer - screening FRC sorters Rolling machine inspection B & R section Packers - B & R section Alignment helper THAN folder Screening Stamping Wrapper man Poly bag man THAN grader Cut piece grader THAN loader Kitty mender in grading Perching checker Finish fold operator and helper Sample man Finish folding loader Bar code operator Mender checker helper Kitty mender CMF/38 CMF/30 CMF/31 CMF/32 CMF/33 CMF/26 CMF/27 CMF/39 CMF/40 CMF/41 CMF/34 CMF/35 CMF/36 CMF/37 CMF/28 CMF/29 CMF/22 CMF/23 CMF/24 CMF/25 CMF/16 CMF/17 CMF/18 CMF/19 CMF/20 CMF/21 CMF/12 Computer operator - mending CMF/10 Computer operator - mending CMF/14 CMF/15 CMF/08 Computer operator - mending CMF/09 Damage Reporter CMF/13 CHECKING, MENDING AND FINISHING Grey checking loader Cleaner - mending CMF/11 Finish Checker - finish folding Segregator cum loader CMF/03 Mender CMF/04 CMF/07 Mender checker CMF/05 CMF/06 Grey Checker CMF/01 CMF/02 Workload Sheets Summary WLS Number Area of work ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 4 4 3 - Designation Proposed Manpower 4 4 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 20 10.67 213.40 2 1 20 0.63 12.60 3 1 40 0.48 19.20 4 1 1 25.64 25.64 A 270.84 B 17 C 316.88 D 440 E 72.02% F 1 G 72.02% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Others such as discussion with the superiors, getting instructions etc,. Remarks: 1. The average length is considered as 150 meters Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Inspect fabric till the fabric roll is completed Write details of completed roll in the record, open new page, write details of the new roll, set counter to zero Write quality details on the fabric - twice Grey Checking Checker Activity Description 2. The inspection will be carried out in cycles of 24.52 minutes followed by a break of 17 % X 24.52 minutes = 4.2 minutes. There can be 14 cycles of inspection in the shift, after accounting for 30 minutes of discussions and a tea time of 14.2 minutes. One of the breaks has to be combined with the time of ten minutes provided to make a tea time of 14.2 minutes. 14 cycles has been calculated based on 410 minutes ( 450-10 minutes tea - 30 minutes discussions). In each cycle 300 meters of fabric can be processed WLS No: CMF/01 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Grey Checking ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 4 - Designation Proposed Manpower 4 4 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 16 0.46 14.72 2 2 20 0.27 10.67 3 1 20 0.12 2.40 4 1 20 0.27 5.33 5 2 20 0.32 12.98 6 2 4 1.71 13.68 A 59.78 B 15 C 68.75 D 450 E 15.28% F 4 G 15.28% Remarks: 1. The average length is considered as 150 meters Keep the empty roll in the designated area Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Grey Checking Loader Activity Description Place new roll on the stand, pull some cloth, tie two ends to the previous fabric Load new roll in the machine, pass through the rollers, pull fabric till the inspection table Untie knots, keep the completed roll in the designated area Load new empty spindle, roll certain length of cloth Collect the rolls to be processed from the respective storage areas, weigh and stack near the machine 2. The utilization being 15.28 % for one person, one loader should be able to handle all four machines, but keeping in mind the interference it is recommended that one loader may be allocated two machines each. The checker will assist the loader in activities wherein the crew size is two personnel.In the initial stage one person per machine is recommended,later one person per two machine could be reached WLS No: CMF/02 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Grey Checking ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2 3 - - Designation Proposed Manpower - - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 5 0.69 6.86 2 2 67 0.51 68.34 3 1 5 0.44 2.20 4 5 1 1 10.00 10.00 A 87.40 B 13 C 98.76 D 960 E 10.29% F - G - Remarks: 1. For stacking the rolls the present norm is 4000 meters per person. Since 5 personnel are deployed per day, 20000 meters has been considered per day. The average roll length is 150 meters, hence giving us about 134 rolls to be processed per day. Converting this on a per shift basis we get 67 rolls to be processed per shift. 2. This position is not being recommended. It is suggested that this activity be performed by the machine loaders. In case of any problem, reconsile Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Grey Checking Segregator cum Loader Activity Description Transport rolls from the grey checking machines to work area Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Stack the rolls as per the sequence, note details in the register Move the empty trolley back to grey checking area Send recorded figure in the register to the computer WLS No: CMF/03 WORK LOAD DETAILS SHEET Checking, Mending & Shifts A B C G Grey Checking ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 45 Designation Proposed Manpower - - - 28 Sl. No Crew Size Freq/ Shift (meters) Basic Time (Mins) Total Time (Mins) 1 1 9000 1.00 9000.00 2 1 60 3.49 209.23 3 1 60 1.00 60.00 4 1 9000 0.18 1620.00 5 1 60 1.04 62 A 10951.63 B 17 C 12813.41 D 480 E 59.32% F 28 G 95.34% Time in minutes per meter Weight ed average 0.16 0.04 0.36 0.09 0.963 0.24 2.52 0.63 1.00 Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Category Total Workload ( in man minutes ) 1 Weight 25% Proposed Utilisation(%) Remarks: 1. The time of one minute per meter of fabric has been arrived at after studying the various categories of the fabric being mended and based on the time taken for each of these categories. Based on the discussions with the various personnel it was decided to allocate 25 % weightage to each of the four categories. The weighted average time per meter is 60 seconds ~ 1 minute. If the weights are going to change in the future then the weighted average time also will be changing. 2 3 4 25% 25% 25% Mending Mender Activity Description Put the piece on the mending table for mending, rectify the defects if found on the mending table, put flag on unmendable defects Weighted average time in minutes per meter Collect fabric in trolley, transport trolley to the rerolling machine / mending checker and back to work place Transport the 'to be processed material' near the work place and reposition trollies after completion Check the fabric along with the mended fabric checker Reposition trollies, tie knots to the fabric and push fabric in the bin WLS No: CMF/04 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift (meters) Basic Time (Mins) Total Time (Mins) 1 2 A 1593.00 B 17 C 1863.81 D 480 E 129.43% F 4 G 97.07% Total Workload ( in man minutes ) Remarks: 1. The time of one minute per meter of fabric has been arrived at after studying the various categories of the fabric being mended and based on the time taken for each of these categories. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) 1 9000 Basic Workload per Shift ( in man minutes) 0.18 Rest & Relaxation Allowances ( % ) 1593 Mending Mender Checker Activity Description Check the fabric along with the mender, get mendable defects corrected by the mender Record the details of the fabric checked and send to the computer operator WLS No: CMF/05 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 60 1.04 62 A 62.40 B 13 C 70.51 D 480 E 14.69% F - G - Total Workload ( in man minutes ) Remarks: 1. This activity may be performed by the mender who brings his fabric for checking. This is being shifted to the corresponding workload sheet. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Mending Mender Helepr Activity Description Reposition trollies, tie knots to the fabric and push fabric in the bin Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) WLS No: CMF/06 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 17 Designation Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 23 0.97 44.62 2 2 1020 2.59 2641.80 A 2686.42 B 17 C 3143.11 D 480 E 38.52% F 8 G 81.85% Time in man-minutes per meter Weighte d average 0.67 0.17 1.95 0.49 2.46 0.62 5.28 1.32 2.59 2 25% Weighted average time in minutes per meter 2. Four groups of two personnel each are being recommended. 3 25% 4 25% Proposed Utilisation(%) Remarks: 1. The time of one minute per meter of fabric has been arrived at after studying the various categories of the fabric being kitty mended and based on the time taken for each of these categories. Based on the discussions with the various personnel it was decided to allocate 25 % weightage to each of the four categorie. The weighted average time per meter is 2.59 man-minutes per meter. If the weights are going to change in the future then the weighted average time also will be changing. Category Weight 1 25% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Check and remove the superficial defects in the fabric after observing the singeing and finish fabrics Kitty Mending Kitty Mender Activity Description Load new fabric roll, reposition trollies WLS No: CMF/07 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 30.00 30.00 2 1 1 60.00 60.00 3 1 1 60.00 60.00 4 1 1 15.00 15.00 A 165.00 B 15 C 189.75 D 480 E 39.53% F 1 G 39.53% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Based on the feedback of the menders, inspect the piece, call the concerned supervisor of weaving, discuss with him enter details in the register Proposed Utilisation(%) Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Mending Damage Reporter Activity Description Distribute the fabric after grey checking and make entries in the allocation register Enter details mender-wise in the mender's production register Based on the feedback of the menders, inspect the piece, call the concerned supervisor of spinning, discuss with him enter details in the register WLS No: CMF/08 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 17.54 17.54 2 1 1 39.47 39.47 3 1 1 26.32 26.32 4 1 1 13.16 13.16 5 1 1 13.16 13.16 6 1 1/2 13.16 6.58 7 1 1 19.74 19.74 8 1 1 26.32 26.32 9 1 1 10.00 10.00 Calculate 'upto date' and 'daily' production for loomshed in SAP and export data to excel to prepare 'khata wise daily grey checking report' Calculate the stock pending in the mending from SAP and convert to excel Perform loom out after the completion of the grey checking, mending and mending checking Make entry from the menders production register to excel sheet and once in 15 days calcualte the quantum of work completed using calculator and record the same in register Manually enter the number of personnel present after checking, in a printed format, check with the deposited cards, & for people who are on OT make entry in the OT register. Prepare OT list, send to time office. Get the 'daily present employee list for the date' every 2-3 days from the time office and verify with manually entered data in OT register. In case of any deviations in the list, go to the time office and clarify. Get sign of the section head and the departmental head on the 'daily present employee list for the date' and submit to time office Enter leave details in the register and submit the forms to time office Mending Computer operator Activity Description Mark attendance for all workmen (77 in mending and 24 in grey checking) For material going out for mending, prepare challan sub- contractor wise. Compute the total per day per worker employed and check whether it matches with 4000 meters Prepare loomwise major damage report WLS No: CMF/09 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Mending Computer operator Activity Description WLS No: CMF/09 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending 10 1 1/7 120.00 17.14 A 189.42 B 15 C 217.84 D 480 E 45.38% F 1 G 45.38% Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Basic Workload per Shift ( in man minutes) Prepare special reports as per the instructions of the HOD ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 - - - Designation Proposed Manpower 1 - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 276 0.31 84.64 2 1 1 13.50 13.50 3 1 1 15.00 15.00 4 1 1 13.16 13.16 5 1 1 13.50 13.50 6 1 1 10.00 10.00 7 1 1/7 120.00 17.14 A 166.94 B 13 C 188.64 D 450 E 41.92% F 1 G 41.92% Prepare special reports as per the instructions of the HOD Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Mending Computer operator Activity Description Enter grey checking report in SAP for all 3 shifts (276 per day) (quality, meter and weight) Make entries of the checkers in SAP Input piece number and code number of menders in SAP from the allocation register and after completion of works, enter details in SAP Input piece number and code number for material being sent out for mending in SAP Prepare loom damage report from grey checking report When the mended material returns from the sub-contractor, make necessary entries in SAP WLS No: CMF/10 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 276 0.46 126.91 2 1 1 40.00 40.00 3 1 1 15.00 15.00 4 1 1 15.00 15.00 5 1 1/7 120.00 17.14 A 214.06 B 13 C 241.88 D 480 E 50.39% F 1 G 50.39% 1. For both the compter operators put together the utilization is 90 %. Once computer operator is recommended in the general shift. Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Rest & Relaxation Allowances ( % ) Prepare 'summary of non-compliance pieces from 01.01.2012 onwards', in excel For a particular quality number, if the defects are more then take out the particular grey checking report, based on the instructions of the superiors Receive 'off standard card' from weaving production, enter the piece number and meters and hand over to quality control Proposed Utilisation(%) Remarks: Mending Computer operator Activity Description Enter grey checking report in SAP for all 3 shifts (276 per day) (defects details) Prepare special reports as per the instructions of the HOD Basic Workload per Shift ( in man minutes) WLS No: CMF/11 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Mending ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 - - - Designation Proposed Manpower 1 - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 85.03 85.03 2 1 1 81.40 81.40 3 1 1 3.00 3.00 A 169.43 B 13 C 191.46 D 450 E 42.55% F 1 G 42.55% WLS No: CMF/12 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A Cleaner Activity Description Clean with broom stick the mending and grey checking area B Collect dust and waste in the polythene covers and tranfer to the waste yard Present Utilisation(%) Proposed Manpower per shift Mending Proposed Utilisation(%) C G Mending Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Clean with mop the mending and the grey checking areas ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 45.00 45.00 a) b) c) 2 1 1 30.00 30.00 3 1 1 10.00 10.00 4 1 1 60.00 60.00 5 1 1 15.00 15.00 A 160.00 B 15 C 184.00 D 480 E 38.33% F 1 G 38.33% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Proposed Utilisation(%) Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Measure the cut pieces cut by graders Reverse fold (place yellow strip inside) Direct fold (green slip) Reject slip Match the samples with the process house materials Finish Folding Finish Checker Activity Description Check the process batch card for QC approval. If approved, then make entries in the register for qualititeswhich are to be sent for In the direct fold machine check the length and in case of any problem, get it rectified by the fitter Enter details of the data written in the register into excel sheet. Take out printout. Send the data regarding the pieces packed to marketing department who in turn provide information regarding the assortment to be carried out. WLS No: CMF/13 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 4 4 4 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 60 1.08 64.64 2 1 60 0.29 17.28 3 1 60 7.35 441.00 4 1 6 2.32 13.92 5 1 10 0.80 8.00 6 1 10 1.60 16.00 A 560.84 B 17 C 656.18 D 440 E 37.28% F 2 G 74.57% Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift 2. For a production of 6000 meters per shift, two machines need to be operated and hence two operators per shift are being recommended 3. The inspection will be carried out in cycles of 17.44 minutes followed by a break of 17 % X 17.44 minutes = 3.0 minutes. There can be 20 cycles of inspection in the shift, after accounting for 15 minutes of discussions and a tea time of 13.0 minutes. One of the breaks has to be combined with the time of ten minutes provided to make a tea time of 13.0 minutes. 20 cycles has been calculated based on 425 minutes ( 450-10 minutes tea - 15 minutes discussions). Each cycle 200 meters of fabric can be processed. Proposed Utilisation(%) Remarks: 1. Each roll is 100 meters and the processing is 6000 meters per shift Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Transport empty horse to the process house, check materials on new horse, and transport the new horse to the perching machine Insert new tag cartridge Transport completed trolley to the next work station and bring back empty trolley and position Perching Perching Checker Activity Description Tag at four places and affect changeover Reset meter and start new page Perform checking, insert tag whereever required, note details in the register WLS No: CMF/14 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 6 - Designation Proposed Manpower 4 4 4 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 27 0.99 53.64 2 1 27 0.20 5.40 3 1 27 1.59 42.84 4 1 265 2.09 553.85 5 6 7 1 265 1.48 392.20 8 1 265 0.48 125.88 9 1 265 0.21 56.31 A 1396.89 B 14 C 1592.46 D 480 E 331.76% F 4 G 82.94% Pull fabric from the fold machine onto work table Perform counting 2 265 0.31 Position trolley, load fabric onto it Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) 2. Two machines per shift need to be operated to fulfill the production requirements of 26500 meters per day. Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Remarks: 1. Folding time and checking time is for 100 meters C G Finish Folding 166.77 Proposed Utilisation(%) Scrutinize papers Pull fabric into the machine, adjust Start folding Push completed onto work table and tear fabric Write details on fabric, paper Finish folding Operator Activity Description Position perching trolley WLS No: CMF/15 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 200 0.82 164.00 2 1 200 0.25 50.00 3 1 200 0.99 197.50 4 1 200 0.56 112.00 5 1 200 0.75 150.00 6 1 30.00 30.00 A 703.50 B 14 C 801.99 D 480 E 83.54% F 2 G 83.54% Grading Sample man Activity Description Cut sample cloth, write number on cloth, keep aside, arrange, compare with assorted grey card WLS No: CMF/16 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Clarify shade number to the next section personnel Paste the sample fabric in the sample book Print out bar code stickers, stick and tag Deliver sample fabric to warehouse Maintain sample book of production, marketing and ware house seperately Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 265 0.21 56.31 2 1 150 1.91 285.75 A 342.06 B 14 C 389.95 D 480 E 40.62% F 1 G 81.24% C G Finish Folding Grading Loader Activity Description Assist folding helper to load fabric to the trolley WLS No: CMF/17 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B Total Workload ( in man minutes ) Shift double folded fabric to the graders, write piece number, quality number and graders name in the note book Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 25 Designation Proposed Manpower - - - 18 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 3 4 5 6 7 8 9 10 1 1 270.00 270.00 11 1 200 0.31 62.00 A 6955.33 B 17 C 8137.74 D 480 E 67.81% F 18 G 94.19% 90.00 2. The present practice of each person grading 1000 meters each has been aggregated for the 25 graders as 25000 meters per shift Remarks: 1. Point 1-7, the frequency is mentioned in meters Unload the folded fabric near to the work table Basic Workload per Shift ( in man minutes) WLS No: CMF/18 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding Grading THAN Grader Activity Description 1 Cleaning the grading table before starting the grading. Put folded piece on the table for grading. Check the piece throughly . Take out the fresh THAN , Safari ,Suit length , PL ,Cut and FRC to avoid the defects. Recording the THAN, PL,and FRC in the grading inspection sheet. Send back the fabric for rectification which is having stain, crease, seinging line.Wrapper mark, width variation to process house 0.26 6533.33 Proposed Utilisation(%) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Discuss with Incharge, get clarifications etc,. 90.00 Put the damage fabric on the damage table for showing the defects the concerned departmental Head. Put the PL/Cut Length / and FRC in the specified area. Put the stamp of category wise on PL/CL/ and FRC. 25000 1 1 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 9 Designation Proposed Manpower - - - 7 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 3 4 5 6 7 8 1 1 175 175 9 1 58 0.31 17.98 A 2743.48 B 17 C 3209.87 D 480 E 74.30% F 7 G 95.53% 2515.5 35 Unload the folded fabric near to the work table Basic Workload per Shift ( in man minutes) Discuss with Incharge, get clarifications etc,. 1 5850 0.43 1 1 1. Point 1-5, the frequency is mentioned in meters Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) 35 Put the stamp of category wise on PL/CL/ and FRC. Put the PL/Cut Length / and FRC in the specified area. Remarks: G Finish Folding 2. The present practice of each person grading 650 meters each has been aggregated for the 9 graders as 5850 meters per shift Cleaning the grading table before starting the grading. Put folded fabric piece on the table for grading. Check the piece throughly . Take out the fresh , Safari ,Suit length , PL ,Cut and FRC to avoid the defects. Recording the PL,and FRC in the grading inspection sheet. Proposed Manpower per shift Proposed Utilisation(%) Grading Cut piece Grader Activity Description WLS No: CMF/19 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 19 8.10 307.80 2 2 19 4.14 157.32 A 465.12 B 14 C 530.24 D 480 E 55.23% F 2 G 55.23% Remarks: 1. As per data provided, 15000 meters ie., 1500 thans have to be transported daily. Out of this 50 % has been considered as transporting upto the work table and which involves no unloading and 50 % has been considerd as transporting to the concerned area and unloading in that area. Also in each trip on an average 40 thans are transported, hence there is a need to make 38 trips per shift. 19 trips are for option 1 and 19 trips are for option 2. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Lift THAN from the grading sheet and shift to the patti for folding and unload in the concerned area Basic Workload per Shift ( in man minutes) Grading Loader Activity Description Lift THAN from the grading sheet and shift to the patti for folding WLS No: CMF/20 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 15000 0.03 480.00 A 480.00 B 17 C 561.60 D 480 E 39.00% F 2 G 58.50% Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift 3. Keeping in mind the random nature of occurrence of these events, a manpower of two personnel is recommended and the utilization level is 58.5 % each per shift. Proposed Utilisation(%) Remarks: 1. As per data provided, 10 % of the thans require to be kitty mended every day. Daily 1500 thans are produced, hence 150 thans may require kitty mending. 2. In the 216 meters graded, kitty mending was performed 5 times and time spent was 6.95 minutes. Extrapolating this to 15000 meters we obtain the time thans may require kitty mending in a shift. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Grading Kitty Mender Activity Description Based on the calls of the individual graders, go to the concerned table and rectify the defects. WLS No: CMF/21 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 550 0.30 165.00 2 1 550 0.27 147.40 A 312.40 B 14 C 356.14 D 480 E 74.20% F 1 G 74.20% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Grading Bar code Sticker Operator Activity Description Pick thans from the trolley, input meters into SAP, take printout of the bar code sticker and place in the than bundle. Write details in the register. Affix one sticker onto the fabric, the other onto the tag, attach tag using tag gun, forward to than folder Basic Workload per Shift ( in man minutes) WLS No: CMF/22 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 990 0.27 267.30 2 1 30.00 30.00 3 1 10.00 10.00 4 A 297.30 B 14 C 338.92 D 480 E 70.61% F 1 G 70.61% Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Grading Helper Activity Description Check alignment and cut end of piece Provide raw material for packing Basic Workload per Shift ( in man minutes) Bring water bucket for washing the stamps Assist in joining the wrappers in case of graviera packing Finish Folding WLS No: CMF/23 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 A 366.85 B 15 C 421.88 D 480 E 87.89% F 1 G 87.89% Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Remarks: 1. 275 thans per day has been considered based on the data provided. Based on the field study conducted, the time provided is for a than with an average length of 11.6 meters. 1 275 1.334 366.85 Net Available man-mins Present Utilisation(%) B C Grading THAN Folder Activity Description Check the than length, wrap the fabric on the stra board patti, transfer the than to the screening work station G Finish Folding Total Workload ( in man minutes ) Show the defective piece to the officer, and return back to the grader for rectification of the same WLS No: CMF/24 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 550 0.62 341 A 341.00 B 15 C 392.15 D 480 E 81.70% F 1 G 81.70% Proposed Utilisation(%) Remarks: 1. 550 thans per day has been considered based on the data provided. Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Grading Screener Activity Description Transfer the print screening on the than and forward the than to stamping WLS No: CMF/25 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 550 0.46 253 A 253.00 B 15 C 290.95 D 480 E 60.61% F 1 G 60.61% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: 1. 550 thans per day has been considered based on the data provided. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Grading Stamper Activity Description Stamp the quality number, shade number, meters and forward the than to the next work station Basic Workload per Shift ( in man minutes) WLS No: CMF/26 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 550 0.47 258.5 A 258.50 B 14 C 294.69 D 480 E 61.39% F 1 G 61.39% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: 1. 550 thans per day has been considered based on the data provided. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Grading Wrapper Man Activity Description Stamp the quality number, shade number, meters and forward the than to the next work station Basic Workload per Shift ( in man minutes) WLS No: CMF/27 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 550 0.462 254.1 A 254.10 B 14 C 289.67 D 480 E 60.35% F 1 G 60.35% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: 1. 550 thans per day has been considered based on the data provided. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Grading Poly Bag Man Activity Description Put the than in the specified poly bag, close mouth with cello tape and place in patti Basic Workload per Shift ( in man minutes) WLS No: CMF/28 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1100 0.29 319 A 319.00 B 14 C 363.66 D 480 E 75.76% F 1 G 75.76% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: 1. 550 thans per day has been considered based on the data provided. One person mans two lines presently. As the utilization per line is 76 %, the present manning pattern may be continued Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Grading Than Segregator Activity Description Put the than in the specified poly bag, close mouth with cello tape and place in patti Basic Workload per Shift ( in man minutes) WLS No: CMF/29 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 12 Designation Proposed Manpower - - - 12 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 600 0.25 151.07 2 1 600 0.07 41.4 3 1 1 3.95 3.945 3.1 3.1 4 1 600 0.14 86.3 A 282.72 B 14 C 322.30 D 480 E 67.14% F 1 G 67.14% Remarks: 1. 600 pieces per day has been considered based on the data provided. Arrange for packing Take trolley, go to the storage, get pattis, unload and arrange in work place Get poly baks from storage Pack the PL using the pattis, poly covers Net Available man-mins Present Utilisation(%) PL packing Bar code operator cum packer Activity Description Count, generate bar code for the PL, affix two numbers on each, arrange bundle and keep in the prescribed place Proposed Manpower per shift Proposed Utilisation(%) Sign on sticker Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) WLS No: CMF/30 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 4 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 2400 0.14 336.8 A 336.80 B 14 C 383.95 D 480 E 79.99% F 1 G 79.99% Remarks: 1. 2400 pieces per day has been considered based on the data provided. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) PL packing Screener Activity Description Transfer the print screening on the PL WLS No: CMF/31 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 400 0.13 104 A 104.00 B 14 C 118.56 D 480 E 12.35% F 1 G 24.70% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: 1. 10000 kg to be segregated per month which works out to be 400 kg per day. 2. One person recommended for this activity. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) PL packing FRC Sorter Activity Description Segregate the fabric grade-wise, unit wise, pack in the bag and keep aside Basic Workload per Shift ( in man minutes) WLS No: CMF/32 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 8 8 8 - Designation Proposed Manpower 7 7 7 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 35.00 35 2 1 80 2.55 204 3 1 8000 0.25 1990.4 4 1 2 4.64 9.28 5 1 1 105.00 105.00 A 2343.68 B 17 C 2742.11 D 440 E 77.90% F 7 G 89.03% Proposed Utilisation(%) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Discussion with superiors Remarks: 1. For an inspection of 8000 meters per day, 7 machines need to be operated per day. Basic Workload per Shift ( in man minutes) Carry out inspection, put flag where defect is sighted, enter details in the inspection register Transport empty horse to the process house, check materials on new horse, and transport the new horse to the rolling inspection machine Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Rolling cum inspection Inspector Activity Description Clean machine before starting inspection Change output rolls - Remove the completed roll and place on adjacent rollers, insert cardboard roll & roll some fabric onto it, cut piece and throw in dust bin, cut one sample piece and keep aside, tag the completed roll, write details on the completed r WLS No: CMF/33 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 6 6 4 - Designation Proposed Manpower 4 4 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 133 1.31 348.46 2 2 133 0.36 95.228 3 1 133 0.25 33.25 4 2 133 0.66 175.028 5 1 33.25 1.18 39.24 6 1 133 0.36 47.88 A 739.08 B 14 C 842.55 D 450 E 31.21% F 4 G 46.81% B Total Workload ( in man minutes ) Packers Wrap rolls with poly cover, put cello tape Stack roll in the designated place and back WLS No: CMF/34 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A Write the details of rolls being packed in a register Proposed Manpower per shift B & R Inspection Remarks: Activity Description b) One person for writing the details in the register and generating bar code C G Finish Folding Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Proposed Utilisation(%) Pick rolls from the trolley, place on table, put poly covers, cut extra threads, attach two stickers ('face side' and 'fabric once cut cannot be claimed') and push rolls to the next work station Net Available man-mins Generate bar code, affix stickers on the rolls c) One person for stacking the rolls and acting as an online reliever for the two personnel mentioned in a) 1. For processing of 8000 meters per day, 133 rolls need to be processed @ 60 meters per roll. Transport rolls from the rolling inspection to work place 2. Instead of the six personnel per shift a manning of four is recommended: a) Two personnel for performance of activities 1,2 and 4 Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 4 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 160 1.68 538.24 2 1 480 0.68 327.36 A 865.60 B 14 C 986.78 D 480 E 51.40% F 4 G 51.40% WLS No: CMF/35 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Segregate shade wise and stack B & R Inspection Bale Helpers Activity Description Open bales of outsourced fabric, cut sample piece Remarks: 1. Presently 40 bales per person per day are processed ie., for 4 personnel it amounts to 160 bales per day. 2. In each bale there are three sets of fabric, hence for activity 2, 480 numbers of sets have been considered. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1.1 1 67 0.11 8.23 1.2 1.3 2 2.1 1 20 2.86 57.2 2.2 1 20 1.74 34.78 2.3 1 1 2.00 2.00 A 132.36 B 15 C 152.22 D 480 E 31.71% F 1 G 31.71% WLS No: CMF/36 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding As per the list provided by the marketing department, arrange roll cutting as per serial number, and handover to the sample department. Affix stickers Basic Workload per Shift ( in man minutes) 30.15 B & R Inspection Sample Man Activity Description Sample Preparation Rest & Relaxation Allowances ( % ) Pack it in polythene cover and handover to marketing department peon Grading Inspect fabric, cut sample pieces as per requirement, affix marks, put in poly cover and pack. Prepare challan 1 67 0.45 Handover the hanger material in the sample room Proposed Utilisation(%) Remarks: 1. Activity 1 - 200 samples per three days considered Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 550 0.33 181.50 A 181.50 B 14 C 206.91 D 480 E 43.11% F 1 G 43.11% WLS No: CMF/37 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B Remarks: 1. The walk time is distributed to three thans. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Total Workload ( in man minutes ) Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) C G Finish Folding Input meters into SAP, take printout of the bar code sticker and affix. B & R Inspection Bar code Sticker Operator Activity Description ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 120.00 100.00 2 1 1 30.00 30.00 3 1 1 20.00 20.00 4 1 1 20.00 20.00 5 1 1 20.00 20.00 6 1 1 30.00 30.00 7 1 1 20.00 20.00 8 1 1 15.00 15.00 A 255.00 B 14 C 290.70 D 480 E 60.56% F 1 G 60.56% B & R Inspection Computer operator Activity Description Receive '4-point' inspection report from finish folding inspection, compute fresh and damage, input details in excel and in SAP WLS No: CMF/38 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Input details of the loom wise defects into the excel sheet Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Input in excel the details of the roll number, date, meters, points, grader, beam number Calculate the fresh point / 100 square meter and total points / 100 square meters and input into excel sheet Find out the spinning lot number from SAP and input into spinning value loss report Prepare daily quality wise report Prepare main damage report for damages Maintain excel sheet detailing the meters of fabric given to process house and received from process house Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 3 44.00 132.00 2 1 3 44.00 132.00 3 1 1 3.00 3.00 A 267.00 B 13 C 301.71 D 450 E 33.52% F 1 G 67.05% WLS No: CMF/39 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding Clean with mop the finish folding, B & R inspection and grading area Collect dust and waste in the polythene covers and tranfer to the waste yard Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Finish Folding Cleaner Activity Description Clean with broom stick the finish folding, B & R inspection and grading area Proposed Utilisation(%) Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 30.00 30.00 2 1 1 10.00 10.00 3 1 80 1.00 80.00 4 1 1 30.00 30.00 5 1 1 30.00 30.00 6 1 1 40.00 40.00 7 1 1 30.00 30.00 8 1 1 10.00 10.00 A 260.00 B 15 C 299.00 D 480 E 62.29% F 1 G 62.29% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Ensure proper tagging, stickering and in case the personnel face any problems, resolve the same Attend inter-departmental meeting daily at 3.30 pm Periodically check whether the production targets are being achieved by the graders Show the damaged pieces to the superior and explain the defects Provide stationery to the personnel as per requirements Finish Folding Monitor Activity Description Check the position of materials in process house, compare with the mail already received from PPC, and decide on the number of personnel to deploy for THAN and cut piece In the direct fold machine check the length and in case of any problem, get it rectified by the fitter Give instructions to the graders and ensure that the production is completed as per schedule and on time WLS No: CMF/40 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 30.00 30.00 2 1 1 45.00 45.00 3 a) b) 1 1 30.00 30.00 c) 1 1 90.00 90.00 4 1 1 30.00 30.00 5 1 1 15.00 15.00 A 240.00 B 15 C 276.00 D 480 E 57.50% F 1 G 57.50% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) 10 meter sample has been cut from each quality Party's requirement of rolls is intimated to all the individual workmen 20 cm is cut from each roll which is completed Scrutinize the fabric roll shade and csv report received In case of customer complaints, collect information, investigate and inform superiors B & R Inspection Finish Checker Activity Description Receive hand written list from the process house regarding the materials which will be handed over by the process house along with the approval slips of QC, schedule the material on the machines Check finish of fabrics in process house by feel, note in register, write details on card, and place card in the horse Ensure that WLS No: CMF/41 WORK LOAD DETAILS SHEET Checking, Mending & finishing Shifts A B C G Finish Folding ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 11. PROCESS HOUSE - PRODUCTION ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 11.0 11.1 I II III G T I II III G T 1 Grey Seggreation 2 2 3 - 7 2 2 2 - 6 2 Sample Card Preparation - - - 1 1 - - - 1 1 3 Grey Plaiting 1 1 - - 2 1 1 - - 2 4 Grey Batching 3 3 3 - 9 2 2 2 - 6 5 Job fabric computer data entry - - - 1 1 - - - 1 1 6 Grey incharge - - - 1 1 - - - 1 1 7 Grey Rolling 4 4 - - 8 3 3 - - 6 8 Batch Card and Report preparation 2 1 - - 3 2 2 - - 4 9 Relax scouring Range 8 8 8 - 24 6 6 6 - 18 10 Weight reduction 6 6 6 - 18 4 4 4 - 12 11 Dolly Winch 2 2 - - 4 2 2 - - 4 12 Jumbo Jigger 2 2 2 - 6 2 2 2 - 6 13 Hydro Extraction 1 1 1 - 3 2 2 2 - 6 14 Jet Dyeing 8 8 8 - 24 6 6 6 - 18 15 Auto Jigger 3 3 3 - 9 3 3 3 - 9 16 Stores -1 1 1 1 - 3 1 1 1 - 3 17 Singeing 3 3 - - 6 3 3 - - 6 18 Stenter 12 12 12 - 36 12 12 12 - 36 19 Kier decatising 2 2 2 - 6 2 2 2 - 6 20 MD 2 2 2 - 6 2 2 2 - 6 21 Super Finish 2 2 2 - 6 2 2 2 - 6 22 Shrinking Range 2 2 2 - 6 2 2 2 - 6 PROCESS HOUSE - PRODUCTION Proposed Manpower Remarks S. No Section / Work area Designation SPH Present Manpower Manpower Deployment _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 11.0 11.1 I II III G T I II III G T PROCESS HOUSE - PRODUCTION Proposed Manpower Remarks S. No Section / Work area Designation SPH Present Manpower Manpower Deployment 23 Calendar 2 2 2 - 6 2 2 2 - 6 24 Checker 1 1 - - 2 1 1 - - 2 25 Press 1 1 - - 2 1 1 - - 2 26 Sample Process 1 1 - - 2 1 1 - - 2 27 Gun spotting 1 1 - - 2 1 1 - - 2 28 Jobber 1 - - - 1 1 - - - 1 29 Sweeper 1 - - 4 5 1 - - 3 4 30 Trolley movement 1 1 1 - 3 1 1 1 - 3 31 Stitching 1 1 - - 2 1 1 - - 2 32 Computer operator - - - 1 1 - - - 1 1 33 Hand spotting - - - 2 2 - - - 2 2 34 Machine cleaning 1 1 - - 2 1 1 - - 2 35 Stores -2 - - - 1 1 - - - 1 1 Total 77 74 58 11 220 70 68 51 10 199 SPH The average engagement of manpower in this department has been 175 (without considering over time). _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 11.0 11.2 11.2.1 a) b) c) d) e) f) g) h) Batch card and report preparation - deploy 2 personnel in shifts A and B instead of the present deployment of 2 in A shift and 1 in B shift based on workload Relax scouring - deploy 6 personnel for two machines instead of the present deployment of 8 personnel for two machines Hydro extraction - deploy 2 personnel per shift instead of the present deployment of 1 per shift based on workload Jet Dyeing - deploy 6 personnel - one operator for each machine and two helpers for 4 machines, instead of the present deployment of 8 personnel for 4 machines Sweepers - deploy 4 sweepers per day instead of the present deployment of 5 per day Proposed Changes & Observations PROCESS HOUSE - PRODUCTION Proposed Changes Grey Batching - deploy 2 personnel per shift instead of the present deployment of 3 per shift based on worklaod Grey Rolling - deploy 3 personnel per shift instead of the present deployment of 4 per shift based on worklaod and the work pattern Weight reduction - deploy 4 personnel for three machines instead of the present deployment of 6 personnel. One operator is assigned for each machine and one common helper for all three machines ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 11.0 11.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Machine cleaning PHP/35 Stores - 2 PHP/36 Stitching PHP/32 Computer operator PHP/33 Hand spotting PHP/34 Jobber PHP/29 Sweeper PHP/30 Trolley movement PHP/31 Press PHP/26 Sample processing PHP/27 Gun spotting PHP/28 Shrinking range PHP/23 Calendar PHP/24 Checker PHP/25 KD Lycra PHP/20 Multi Decatising PHP/21 Super finish PHP/22 Singeing PHP/17 Stenter PHP/18 KD Domestic PHP/19 Jet Dyeing PHP/14 Auto jigger PHP/15 Stores - 1 PHP/16 Dolly winch PHP/11 Jumbo jigger PHP/12 Hydro extractor PHP/13 Batch Card and Report preparation PHP/08 Relax Scouring PHP/09 Weight reduction machine PHP/10 Job fabric computer entry PHP/05 Grey Incharge PHP/06 Grey rolling PHP/07 Sample card preparation PHP/02 Grey Plaiting PHP/03 Grey batching PHP/04 PROCESS HOUSE - PRODUCTION Workload Sheets Summary Area of work WLS Number Grey segregation PHP/01 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Grey Seggregation Work Centre Present Manpower 2 2 3 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.21 10.21 2 2 200 1.60 640.00 3 2 17 2.34 79.63 4 2 17 1.41 48.08 A 777.91 B 13 C 879.04 D 900 E 97.67% F 2 G 97.67% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks:25000 mtrs to be transferred to the batching m/c per shift(average 120 mtrs in each roll.Therefore 200 rolls taken as the frequency Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Shift rolls to batching m/c area Take out the required rolls to be transferred to the batching m/c and place them vertically Carry and load rolls on to the trolley (12 rolls on 1 trolley) Unload all the rolls on the ground near batching m/c Seggregation Gey Seggreation Activity Description Take the programe from grey incharge WLS No: PHP/01 WORK LOAD DETAILS SHEET G Shifts A B C PHP ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Grey Seggreation Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.11 10.11 2 1 7 6.77 47.39 3 1 7 30.03 210.21 4 1 7 0.77 5.41 5 1 1 30.14 30.14 A 303.26 B 13 C 342.68 D 480 E 71.39% F 1 G 71.39% WLS No: PHP/02 WORK LOAD DETAILS SHEET G Shifts A B Mark the attendance of all the workers in grey seggrigation Net Available man-mins Present Utilisation(%) Proposed Manpower per shift PHP Sample Card Preparation Sample Card Preparator Activity Description Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) C Remarks: take the strips of all the batches of domestic made by the grey batching operator Cut the samples and staple the same on sample cards and prepare three sets of cards Put the quality no batch no and shade no against each cutting Deliver one set of cards to folding dept.,one set to process house and the third set to marking ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Grey Seggregation Work Centre Present Manpower 1 1 - - Designation Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.44 5.44 2 1 3 8.44 25.32 3 1 46 0.92 42.24 4 1 3 49.20 5 1 3 1.42 4.26 6 1 3 1.74 5.23 7 1 3 10.72 32.17 8 1 3 6.54 19.62 9 1 3 3.45 10.35 A 144.63 B 13 C 163.43 D 450 E 36.32% F 1 G 36.32% Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Production per machine per shift has been taken as 5500 mtrs.Average 120 mtrs in each roll.One trolley contains 2000 mtrs of fabric after being plaited Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Carry the trolley to place near batch m/c Load 1 roll for plaiting (tie with old running cloth) Opening rolls kept near the machine by grey seggrigator on plaiting machine in the trollies or table(2000 mtr on one table) (machine element) Locate the empty trolly or table in proces house and take it to the plaiting machine Adjust the plaits on the table Plaiting - Activity Description Prepare and stitch all the pieces together(in 2000 mtr,16 stitches for 17 pieces are to be made) Take the batch card from batchcard printer and tie the same with the end piece of the trolly Carry the trolly in the process house according to the instruction written on the Batch processing card or according to the process house shift supervisor' instruction Get the programe for the machine from the shift Supervisor WLS No: PHP/03 WORK LOAD DETAILS SHEET G Shifts A B C PHP ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Grey Seggreation Work Centre Present Manpower 3 3 3 - Designation Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 4.55 4.55 2 1 1 15.11 15.11 3 1 46 5.56 255.76 4 1 138 0.26 36.39 5 1 138 0.25 34.22 6 1 7 98.00 7 1 138 0.66 91.38 8 1 7 1.54 10.77 9 1 7 2.24 15.68 A 463.86 B 13 C 524.16 D 1350 E 38.83% F 2 G 58.24% WLS No: PHP/04 WORK LOAD DETAILS SHEET G Shifts A B C PHP Locate the empty rolls in proces house and take it to the Batching machine and aligned the same with machine batching device Load roll on one of the two loading points Grey Batching - Activity Description Get the programe for the machine from the shift Total Workload ( in man minutes ) Remarks:1. Production per machine per shift has been taken as 16500 mtrs.Average 120 mtrs in each roll Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Opening time of 1 batch of 2500 mtr (average length) in fabric accumulator with the help of machine (machine element) Writing no on rolls at the time of rolls being delivered by grey segregation persons (3 rolls at a time) and note down all the pc details on a format and give it to batch card printer ,take the batch card from batchcard printer and tie the same with the end piece of the trolly Giving 1 roll at a time to the grey batching handling person Rest & Relaxation Allowances ( % ) After opening of one roll,write batch no on new roll and stitch with previous roll Remove the completed roll Deliver the roll in the process house according to the instruction written on the Batch processing card or according to the process house shift supervisor' instruction Basic Workload per Shift ( in man minutes) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Gey Seggreation Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 6.67 6.67 2 1 1 65.56 65.56 3 1 1 90.66 90.66 4 1 1 45.34 45.34 5 1 1 37.65 37.65 6 1 1 34.65 34.65 A 280.53 B 13 C 317.00 D 480 E 66.04% F 1 G 66.04% WLS No: PHP/05 WORK LOAD DETAILS SHEET G Shifts A B C PHP After varification of goods received from job weaving against challan the job fabric entry operator takes all the challans from grey incharge Prepare the challan of all the pcs and give it to the logistic dept. for the dispatch of the same After entering all the pcs whether received from Job weaving or sent for job processing he hand over all the challans to grey incharge for filing Job fabric computer data entry Operator Activity Description Find out all the PO and line item and write it down on the challan against which the goods has received from the system Receive all the pcs in the system and book the yarn consumption against the line item recieved and if the yarn stock is not in the system then he contact to the job weaving person and get it changed in the PO In case of goods to be sent to job processing he is entering all the pcs and transfer it to job vendor location in the system Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Gey Seggreation Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 15.78 15.78 2 1 1 20.45 20.45 3 1 25 5.65 141.25 4 1 3 15.56 46.68 5 1 1 30.00 30.00 6 1 1 36.87 36.87 A 291.03 B 13 C 328.86 D 480 E 68.51% F 1 G 68.51% WLS No: PHP/06 WORK LOAD DETAILS SHEET G Shifts A B C PHP Take the daily grey issue programme from PPC dept. Maintain the record of the goods coming from job weaving and sent for job processing Grey incharge Grey incharge Activity Description Show this prog. to process head and take the approval from him for issuing the same In case of B&R goods prepare the shade continuity card and show the same along with previous supply to process head for getting the clearance for grey issue According to the stock reoprt and the grey issuance prog give instruction to grey seggregator, plaiter, grey batcher Co-ordinates with PPC, process head and Mending dept. for different issues related to grey seggregation Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Grey Seggregation Work Centre Present Manpower 4 4 - - Designation Proposed Manpower 3 3 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 10.55 10.55 2 1 46 0.94083 43.28 3 1 46 2.60 4 1 46 0.21 9.73 5 2 46 0.08 6.93 6 1 46 0.28 12.90 7 1 46 0.22 9.95 8 1 46 0.26 12.01 9 2 46 0.09 8.60 10 1 46 0.25 11.40 11 1 45 0.14 6.33 12 2 35 2.45 171.50 13 2 35 0.08 5.33 14 1 35 0.23 8.15 15 1 34 0.19 6.30 16 1 35 0.29 9.98 A 332.95 B 13 C 376.24 D 1800 E 20.90% F 3 G 27.87% Tally against the challan the incoming material Carry the rolls to stack Return for next roll If the Mending goods come from outside they tally it against the challan and put them in the trollies. Place on trolley after rolling Return for next roll Return for next roll Note in register the details of the rolls transferred to the stack Shifting the rolls to Grey Plaiting Destack and load the rolls on shoulder Carry the rolls to the plaiting m/c Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks:1. Production per machine per shift has been taken as 5500 mtrs.Average 120 mtrs in each roll.Average 5 lakh metres comes from outside per month.Therefore 70 rolls comes in two shifts Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) From Job weaving(outside) to stacking in grey Destack and load the rolls on to the shoulder Rolling - Activity Description Carry the rolls to stack Shifting the rolls to Stack from rolling (Loom wise) Destack and load the rolls on to the shoulder Take all the pcs from mending(after final checking) and job weaving in lump form and bring one trolley near the m/c and adjust (tie with old fabric and note the details in the register) Make individual rolls of all the pcs on rolling machine(120-130 mtr average) (machine element) 2. Three personnel are recommended with a utilization of 28 % because of the simultaneous occurance of activities WLS No: PHP/07 WORK LOAD DETAILS SHEET G Shifts A B C PHP Preparatory Activities Bring iron rods for rolling purpose ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Gey Seggreation Work Centre Present Manpower 2 1 - - Designation Proposed Manpower 2 2 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 12.78 12.78 2 1 1 98.87 98.87 3 1 1 87.78 87.78 4 1 1 25.88 25.88 5 1 1 4.77 4.77 6 1 1 66.78 66.78 7 1 20 15.54 310.8 8 1 20 1.43 28.6 A 636.26 B 13 C 718.97 D 900 E 79.89% F 2 G 79.89% Book the consumption of all the pcs production order wise in the system and take out the batch processing card Hand over the batch processing card to grey batcher or the paiter for attatching the same with the material Prepare the summary of grey activities and hand it over to PPC dept. and process house MIS dept. Batch Card and Report preparation Batch Card and Report preparator Activity Description Take the pc wise detail of each batch from grey plaiter and grey batcher Total Workload ( in man minutes ) WLS No: PHP/08 WORK LOAD DETAILS SHEET G Shifts A B C PHP Make the production order of process house Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Take the report of grey reciept from mending and the job weaving on the previous day Prepare the grey issue report of previous day(tallying outside and inside cloth and note category wise production) Prepare the stock report of grey dept.((Job mending out+previous day stock)-export delivery of previous day)) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 8 8 8 - Machine Name Proposed Manpower 6 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 4 1/3 109.8 146.4 2 1 1 5.43 5.4 3 1 1 7.21 7.2 4 2 6 7.84 94.0 5 1 1 433.33 6 1 2 7.91 15.8 7 1 4 1.87 7.5 8 1 3 43.66 131.0 9 2 6 5.43 65.2 10 1 3 30.00 90.0 A 562.52 B 1125.04 C 13 D 1271.30 E 3600 F 35.31% G 6 H 47.09% locate the goods to be run on the machine stitch the end of the material with previous material and ensure all cloth ends are tied together.Rectify the same if found to be broken and start the machine set the machine parameter on the screen and ensure its occurance(average speed of the m/c =30 mtr/min) (machine element) get the chemical issue slip from the shift supervisor and give the issue slip to chemical substore and get the chemical from there for the machine Rest & Relaxation Allowances ( % ) Basic Workload per Shift ( in man minutes) of two relax scouring machines Basic Workload per Shift ( in man minutes) Remarks: 1. Production per machine per shift has been taken as 13000 mtrs.Average 2500 mtrs in each trolley and average speed of the m/c =30 mtr/min). Dissolve the chemical in the bucket and dose the same in the machine Cleaning of all the chambers of scouring as well as drying zone with air and water pressure after reciving the goods at delivery end put the tag of next process on the trolly and deliver it to the designated place of next process and cover the trolly with HDPE trolly cover Relieve the three operators at loading,relaxing and drying areas and manages the work of all the three operators Proposed Utilisation(%) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) C PHP Relax scouring Range Relax scouring range Activity Description clean the filter of the washing cambers,clean the filter of the dryer and cleaning of all the chambers of scouring as well as drying zone and full cleaning of the m/c get the programe for the machine from the shift Supervisor Scouring area Proposed Manpower per shift 2. Six personnel are recommended for 2 machines WLS No: PHP/09 WORK LOAD DETAILS SHEET G Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Scouring area Work Centre Present Manpower 6 6 6 - Machine Name Proposed Manpower 4 4 4 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.61 5.6 2 2 1 3.12 6.2 3 2 1 4.56 9.1 4 2 4 6.17 49.4 5 2 4 5.30 42.4 6 1 1 1.67 1.7 7 1 1 9.50 9.5 8 1 1 101.00 9 1 1 14.00 10 1 1 51.00 11 1 1 14.00 12 1 1 30.00 13 1 1 14.00 14 1 1 60.00 15 1 1 14.00 Get the programe for the machine from the shift Supervisor Take the temperature of the water in the m/c to 90 degree celcius and dissolve the chemical (caustic +solite) in the dosing tank and dose the same in the machine, hold water at 90 degree celcius and allow the temp to drop down from 90 degree celcius to 70 degree celcius (machine element) give the issue slip to chemical substore and get the chemicals from there for the machine(caustic,solide plus,soda ash,oxolic acid,acitic acid and vita foam in case foam is being formed) Drain water and load new water (machine element) Load the fabric rope wise in the machine Cleaning the windows of the m/c Locate the goods to be run on the machine no 2 (1200 mtrs processed i.e. 2 beams of 600-650 mtr ) and clean remaining chemicals Load the fabric(1200 mtr and 300 mtr in one window) in windows and note in the register Stitch (12 stitches for 1200 mtr) both the ends of the fabric loaded in windows Drain water and load new water (machine element) WLS No: PHP/10 WORK LOAD DETAILS SHEET G Shifts A set the machine parameter or program number on the screen and ensure its occurance of the same Weight reduction Weight reduction Activity Description B C PHP Drain water and load new water(2800 lts in this case) (machine element) Drain water and load new water (machine element) Take the temperature of the water in the m/c to 90 degree celcius and do hot wash (machine element) Take the temperature of the water in the m/c to 90 degree celcius and dissolve the chemical (acitic acid +auxilic acid) in the dosing tank a,hold water at 90 degree celcius (machine element) Take the temperature of the water in the m/c to 90 degree celcius and and dissolve soda ash in the dosing tank hold water at 90 degree celcius (machine element) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Scouring area Work Centre Present Manpower 6 6 6 - Machine Name Proposed Manpower 4 4 4 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: PHP/10 WORK LOAD DETAILS SHEET G Shifts A Weight reduction Weight reduction Activity Description B C PHP 16 1 1 30.00 17 1 1 14.00 18 1 1 30.00 19 1 1 14.00 20 1 1 20.00 21 2 1 4.21 8.4 22 2 1 14.90 29.8 23 1 1 2.68 2.7 24 1 1 5.66 5.7 25 1 1 4.12 4.1 26 1 1 14.23 14.2 27 1 1 4.36 4.4 28 1 1 5.21 5.2 A 198.38 595.14 B 13 C 672.51 D 2700 E 24.91% F 4 G 37.36% Basic Workload per Shift ( in man minutes); 3 machines of the same kind Present Utilisation(%) Drain water and load new water (machine element) Perform cool wash (machine element) Drain water and load new water (machine element) Take the temperature of the water in the m/c to 90 degree celcius and do hot wash (machine element) Proposed Utilisation(%) Proposed Manpower per shift Bring on more trolley and place polythene sheets into it Unload the material in trolley Tearing apart the stitched material Take the trolley to reopenor 1 For each of the weight reduction machines one operator and one helper who will help all the three operators and also act as an online reliever. Tie the fabric with the old fabric already hung and run the m/c till it passes to the other side of the reopenor where it is coming after being reopened Start reopening after reciving the goods at delivery end put the tag of dry for next process on the trolly and deliver it to the designated place of drying process and cover the trolly with polythene sheet Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Basic Workload per Shift ( in man minutes) Locate the empty trolly in the process house for next fabric Net Available man-mins Unload the material in trolley Wash at 90 degree celcius (machine element) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Scouring area Work Centre Present Manpower 2 2 - - Machine Name Proposed Manpower 2 2 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.32 5.3 2 2 10 6.54 130.8 3 2 10 1.11 22.2 4 1 10 0.90 9.0 5 1 1 2.63 2.6 6 1 1 5.75 5.8 7 1 1 1.42 1.4 8 1 1 34.16 9 1 1 79.63 10 1 1 70.43 11 1 1 18.45 B C PHP Load the fabric rope wise in the machine (total 10 nozzles and 100 mtrs to be loaded in each nozzle) Dolly Winch Dolly Winch Activity Description Get the programe for the machine from the shift Supervisor WLS No: PHP/11 WORK LOAD DETAILS SHEET G Shifts A Dissolve the chemical(DTC:800 gms) in the dosing tank and dose the same in the machine Fill water in the m/c, perform cold washing and drain the water (machine element) Fill new water, pass chemical (DTC:500 gms), increase the temperature upto 50 degree celcius, hold at 50 degree celcius and drain the water (machine element) Fill new water in the m/c,increase the temperature upto 50 degree celcius and perform two hot wash (machine element) Stitch the ends of all the ropes to make them endless rope of the fabric Note all the piece detail rope wise and process parameter in the register in a given format Set the machine parameter or program number on the screen and ensure its occurance of the same Get the chemical issue slip from the shift supervisor and give the issue slip to chemical substore and get the chemical from there for the machine Drain water and fill new water (machine element) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Scouring area Work Centre Present Manpower 2 2 - - Machine Name Proposed Manpower 2 2 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) B C PHP Dolly Winch Dolly Winch Activity Description WLS No: PHP/11 WORK LOAD DETAILS SHEET G Shifts A 12 1 1 70.00 13 1 1 54.00 14 1 1 54.00 15 1 1 33.00 16 1 1 9.00 17 2 1 59.64 119.3 18 1 1 4.24 4.2 19 1 1 14.43 14.4 20 1 1 4.65 4.7 A 319.72 B 13 C 361.28 D 900 E 40.14% F 2 G 40.14% Drain water and fill new water and do cold wash (machine element) Rest & Relaxation Allowances ( % ) Fill new water in the m/c,increase the temperature upto 50 degree celcius,hold at 50 degree celcius and drain the water (machine element) Fill new water in the m/c,increase the temperature upto 50 degree celcius,hold at 50 degree celcius and drain the water (machine element) Unload the material in trolley Locate the empty trolly with hole and unload the matrial in it Total Workload ( in man minutes ) Remarks: Drain out the water Basic Workload per Shift ( in man minutes) After reciving the goods at delivery end put the tag of dry for next process on the trolly and deliver it to the designated place of drying process and cover the trolly with polythene sheet Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Open the fabric rope with the help of ropeopener in an trolly with polythene sheet Dissolve the chemical (DTC:300 gms) in the dosing tank and dose the same in the machine,increase the temperature upto 50 degree celcius, hold at 50 degree celcius and drain the water (machine element) Take the material in rope form to the rope opener and stitch the end with the previous cloth ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Scouring Section Work Centre Present Manpower 2 2 2 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 4.59 4.59 2 1 2 4.83 9.66 3 2 2 45.23 180.92 4 1 2 2.57 5.14 5 1 2 8.77 6 1 2 9.50 19 7 1 6 25.00 8 1 2 15.76 9 1 6 25.00 10 1 2 15.76 11 1 2 26.14 52.28 12 2 2 44.65 178.6 13 2 2 4.65 18.6 14 2 2 8.92 35.68 A 504.47 B 13 C 570.05 D 900 E 63.34% F 2 G 63.34% Rest & Relaxation Allowances ( % ) Locate the empty trolly with hole and unload the material in it After unloading the goods put the tag of dry for next process on the trolly and deliver it to the designated place of drying process and cover the trolly with polythene sheet Clean the machine filter before starting of any batch Roll from one roll to another (machine element) Present Utilisation(%) Proposed Manpower per shift Roll from one roll to another (machine element) Total Workload ( in man minutes ) Jumbo Jigger Activity Description Drain water and fill new water (machine element) Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (2500 mtr at a time) Basic Workload per Shift ( in man minutes) B Drain water and fill new water (machine element) Shifts Fill water in the m/c (4000-5000 ltr) (machine element) Jumbo Jigger Stitch leader cloth with the main fabric and load the material on the machine Get the chemical issue slip from the shift supervisor and give the issue slip to chemical substore and get the chemicals(hydro,caustic,soda ,catsol and BTC) from there for the machine and dissolve the chemical in the dosing tank and dose the same in the machine Set the machine parameter or program number on the screen and ensure its occurance of the same Remarks: WLS No: PHP/12 WORK LOAD DETAILS SHEET G C Proposed Utilisation(%) Take chemical (acid) and add, roll from one roll to another for one round PHP Net Available man-mins A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Scouring Section Work Centre Present Manpower 1 1 1 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.27 5.27 2 1 1 3.27 3.27 3 2 11 9.81 215.82 4 2 11 0.83 18.26 5 1 11 45.00 6 2 11 10.21 224.62 7 1 11 2.12 23.32 8 1 11 5.72 62.92 9 1 11 1.03 11.33 10 1 11 3.55 11 1 11 3.21 35.31 12 1 1 3.85 3.85 A 603.97 B 13 C 682.49 D 450 E 151.66% F 2 G 75.83% Net Available man-mins After complition of the cycle take out the goods from the machine in a cleaned trolly Remarks: Start the m/c and do hydro extraction (machine element) After reciving the goods at delivery end put the tag of dry for next process on the trolly and deliver it to the designated place of drying process and cover the trolly with polythene sheet Locate the empty trolly in the process house for next fabric Tie the fabric with the old fabric already hung and run the m/c till it passes to the other side of the reopenor where it is coming after being reopened Start reopening (machine element) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) C Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Hydro Extraction Hydro Extractor Activity Description Bring on more trolley and place polythene sheets into it Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine PHP Close the cover of the m/c and note the details in theregister Take the trolley to reopenor Load the goods in piled form in Hydro extractor as per the program given (300 mtr at a time) (machine element) WLS No: PHP/13 WORK LOAD DETAILS SHEET G Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dyeing section Work Centre Present Manpower 8 8 8 - Machine Name Proposed Manpower 6 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.12 5.12 2 1 4 4.08 16.32 3 1 4 3.00 4 2 4 25.32 202.56 5 1 4 22.87 91.48 6 1 4 6.76 7 1 4 14.57 8 1 4 17.34 9 1 4 52.32 10 1 4 30.00 11 1 4 22.67 12 1 4 3.00 13 1 4 18.00 14 1 4 15.77 63.08 15 1 4 1.11 4.44 16 1 4 4.79 19.16 17 1 4 1.19 4.76 WLS No: PHP/14 WORK LOAD DETAILS SHEET G Shifts A B C PHP Dyeing section Jet Dyeing Activity Description Go the temperature up to 80 degree celcius and tuck in 1 kg air at the same temperature (machine element) Add chemical to m/c at 60 degree celcius (machine element) Load the goods in the machine as per the program given(includes stitching both the ends to one another) Add color and hold at the same temperature (machine element) Fill water in m/c(350 ltr) (machine element) Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (350 mtr at a time) Bring on more trolley and place polythene sheets into it Get the colors and chemicals from the stores as per the chemicals issue slip.(acitic acid,DFT ) and make color Open the valve and allow the temperature to come down to 80 degree celcius and sent out air at the same temperature (machine element) 3.5 degree celcius steam will be blown for prog 5 and 1 degree celcius steam for prog no 8 and reach the temp in both cases to 130 degree celcius (machine element) Take the trolley to reopenor Hold at the same temperature (machine element) Drain the water at 70 degree celcius (machine element) Fill water in m/c(350 ltr) and perform cold wash (machine element) When temperature decreases to 30 degree celcius,make hold of whatever stitch they get cut sample,dry it and send to supervisor Tie the fabric with the old fabric already hung and run the m/c till it passes to the other side of the reopenor where it is coming after being reopened ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dyeing section Work Centre Present Manpower 8 8 8 - Machine Name Proposed Manpower 6 6 6 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: PHP/14 WORK LOAD DETAILS SHEET G Shifts A B C PHP Dyeing section Jet Dyeing Activity Description 18 1 4 4.14 19 1 4 3.82 15.28 20 2 4 10.22 81.76 A 503.96 2015.84 B 13 C 2277.90 D 3600 E 63.27% F 6 G 84.37% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) 1. Four operators for 4 machines and two helpers are recommended Hand over the thoroughly cleaned machine to next shift operator Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Net Available man-mins after reciving the goods at delivery end put the tag of dry for next process on the trolly and deliver it to the designated place of drying process and cover the trolly with polythene sheet Remarks: Basic Workload per Shift ( in man minutes); 4 m/cs Total Workload ( in man minutes ) Start reopening (machine element) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dyeing Section Work Centre Present Manpower 3 3 3 - Machine Name Proposed Manpower 3 3 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.43 5.43 2 1 1 4.83 4.83 3 1 1 51.24 51.24 4 1 1 32.50 5 1 1 24.56 24.56 6 1 1 5.00 7 1 2 10.12 8 1 1 10.00 9 1 4 13.33 10 1 2 42.09 84.18 11 1 2 10.00 12 1 1 5.00 Drain water,fill new water (machine element) Cut a sample from the fabric while in dyeing solution and show the sample to the shift officer for the shade matching and if approved complete the further dyeing cycle. If the shade does not match ,then take the required addition of the color as suggested by shift officer and run again till the shade is matched. Run from one roll to another in same color for cooling (machine element) Drain water,fill new water (machine element) Add the other half color in tank and run from one roll to another and add 500 gms hydro in each round (10 minutes - machine element) Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (700 mtr at a time i.e. two beams of 350 mtrs) Add chemicals in tanks and run from one roll to another (machine element) Fill water(800 ltrs) and perform two rounds of hot wash at 60 degree celcius (machine element) Add half color in tank and run from one roll to another (machine element) Load from trolley and do stitching(6 stitches for two beams) Get the colors and chemicals from the stores as per the chemicals issue slip(Hydro,caustic,hydrogen peroxide,acitic acid,soda ash,soap and make color according to the requirement) B C PHP Auto Jigger Jigger Dyeing Activity Description WLS No: PHP/15 WORK LOAD DETAILS SHEET G Shifts A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dyeing Section Work Centre Present Manpower 3 3 3 - Machine Name Proposed Manpower 3 3 3 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) B C PHP Auto Jigger Jigger Dyeing Activity Description WLS No: PHP/15 WORK LOAD DETAILS SHEET G Shifts A 13 1 2 20.00 14 1 1 5.52 15 1 3 10.00 16 1 2 10.46 17 1 1 6.45 18 1 4 10.00 19 1 1 5.00 20 1 2 10.00 21 1 1 15.00 22 1 1 6.35 23 1 2 10.00 24 1 1 4.79 4.79 25 1 1 18.18 18.18 26 1 1 3.22 3.22 A 196.43 589.29 B 13 C 665.90 D 1350 E 49.33% F 3 G 49.33% Drain water,fill new water and add hydrogen peroxide to it (machine element) Perform washing in new water (machine element) Send to next section Net Available man-mins Present Utilisation(%) Unload the fabric in the trolley Basic Workload per Shift ( in man minutes);Three m/cs of Auto Jigger Run from one roll to another (machine element) Run from one roll to another (machine element) Run from one roll to another in hot temperature (machine element) Bring on more trolley and place polythene sheets into it Add acitic acid and run from one roll to another (machine element) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Run from one roll to another (machine element) Drain water,fill new water,add soda ash and soap (machine element) Drain water,fill new water (machine element) Drain water,fill new water and run from one roll to another in cold temperature (machine element) Drain water,fill new water and add acitic acid (machine element) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Stores Work Centre Present Manpower 1 1 1 - Machine Name Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 35 6.66 233.1 2 1 1/3 60.65 20 2/9 3 1 1 70.77 70.77 A 324.09 B 13 C 366.22 D 450 E 81.38% F 1 G 81.38% WLS No: PHP/16 WORK LOAD DETAILS SHEET G Shifts A B Fill the receipt form and fill the details in the register Rest & Relaxation Allowances ( % ) - Stores Activity Description According to the issue slip issued by the Supervisor he issues the chemicals to different operators Total Workload ( in man minutes ) Basic Workload per Shift ( in man minutes) C PHP Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) He get the chemical issued from Main stores as per the expected consumption for two days ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dyeing section Work Centre Present Manpower 3 3 - - Machine Name Proposed Manpower 3 3 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 3.89 3.89 2 2 1 68.92 137.84 3 1 12 5.67 68.04 4 2 12 2.54 60.96 5 2 12 27.77 6 2 12 3.34 80.16 A 350.89 B 13 C 396.51 D 1350 E 29.37% F 3 G 29.37% WLS No: PHP/17 WORK LOAD DETAILS SHEET G Shifts A B C PHP Clean the machine rollers and gas burners before starting the machine and clean the water scruber and fill fresh water in it After getting the goods in the trolly remove the trolly from delivery end and take the trolly out of the singeing room Stitch the main fabric with leading cloth and run the fabric on the machine with the given parameters on the batch processing card Locate the goods to be run on the machine Ensure the crease free enrty of the goos in the machine otherwise no singe portion will come and run till trolley gets empty (machine element) Singeing machine Singeing machine Activity Description Get the programe for the machine from the shift Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks:1. Production per machine per shift has been taken as 29000 mtrs.Average 2500 mtrs in each trolley and average speed of the m/c =90 mtr/min). Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Wet finishing section Work Centre Present Manpower 12 12 12 - Machine Name Proposed Manpower 12 12 12 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.12 5.12 2 1 9 5.63 50.67 3 1 3 24.41 73.23 4 1 9 12.73 114.57 5 1 1 6.56 6.56 6 1 9 50.66 7 1 8 14.56 116.48 8 1 9 6.34 57.06 9 1 9 3.12 28.08 10 1 3 30.00 90 A 541.77 1625.31 B 13 C 1836.60 D 5400 E 34.01% F 12 G 34.01% Locate the empty trolly in the process house for next fabric Basic Workload per Shift ( in man minutes);Three m/cs Basic Workload per Shift ( in man minutes) Stitch the material with the the leading cloth and give signal to the feeder man to operate the machine Relieve the three operators for lunch,report damage if in case it happens Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks:1. Production per machine per shift has been taken as 17000 mtrs.Average 2500 mtrs in each trolley and average speed of the m/c =37 mtr/min). - Stenter machine Activity Description Plaiter man check all the material deliver at delivery end (average 650 mtrs of one quality),note down the process parameter and batch details of all the batches run on the machine. After reciving the goods at delivery end put the tag of dry for next process on the trolly and deliver it to the designated place of drying process and cover the trolly with polythene sheet Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine(1800-2000 mtrs average) Feeder man set all the parameter of the machine according to the instruction given by the supervisor and ensures the proper feeding of the fabric in the machine at desired parameter (machine element) Cleans the filter of the machine after every hour in running condition of the machine Take the chemical issue slip from the supervisor and bring the chemicals from the substore.Make the finishing chemical solution in the dosing tank and make the required voume The machine starts running (average speed of m/c=37.5 meters per minute) (machine element) WLS No: PHP/18 WORK LOAD DETAILS SHEET G Shifts A B C PHP ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 2 2 2 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.61 5.61 2 1 5 4.56 22.8 3 1 1 30.00 30 4 2 21 3.73 156.66 5 1 21 10.16 6 1 21 20.12 7 1 21 5.61 117.81 8 1 21 0.91 19.1275 9 1 5 2.89 14.45 A 366.46 B 13 C 414.10 D 900 E 46.01% F 2 G 46.01% Machine operator feed all the details of batch run on the machine with prog. No. in a format register Machine helper will locate the empty tables from out side the folding dept. and clean the same before taking the goods on it and does the plaiting of all the material coming out of the machine at delivery end and during plaiting the helper will check all the material Basic Workload per Shift ( in man minutes) After getting the goods on trolly put the trolly in line designated for the ready for fold material with the batch processing card Send the rolled fabric for steaming (machine element) Clean with air pressure and check the machine input parameter like steam pr., air pr. etc. Load the material as per the programe given by the shift supervisor and load it upto wrapper of the m/c and make a cut Rest & Relaxation Allowances ( % ) Remarks: Production per machine per shift has been taken as 9400 mtrs.Average 2000 mtrs in each trolley and 450 mtrs can be loaded at a time.Speed of m/c is 60 mtrs per minute Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) - Kier decatising Activity Description Running Domestic Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (2000 M/C runs upto first fabric's end(i.e. average 100 mtrs).Adjusts the stitches,cut extra cloth for domestic fabric and start the m/c again (avg speedof m/c =60 mtrs per minute) (machine element) WLS No: PHP/19 WORK LOAD DETAILS SHEET G C Shifts A B PHP ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 2 2 2 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.61 5.61 2 1 21 4.56 95.76 3 1 1 30.00 30 4 2 21 3.73 156.66 5 1 21 5.58 6 1 21 20.12 7 1 21 5.43 114.03 8 1 21 0.91 19.1275 9 1 21 2.89 60.69 A 481.88 B 13 C 544.52 D 900 E 60.50% F 2 G 60.50% Send the rolled fabric for steaming (machine element) Clean with air pressure and check the machine input parameter like steam pr., air pr. etc. WLS No: PHP/20 WORK LOAD DETAILS SHEET G C Shifts A B PHP Machine operator feed all the details of batch run on the machine with prog. No. in a format register Load the material as per the programe given by the shift supervisor and load it upto wrapper of the m/c and make a cut with hands (Here,besides cutting,they have to write details of the fabric on each piece viz.mtrs,quality) after getting the goods on trolly put the trolly in line designated for the ready for fold material with the batch processing card - Kier decatising Activity Description Machine helper will locate the empty tables from out side the folding dept. and clean the same before taking the goods on it Running Lycra Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (150 mtrs average) M/C runs.Adjusts the stitches,cut extra cloth for lycra fabric and start the m/c again(avg speedof m/c =40 mtrs per minute) (machine element) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Remarks: Production per machine per shift has been taken as 3200-3400 mtrs.Average 100-150 mtrs loaded each time.Speed of m/c is 40 mtrs per minute Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 2 2 2 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 4.76 4.76 2 1 6 3.89 23.34 3 2 1 30.00 60 4 2 6 8.82 105.84 5 1 6 6.53 39.18 6 1 6 56.21 7 1 6 3.85 23.1 A 256.22 B 13 C 289.53 D 900 E 32.17% F 2 G 32.17% Clean the m/c with cloth and air pressure and belt cleaning WLS No: PHP/21 WORK LOAD DETAILS SHEET G Shifts A B C PHP Proposed Manpower per shift Proposed Utilisation(%) Remarks: Production per machine per shift has been taken as 7000 mtrs.Average 1000-1500 mtrs loaded each time.Speed of m/c is 20-30 mtrs per minute - Multi decatising Activity Description After getting the goods on trolly put the trolly in line designated for the ready for fold material with the batch processing card Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (1000-1500 mtrs average) Machine helper will locate the empty tables from out side the folding dept. and clean the same before taking the goods on it Basic Workload per Shift ( in man minutes) load the material as per the proograme given by the shift supervisor Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Machine operator runs the m/c(average speed=25 metres per minute) and feed all the details of batch run on the machine with prog. No. in a format register (machine element 50 minutes) (machine element) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 2 2 2 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 5.03 5.03 2 1 4 4.12 16.48 3 2 1 30.00 60 4 2 1 25.76 51.52 5 2 4 6.61 52.88 6 1 4 66.66 7 1 4 4.51 18.04 8 1 4 0.90 3.617333 9 1 4 2.13 8.52 A 216.09 B 13 C 244.18 D 900 E 27.13% F 2 G 27.13% Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Load the material as per the programe given by the shift supervisor Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) after getting the goods on trolly put the trolly in line designated for the ready for fold material with the batch processing card Machine helper will locate the empty tables from out side the folding dept. and clean the same before taking the goods on it Remarks:Production per machine per shift has been taken as 8000 mtrs.Average 2000 mtrs loaded each time.Speed of m/c is 30 mtrs per minute - Superfinish machine Activity Description Machine operator feed all the details of batch run on the machine with prog. No. in a format register Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (2000 mtrs average) Start the m/c and check the machine input parameter like steam pr., air pr. Etc.(average speed=30 mtrs per minute) (machine element) Clean the m/c with cloth and air pressure and silicon belt cleaning Net Available man-mins Add waste cloth and take temperature to 130-140 degree celcius WLS No: PHP/22 WORK LOAD DETAILS SHEET G C Shifts A B PHP ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 2 2 2 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 4.78 4.78 2 1 6 3.82 22.92 3 2 1 10.24 20.48 4 1 6 18.33 5 2 6 7.63 91.56 6 1 6 76.66 7 1 6 3.71 22.26 8 1 6 0.94 5.64 A 167.64 B 13 C 189.43 D 900 E 21.05% F 2 G 21.05% Carry the processed goods to the designated place for further process after covering the goods and attaching the batch process card with the goods. Add waste cloth old running m/c and pass through the m/c and raise the tmeperature of the m/c upto 130 degree celcius to start the function (machine element) WLS No: PHP/23 WORK LOAD DETAILS SHEET G Shifts A B C PHP - Shrinking Range. Activity Description Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (2000- 2500 mtrs average) Start the m/c and check the machine input parameter like steam pr., air pr. Etc.(average speed=30 mtrs per minute) (machine element) Clean the m/c with cloth and air pressure and silicon belt cleaning Remarks: Production per machine per shift has been taken as 12000 mtrs.Average 2000-2500 mtrs loaded each time.Speed of m/c is 30 mtrs per minute Basic Workload per Shift ( in man minutes) Load the material as per the programe given by the shift supervisor Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Keep a record of the goods processed with all the details. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 2 2 2 - Machine Name Proposed Manpower 2 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 4.44 4.44 2 1 5 5.69 28.45 3 2 1 18.82 37.64 4 2 5 7.62 76.2 5 1 5 53.10 6 1 5 5.12 25.6 7 1 5 0.95 4.75 8 1 5 4.21 21.05 A 198.13 B 13 C 223.89 D 900 E 24.88% F 2 G 24.88% A B C Proposed Utilisation(%) PHP - Calender Activity Description Shifts Remarks: Production per machine per shift has been taken as 9000 mtrs.Average 1800 mtrs loaded each time.Speed of m/c is 30 mtrs per minute Carry the processed goods to the designated place for further process after covering the goods and attaching the batch process card with the goods. Basic Workload per Shift ( in man minutes) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Rest & Relaxation Allowances ( % ) WLS No: PHP/24 WORK LOAD DETAILS SHEET G Keep a record of the goods processed with all the details. Get the programe for the machine from the shift Supervisor Locate the goods to be run on the machine (1800 mtrs average) Start the m/c and check the machine input parameter like temp(average speed=30 mtrs per minute) (machine element) Clean the m/c with cloth and air pressure and take temperature to 70 degree celcius Arrange for the empty trolley or table as per the requirement for delivery end. Load the material as per the programe given by the shift supervisor ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - - Machine Name Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 3.81 3.81 2 1 3 15.27 45.81 3 1 3 6.51 19.53 4 1 8 1.19 9.52 5 1 5 5.38 26.9 6 1 1 5.82 5.82 7 1 5 48.92 244.6 8 1 5 3.18 15.9 9 1 5 3.88 19.4 A 391.29 B 13 C 442.16 D 450 E 98.26% F 1 G 98.26% Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Go to the finish folding deptt. to lift the defective goods for reprocessing Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Arrange the reprocess goods process wise and open them on the plaiter and prepare small batches process wise Remarks: Checker Checker Activity Description Take the batches for the respective processes and inform to shift officer. Takes the program from shift officer for the goods to be checked. Checks all the goods of Piece Dyeing and Top Dyed as per instructions given and in case of any damage , informs to the shift officer for corrective action to be taken Get the program for the treatment of reprocess goods from the shift officer Attach the tags with every batch with details of batch No. and the process to be done. Takes the O.K.goods to the designated place for further process. Cut the cuttings of defective goods if any and give them for the treatment in the lab. WLS No: PHP/25 WORK LOAD DETAILS SHEET G C Shifts A B PHP Spotting ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 1 1 - - Machine Name Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 45 3.32 149.4 2 1 3 3.32 9.96 3 1 45 4.51 202.95 4 1 3 3.12 9.36 A 371.67 B 13 C 419.99 D 450 E 93.33% F 1 G 93.33% Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Returns the ironed pcs. to the respective graders in finish folding. WLS No: PHP/26 WORK LOAD DETAILS SHEET Press Ironing Shifts A B C PHP G Collects the than lengths or PL which are having superficial creases and need not to be reprocessed.(12 to 50 mtrs average length) Does the steam Ironing to the fabric having creases and ensures that the creases are totally removed without disturbing its fold. Activity Description Coordinates with all the graders in finish folding. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Sample processing Work Centre Present Manpower 1 1 - - Machine Name Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 2 6.54 13.08 2 1 1 5.64 5.64 3 1 10 5.31 53.1 4 1 10 10.21 102.1 5 1 10 2.22 22.2 6 1 10 8.87 88.7 7 1 10 8.74 87.4 8 1 2 7.65 15.3 A 387.52 B 13 C 437.90 D 450 E 97.31% F 1 G 97.31% Net Available man-mins Present Utilisation(%) Proposed Manpower per day Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Checks all the samples received for any defect or stains at the grey stage. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Sample processing Sample processing Activity Description Recieves the samples from Design development for processing along with the instructions slip.(average 10- 12 samples) Shows the samples and the instructions to the concerned officer and gets instructions for processing of different samples. Deliver the samples at the respective m/cs and follow each and every process personally. Deliver the samples to the finish folding deptt. Checks the initial parameters like GSM ,width etc.and enters in his records After going through 8-10 m/cs ,cut half meter of each sample ,take it to lab and make entry i.e. for which GR testing is to be done Seggregates the different samples as per the suggested process routes take these samples to lab and cut in required shapes and note in the register,come back again cut in required shape and paste in the continuity card WLS No: PHP/27 WORK LOAD DETAILS SHEET G Shifts A B C PHP ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - - Machine Name Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 4.18 4.18 2 1 1 22.38 22.38 3 1 1 221.66 221.66 4 1 1 3.91 3.91 A 252.13 B 13 C 284.91 D 450 E 63.31% F 1 G 63.31% C Spotting Takes program from shift officer for the goods to be done spotting Shifts A B After removing the stains hands over the goods to the shift officer for further processes. WLS No: PHP/28 WORK LOAD DETAILS SHEET Spotting Gun Spotting PHP G Takes the goods to his machine and load on to the m/c (1500-2000 mtrs in one trolley) Remove the stains with Gun spotting machine(average speed of m/c =15 mtrs per minute) Activity Description Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 - - - Machine Name Proposed Manpower 1 - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 115.87 115.87 2 1 1 145.11 145.11 3 1 1 9.17 9.17 4 1 1 12.76 12.76 5 1 3 5.12 15.363 6 1 3 14.33 42.99 7 1 1 4.00 4 A 345.26 B 13 C 390.15 D 450 E 86.70% F 1 G 86.70% WLS No: PHP/29 WORK LOAD DETAILS SHEET G Shifts A B C PHP Jobber - Jobber Activity Description Arranges for thr opening of China goods from the rolls. Prepares the position of goods lying for Finish folding and Seggregates the O.K. goods and undertesting goods and prepares separate position for O.K. goods Maintains good house keeping in the ready goods section and ensures that all the trollies are well covered and labelled. Gives the samples(40 cms) of RMG goods for testing in the lab after final mechanical process. Checks the goods in folding deptt. which are to be taken back for reprocessing. Coordinates with the concerned Folding person and offers him the O.K. goods for folding and grading. Gets approval on the batchcards of all the undertesting goods after the complete testing. Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 - - 4 Machine Name Proposed Manpower 1 - - 3 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 3 91.11 273.33 2 1 3 96.23 288.69 3 1 3 25.31 75.93 4 1 3 28.78 86.34 5 1 1/4 52.45 13.1125 6 1 4 30.11 120.44 7 1 3 15.11 45.33 8 1 2 62.10 124.2 9 1 2 65.87 131.74 10 1 2 90.84 181.68 11 1 1 24.81 24.81 12 1 1/4 44.98 11.245 13 1 1 34.12 34.12 A 1410.97 B 13 C 1594.39 D 2370 E 67.27% F 3 G 84.36% Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Cleaning of all the walls of the deptt Clean the m/c Sweeping the segregation deptt Rest & Relaxation Allowances ( % ) Cleaning of all the walls of the deptt Cleaning of all the toilets. Basic Workload per Shift ( in man minutes) Cleaning of all the drain pipes and sewer lines of the deptt. - Sweeper Activity Description Removes unwanted dust and dirt from the deptt and throws the same in the waste yard out side the deptt. For Scouring Section,Dyeing section,Wet finishing section Sweeps the the floor of whole deptt.and keeps it neat and clean. For Dry finish section Sweeps the the floor of whole deptt.and keeps it neat and clean. Removes unwanted dust and dirt from the deptt and throws the same in the waste yard out side the deptt. Cleaning of all the drain pipes and sewer lines of the deptt. Cleaning of all the toilets. Segregation Deptt Fill the bags with waste cuts(big cuts being torn apart into smaller cuts) and send them out WLS No: PHP/30 WORK LOAD DETAILS SHEET G Shifts A B C PHP Sweeper ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Trolley movement Work Centre Present Manpower 1 1 1 - Position Name Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 60 3.89 233.4 2 1 20 3.34 66.8 A 300.20 B 13 C 339.23 D 450 E 75.38% F 1 G 75.38% WLS No: PHP/31 WORK LOAD DETAILS SHEET G Shifts A Proposed Utilisation(%) - Trolley mover Activity Description Moves trollies in the deptt. to the required places and arranges them in systematic manner to maintain good house keeping Basic Workload per Shift ( in man minutes) Remarks: Wipes all the trolley covering pallies for any dust etc and covers all the trollies with the cleaned pallies. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins B C PHP Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 - - Machine Name Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1/3 21.73 7.24 2 1 1/3 32.60 10.87 3 1 1/3 98.54 32.85 4 1 4 18.11 72.44 5 1 12 9.06 108.66 6 1 3/7 9.06 3.88 7 1 1/3 23.54 7.85 8 1 2/5 97.76 39.10 9 1 5 22.64 113.19 A 396.08 B 13 C 447.57 D 450 E 99.46% F 1 G 99.46% WLS No: PHP/32 WORK LOAD DETAILS SHEET G Shifts A B C PHP Stitching Net Available man-mins Present Utilisation(%) - Stitching Activity Description Stitching for fabric coming from Calender Stitching for fabric coming from Seinging Stitching for fabric coming from LR Stitching for fabric coming from Relax Scouring Stitching for fabric coming from Kitty Mending Stitching for fabric coming from KD Basic Workload per Shift ( in man minutes) Stitching for fabric coming from outside(China) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Stitching for fabric coming from Than Reject from folding Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Computer Operator Work Centre Present Manpower - - - 1 Machine Name Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 170.76 170.76 2 1 3 28.87 86.61 3 1 1 62.19 62.19 4 1 1 45.71 45.71 5 1 1 8.16 8.157 A 373.43 B 13 C 421.97 D 450 E 93.77% F 1 G 93.77% WLS No: PHP/33 WORK LOAD DETAILS SHEET G Shifts A B C PHP Does the confirmation of all the prodn. Orders. Generates all the MIS reports at the month end. Does the chemical issue reservation on daily basis. Feeds the routing of all the new shades in case of P.D. fabrics - Computer Operator Activity Description Prepares the daily position of the deptt. Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Position Name Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 1 5.61 11.22 2 2 1 5.91 11.82 3 2 1 4.42 8.84 4 2 1 204.22 408.44 5 2 1 3.91 7.82 A 448.14 B 13 C 506.40 D 960 E 52.75% F 2 G 52.75% After removing the stains hand over the goods to shift officer for further processing Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins - Spotting Activity Description Takes program from shift officer for the goods to be done spotting Gets chemicals from the color room from store Removes the stains with help of chemical and rubbing the same with brush Take the trolley to the spotting table WLS No: PHP/34 WORK LOAD DETAILS SHEET G Shifts A B C PHP Spotting ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Dry finish section Work Centre Present Manpower 1 1 - - Machine Name Proposed Manpower 1 1 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 4 81.83 327.32 A 327.32 B 13 C 369.87 D 450 E 82.19% F 1 G 82.19% Press Ironing Activity Description He cleans all the machines from outside with the used cloth or by using air pressure wherever required. G WLS No: PHP/35 WORK LOAD DETAILS SHEET Shifts A B C PHP Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Machine Name Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 2 46.77 93.54 2 1 2 55.65 111.3 3 1 1/3 33.74 11.24667 4 1 2 32.65 65.3 A 281.39 B 13 C 317.97 D 450 E 70.66% F 1 G 70.66% WLS No: PHP/01 WORK LOAD DETAILS SHEET G Shifts A B C PHP Stores Maintains cleanliness in the color room and ensures that all the containers containing chemicals and dyes are properly covered. Loading and unloding of all the chemicals coming from Main store Pours the chemicals from big containers into the smaller ones as and when required. Rest & Relaxation Allowances ( % ) Basic Workload per Shift ( in man minutes) - Stores Activity Description Cleans all the containers containing chemicals for any spill over etc. Proposed Utilisation(%) Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 12. PROCESS HOUSE - MAINTENANCE ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 12 12.1 I II III G T I II III G T 1 Shift maintenance Electrician 1 1 1 - 3 1 1 1 - 3 2 General shift maintenance - attending to major breakdowns and preventive maintenance Electrician - - - 2 2 - - - 2 2 3 Water softener operator cum boiler helper Softener operator 1 1 1 - 3 - - - - - 4 Shift maintenance Fitter 1 1 1 - 3 1 1 1 - 3 Fitter and Welder - - - 5 5 - - - 5 5 Helper - - - 3 3 - - - 3 3 Oilman - - - 1 1 - - - 1 1 6 SAP input and computer operation Computer operator - - - 1 1 - - - 1 1 7 Motor maintenance Motor Fitter - - - 2 2 - - - 2 2 8 Lighting of mill and outside Electrician - - - 1 1 - - - 1 1 Helper - - - 1 1 - - - 1 1 Total 3 3 3 16 25 2 2 2 16 22 PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING) Proposed Manpower Remarks S. No Section / Work area Designation Present Manpower General shift maintenance - attending to major breakdowns and preventive maintenance 5 Manpower Deployment _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 12 12.2 12.2.1 a) 12.2.2 a) b) - - - - c) As per utilization a crew of three fitters are sufficicient for the performance of the maintenance activities in the general shift. Since the data provided does not provide any information about the simultaneous occurance of the preventive maintenance activities and the breakdown maintenance activities and simultaneous occurance of the breakdowns itself, a crew of five fitters is proposed to be continued. But the data regarding the simultaneous occurance has to be studied and only thereafter the strength can be rationalized to three fitters.In the workload sheet, the utilization level for the crew of three fitters is displayed. The manpower has been computed with a loading factor of 80 % for the maintenance personnel. The 80 % loading has been considered to take into account the following Variation in machine availability Collection & deposit of tools, dress change Effort variation The following need improvements to make the maintenance function more effective Records keeping The start and end times for both the preventive maintenance and the breakdown maintenance to be maintained. This would help in the analysis of the breakdowns and in maintenance planning Use of standard operating procedures PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING) Proposed Changes & Observations Deploy none as Water softener operator. The utilizationof this position holder is 38 % and if the water softening duties are removed then the utilization works out to be 20 %. The water softening plant may be operated by the Humidity operator and remaining activities stand shifted to the Boiler attendant Proposed Changes Getting consumables from the sub store etc, Observations For the preventive maintenance activities the personnel should use SOP's which will also detail the time element of the activities to be carried out. Presently checklists are used, but SOP's will reduce the variations and also act as benchmarks Effective supervision It is observed that the breaks (tea and lunch) taken by the maintenance personnel are not synchronized and the allowed time / more than the allowed time for the same is utilized. The maintenance personnel to be trained and educated that during the preventive maintenance / breakdown maintenance the times for the breaks can be kept at minimum so that the crew is able to focus better on the maintenance aspects ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 12 12.2 PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING) Proposed Changes & Observations 12.2.2
Planning The activities to be so planned and peformed that the time taken is minimized. Activites that can be carried out in parallel have to be planned. For example, when the production personnel are shutting down the machine and handing over for production, the maintenance personnel can start their activities such as keeping the grease gun ready, bring all the tools, arrange in the workplace, bring the bearings and other consumables which are likely to be changed and keep ready in the workplace. It is observed that the personnel keep making rounds to the workshop often to get tools, bearings etc,. Also when the capacity of the grease gun is known then why not have more than one grease gun for the maintenance works. Observations ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 12 12.3 S.No 1 2 3 4 5 6 7 8 9 10 Computer operator PHM/MECH/08 PHM/MECH/09 PHM/MECH/10 Electrician - general shift Hleper - general shift Motor Fitter Shift Fitter PHM/MECH/04 PHM/MECH/05 PHM/MECH/06 PHM/MECH/07 Shift Electrician Softener operator Oilman PHM/MECH/03 PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING) Hleper - general shift Fitter - general shift PHM/MECH/01 PHM/MECH/02 Workload Sheets Summary WLS Number Area of work ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 5 Designation Proposed Manpower - - - 5 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 2702.78 2702.78 2 1773.91 1773.91 3 223.83 A 4700.52 B 15 C 5405.60 D 1920 E 56.31% F 3 G 93.85% Other miscellaneous works B C G Mechanical Preventive maintenance works Breakdown maintenance works Process House Fitter Activity Description 3. As per utilization a crew of three fitters are sufficicient for the performance of the maintenance activities. Since the data provided does not provide ant information about the simultaneous occurance of the preventive maintenance activities and the breakdown maintenance activities and simultaneous occurance of the breakdowns itself, a crew of five fitters is proposed to be continued. But the data regarding the simultaneous occurance has to be studied and thereafter the strength can be rationalized to three fitters. Remarks: 1. Available man hours per year has been calculated @ 25 working days per month Net Available man-hrs per year Present Utilisation(%) WLS No: PHM/MECH/01 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A Proposed Manpower per shift Proposed Utilisation(%) 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - 3 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 2456.13 2456.13 2 1339.36 1339.36 3 189.77 A 3985.26 B 15 C 4583.05 D 1920 E 79.57% F 3 G 79.57% 1. Available man hours per year has been calculated @ 25 working days per month Other miscellaneous works 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) Process House Helper Activity Description Preventive maintenance works Net Available man-hrs per year Breakdown maintenance works WLS No: PHM/MECH/02 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A B C G Mechanical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 805.29 805.29 2 450.00 450.00 3 62.76 A 1318.05 B 15 C 1515.76 D 1920 E 78.95% F 1 G 78.95% 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity Daily routine works Proposed Manpower per shift Proposed Utilisation(%) 1. Available man hours per year has been calculated @ 25 working days per month Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) Net Available man-hrs per year Present Utilisation(%) Basic Workload per Shift ( in man minutes) Other miscellaneous works Process House Oilman Activity Description Preventive maintenance works Remarks: WLS No: PHM/MECH/03 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A B C G Mechanical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 353.52 353.52 2 761.79 761.79 3 55.77 A 1171.08 B 15 C 1346.74 D 1920 E 35.07% F 2 G 35.07% Preventive maintenance works WLS No: PHM/MECH/04 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A B C G Electrical Net Available man-hrs per year Breakdown maintenance works Other miscellaneous works Process House Electrician Activity Description 1. Available man hours per year has been calculated @ 25 working days per month Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity 3. There are two electricians working in the general shift and two personnel looking after the lighting of plant and outside. This is the total workload for the two crews (1 Electrician and 1 Helper composition). The workload for the helper category personnel are detailed in the next workload sheet. Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 312.17 312.17 2 472.42 472.42 3 39.23 A 823.82 B 15 C 947.39 D 1920 E 24.67% F 2 G 24.67% WLS No: PHM/MECH/05 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A B C G Electrical Breakdown maintenance works Other miscellaneous works Basic Workload per Shift ( in man minutes) Process House Helper Activity Description Preventive maintenance works 2. The crew size for breakdown maintenance is as per the requirement. We have only considered the man hrs required for the performance of the activity Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) Net Available man-hrs per year 1. Available man hours per year has been calculated @ 25 working days per month ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Year Basic Time (Hrs) - man hrs Total Time (Hrs) 1 1166.96 1166.96 2 380.87 380.87 3 77.39 A 1625.22 B 15 C 1869.00 D 1920 E 48.67% F 2 G 48.67% 1. Available man hours per year has been calculated @ 25 working days per month Breakdown maintenance works Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per year) Net Available man-hrs per year Other miscellaneous works Process House Motor Fitter Activity Description Preventive maintenance works WLS No: PHM/MECH/06 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - 1 2 Date Total time 20-Dec 650 21-Dec 585 22-Dec 670 23-Dec 595 24-Dec 690 25-Dec 750 26-Dec 570 27-Dec 645 28-Dec 540 29-Dec 750 30-Dec 870 31-Dec 735 8050 3 4 5 6 / = 0.47 For / = 0.47 we find that the utilization of the shift electrician is 47 % per shift. Hence it is recommended that the deployment of one per shift may be continued. 10 11 10 12 Data provided for the period december 20-31 December 2011 Number of complaints attended on each day and the total time spent for the same is 14 11 11 The average arrival rate is 135/12 = 11.25 per day and the average servicing rate = 24*60/60 = 24 per day WLS No: PHM/MECH/07 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A 135 12 Number of complaints Process House B C G Electrical The average time to resolve a complaint works out to be 60 minutes 11 11 11 11 Fitter ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - 1 2 Date Total time 20-Dec 405 21-Dec 290 22-Dec 390 23-Dec 450 24-Dec 475 25-Dec 515 26-Dec 385 27-Dec 260 28-Dec 340 29-Dec 620 30-Dec 535 31-Dec 600 5265 3 4 5 6 10 10 For / = 0.30 we find that the utilization of the shift electrician is 30 % per shift. Hence it is recommended that the deployment of one per shift may be continued. 131 The average time to resolve a complaint works out to be 40 minutes The average arrival rate is 131/12 = 10.92 per day and the average servicing rate = 24*60/40 = 36 per day / = 0..30 10 11 10 9 11 15 Process House Electrician Data provided for the period december 20-31 December 2011 Number of complaints attended on each day and the total time spent for the same is Number of complaints 12 10 13 10 WLS No: PHM/MECH/08 WORK LOAD DETAILS SHEET Process House Maintenance Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower - - - - Sl. No Crew Size Freq/ Shift Basic Time - man mins Total Time (mins) 1 1 30.00 30.00 2 a) b) 1 1 30.00 30.00 c) 1 1 10.00 10.00 d) 1 1 20.00 20.00 e) 1 1 10.00 10.00 3 1 4 10.00 40.00 4 a) 1 1/15 120.00 8.00 A 148.00 B 15 C 170.20 D 450 E 37.82% F 1 G 37.82% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per day) Net Available man-hrs per day 1. The water softener plant is operated by the Humidity operator also (from electrical maintenance - Loomshed). Hence having one more person in the shift to perform the same operation is not required. The overall utilization is 38 %, but if the softener plant operation is removed then it becomes 20 %. 2. Activity 1 and 4 may be shifted to the boiler attendants. Activity 4 is not a regular activity. Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Operate push buttons to operate pumps Operate valves, perform back wash Operate valves to transfer salt water to tank Charge 14 bags of salt to the salt water tank Give water samples to laboratory for testing 3. This position is not being recommended Check performance of the pumps in the diggy pump house Boiler monitoring (This is operated only during the shutdown of the turbine which occurs six times in a year for a duration of 10 days on one occasion and 1-2 days on others) Check the fire performance, water level, steam meter, gas emission and charge chemical whenever required. Process House Water Softener Operator Activity Description Monitor the overflow from the hold tank, in case of overflow, switch off pump in the nearby area Operate the softener plant WLS No: PHM/MECH/09 WORK LOAD DETAILS SHEET Process House Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Day Basic Time - man mins Total Time (mins) 1 1 1 30.00 30.00 2 1 1 15.00 15.00 3 1 1 15.00 15.00 4 1 1 10.00 10.00 5 1 1/6 30.00 5.00 6 1 1/6 120.00 20.00 6.1 6.2 A 95.00 B 15 C 109.25 D 450 E 24.28% F 1 G 24.28% 1. The utilization is 25 % for this position holder 2. This position is being recommended for the present 3. This position may be reviewed to ascertain whether it is possible to shift the activities performed to the supervisory personnel of the department. Rest & Relaxation Allowances ( % ) Total Workload ( in man hours per day) Net Available man-hrs per day Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Others Give material samples to purchase department Prepare reports based on the instructions of the HOD Basic Workload per Shift ( in man minutes) Remarks: Check the status of the release of the indents in SAP and inform the HOD about the same Prepare new indents Go to purchase department, get bills of the service providers, make entry in SAP and return the bills to the purchase department Process House Computer Operator Activity Description Collect the register from the weaving and SPH, with the values of the TPP compute the values and input into SAP. Take out the print out of the daily power consumption report - ZPP Collect the RO water consumption, coal consumption from thermopack, enter into SAP, take print out of the daily utility report WLS No: PHM/MECH/10 WORK LOAD DETAILS SHEET Process House Shifts A B C G Electrical ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 13. LOGISTICS ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 13.0 13.1 I II III G T I II III G T Rack Monitor - - - 9 9 - - - 6 6 Sample Maker (B&R) - - - 7 7 - - - 5 5 Sample Dispatch - - - 3 3 - - - 2 2 Return /Purchase Goods - - - 4 4 - - - 4 4 Invoicing - - - 6 6 - - - 3 3 Workmen - - - 6 6 - - - 4 4 Packers and Checkers - - - 14 14 - - - 10 10 Packing Section for Loose - - - 7 7 - - - 4 4 Bag Stitching - - - 8 8 - - - 8 8 Loader / Marker - - - 15 15 - - - 8 8 RMG - - - 8 8 - - - 6 6 Sample (Domestic) - - - 16 16 - - - 16 16 Loose Opening Section - - - 17 17 - - - 10 10 Combo Packing - - - 24 24 - - - 10 10 Suit Length / Safari - - - 12 12 - - - 8 8 PL Packing - - - 16 16 - - - 9 9 Good Cut / FRC - - - 6 6 - - - 4 4 Packers and Checkers - - - 24 24 - - - 18 18 Loader / Checker - - - 16 16 - - - 10 10 Regrading / General - - - 12 12 - - - 9 9 Total 0 0 0 230 230 0 0 0 154 154 Designation Present Manpower Manpower Deployment LOGISTICS Proposed Manpower Remarks OLD WAREHOUSE NEW WAREHOUSE S. No Section / Work area 1 2 _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 13.0 13.2 13.2.1 I a) b) c) d) e) f) g) h) II a) b) c) d) e) f) Rack monitor - Deploy six personnel in general shift instead of the present deployment of 9 personnel based on workload Sample maker - Deploy five personnel in general shift instead of the present deployment of 7 personnel based on workload Sample dispatch - Deploy two personnel in the general shift instead of the present deployment of three in the general shift. The combined workload is 26.08 % and two personnel are recommended because of the crew size limitations. Invoicing - Deploy 3 personnel in general shift instead of the present deployment of 6 personnel based on workload LOGISTICS Proposed Changes & Observations Proposed Changes Old ware house Loader / Marker - Deploy 8 personnel instead of the present deployment of 15 personnel in general shift based on workload New Warehouse Workmen - RMG godown - Deploy 6 personnel instead of the present deployment of 8 based on workload Workmen - Deploy 4 personnel instead of the present deployment of 6 personnel based on workload and simultaneous requirements Packers and checkers - Deploy 10 personnel instead of the present deployment of 14 personnel based on workload and simultaneous requirements Packers Loose - Deploy 4 personnel instead of the present deployment of 7 personnel, based on workload, crew size and simultaneous requirements Good cut / FRC - Deploy 4 personnel instead of the present deployment of 6 personnel based on workload Loose opening - Deploy 10 personnel instead of the present deployment of 17 based on workload Combo packing - Deploy 10 personnel instead of the present deployment of 24 personnel based on workload Suit length / safari - Deploy 8 personnel instead of the present deployment of 12 personnel based on workload PL packing - Deploy 9 personnel instead of the present deployment of 16 personnel ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 13.0 13.2 13.2.1 LOGISTICS Proposed Changes & Observations Proposed Changes II g) h) i) Regrading / General - Deploy 9 personnel instead of the present deployment of 12 personnel Packers and checkers - Deploy 18 personnel instead of the present deployment of 24 personnel based on workload and simultaneous requirements Loader / Marker - Deploy 10 personnel instead of the present deployment of 16 personnel based on worklaod New Warehouse ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 13.0 13.3 S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LOGISTICS Workload Sheets Summary Area of work WLS Number Sample dsipatch - old WH LOG/03 Return purchase goods - old WH LOG/04 Rack monitor - old WH LOG/01 Sample maker - old WH LOG/02 Packers and Checkers LOG/07 Packing loose LOG/08 Invoicing LOG/05 Workmen LOG/06 Workmen - RMG godown LOG/11 Sample maker - domestic LOG/12 Bag stitching LOG/09 Loader LOG/10 Loose opening LOG/13 LOG/14 LOG/15 Combo Packing Suit Length / Safari Regrading / General PL Packing Good Cut / FRC Packers and Checkers Loader / Checker LOG/20 LOG/16 LOG/17 LOG/18 LOG/19 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 9 Designation Proposed Manpower - - - 6 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 3 25 0.68 51.15 2 3 25 2.58 193.13 3 3 25 1.14 85.65 4 2 25 5.46 273.13 5 2 25 0.53 26.40 6 2 24 0.58 28.00 7 2 24 2.29 109.88 8 2 24 0.86 41.49 9 1 24 32.51 780.15 10 1 24 0.29 6.88 11 3 26 0.56 43.71 12 3 26 1.37 106.47 13 3 26 0.85 66.12 14 2 26 3.91 203.42 Carry thr rolls to the warehouse Load the rolls on to the trolley(18 on one trolley) Shift rolls from final packing section to the old warehouse Take trolley to respective positions in the finish section Take to packing section and place aside Take the trolley to the scanning section Take the trolley to the scanning section Scan the pieces one by one and transfer on to the other trolley Scan the pieces one by one and transfer on to the other trolley Take the trolley to the loose packing section and leave the trolley there Shift PL from PL section to the old warehouse Take trolley to respective positions in the PL section G Receipt Section Shift fresh from final packing section to the old warehouse Take trolley to respective positions in the finish section Load the pieces(average 70-80 pieces being loaded in one trolley) on to the trolley Old Warehouse Rack Monitor Activity Description Scan and transfer to other trolley WLS No:LOG/01 WORK LOAD DETAILS SHEET Logistics Shifts A Load the pieces(average 65-70 pieces,11 PL in one piece) on to the trolley B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 9 Designation Proposed Manpower - - - 6 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Receipt Section Old Warehouse Rack Monitor Activity Description WLS No:LOG/01 WORK LOAD DETAILS SHEET Logistics Shifts A B C 15 2 26 3.83 198.90 A 2214.47 B 13 C 2502.35 D 4320 E 57.92% F 6 G 86.89% Stack the rolls for packing to transferring outside Remarks:Fresh has average 10-12 mtrs and Roll has average 40-50 mtrs.One PL has average 1.2-1.3 mtrs.Frequency has been taken on the basis of past data (for resh,rolls and PL) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 7 Designation Proposed Manpower - - - 5 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 150.66 150.66 2 1 2 75.76 151.52 3 1 1 45.65 45.65 4 1 3 5.54 16.62 5 1 3 27.65 82.95 6 1 3 4.32 12.96 7 1 3 3.88 11.64 8 1 3 28.77 86.31 9 1 3 1.56 4.68 10 1 3 5.65 16.95 11 1 3 162.66 487.98 12 1 3 50.32 150.96 Sample preparation of PL Note down quality/shades on to the paper (18 quality's average12 shades in this case) Find the required quality's shades(whichever is available,average 12 shades per quality) and cut shades Press the pieces and bring to m/c WLS No:LOG/02 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Sample Old Warehouse Sample Maker (B&R) Activity Description Monitoring and sample sticker preparation as per packing slip and as required for record. Handing over of all stickers required in sampling to concerned workmen. Co- ordination with store and indentor for desired packing material for sample preparation. Coordination with sales and logistic team for preparation of samples as desired. Maintenance of racks of sample fabric as per quality and shade Preparatory Activities Bring and adjust the material required for sample making like glue,samle boards pins and other materials Press the piece and bring to m/c Take the piece to the m/c and cut it according to the requirement Bring covers,paste sticker and write quality nos on them.Place the cut pieces on to the covers and put stapler and adjust Take the final sample to the sample dispatch and put there for dispatch Sample preparation of fent Take the print out of the email and note down quality on to the paper from the email sent for the requisite demands(18 quality's average 2-3 shades in this case) Find the required quality and cut piece ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 7 Designation Proposed Manpower - - - 5 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No:LOG/02 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Sample Old Warehouse Sample Maker (B&R) Activity Description 13 1 3 5.62 16.86 14 1 3 93.78 281.34 15 1 3 1.26 3.78 16 1 3 4.97 14.91 17 1 3 28.43 85.29 18 1 3 4.59 13.77 19 1 3 5.65 16.95 20 1 3 43.20 129.6 21 1 3 1.18 3.54 22 1 3 5.82 17.46 23 1 3 25.27 75.81 24 1 3 4.42 13.26 25 1 3 1.76 5.28 Sample preparation of Hanger Note down quality/shades on to the paper (18 quality's average 2-3 shades in this case) Find the required quality's shades(whichever is available,average 2-3 shades per quality) and cut shades Press the pieces and bring to m/c Take the pieces to the m/c and cut them according to the requirements Sample preparation of Card Note down quality/shades on to the paper (18 quality's average 3 shades to be pasted in this case) Find the required quality's shades(whichever is available,average 3 shades per quality) and cut shades Press the pieces and bring to m/c Take the pieces to the m/c and cut them according to the requirements Bring covers,paste big sample as base and small samples at the bottom of the card and adjust,paste stickers on the card and write quality details Take the final sample to the sample dispatch and put there for dispatch Take the pieces to the m/c and cut them according to the requirements Bring covers,paste sticker and write quality nos on them.Place the big cut pieces on to the right side of the covers and put 12 shades on left side,staple Take the final sample to the sample dispatch and put there for dispatch ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 7 Designation Proposed Manpower - - - 5 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No:LOG/02 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Sample Old Warehouse Sample Maker (B&R) Activity Description 26 1 3 16.76 50.28 27 1 3 1.15 3.45 A 1950.46 B 13 C 2204.02 D 3360 E 65.60% F 5 G 91.83% Bring covers,staple big sample as base of the hanger and small samples at the bottom of the hanger and adjust,paste stickers on the hanger and write quality details Take the final sample to the sample dispatch and put there for dispatch Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 3 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 350 0.27 95.20 2 2 23 1.09 50.14 3 2 23 0.74 33.85 4 2 23 0.34 15.76 5 1 23 0.95 21.74 6 1 23 0.21 4.85 A 221.54 B 13 C 250.34 D 1440 E 17.38% F 2 G 26.08% Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) G Sample Dispatch Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) C Remarks: Old Warehouse Dispatcher Activity Description WLS No:LOG/03 WORK LOAD DETAILS SHEET Logistics Shifts A B For Dispatching Segregate the samples according to delivery sheet and paste on each sample ,sticker generatd by computer Again scan for dispatch Segregate according to party requirements and paste address on each packet(average 5-10 samples in each packet) Take the packet to dispatch and take back LR number which is to be entered into the system Samples made last evevning,transferred to the dispatch section the next morning are segregated (for grasim,graviera and esp) and placed For receiving Receipt by scanning each sample ,tie for each category and place at its respective position ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 4 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 96.87 96.87 2 2 3 1.56 9.36 3 1 3 45.87 137.61 4 1 3 34.65 103.95 5 1 3 15.55 46.65 6 2 5 1.34 13.40 7 1 5 7.46 37.30 Take pieces one by one,open each piece and remove old board ,tag and cut worn out pieces and repack it again with new board and place aside Pack the remaining 15 pieces after placing new bar code and new length parameter and pack them in plastic and place aside Goods coming from parties(fresh and EP) Take the jute bag ,open and take out the pieces(average 10 pieces comes in 1 bag) Open the bags adjust the fabric neatly ,place new tag and repack Intimation recvd from marketing / outsource purchaser alongwith documents to release the goods from transporter. The person then goes to transporters to release the returned/puchased goods by handing over the LR and by shifting of same to the mill by arranging the vehicle / loaders. Handing over of goods to concerned authority. In case of return goods, the matching of recvd stock with return sale order and its verification. The difference if any is informed to concerned for rectification. The co-ordination with accounts department for to pay freight and carriage charges for return / purchased goods and reconcilliation of same. Measure each piece and place it shadewise while noting(average 15 pieces come in 1 bag) Old Warehouse Workmen Activity Description Goods coming from showroom(used fresh) Take the jute bag ,open and take out the pieces WLS No:LOG/04 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Return /Purchase Goods ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 4 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Old Warehouse Workmen Activity Description WLS No:LOG/04 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Return /Purchase Goods 8 2 4 1.59 12.72 9 1 4 17.89 71.56 10 2 3 1.33 7.98 11 2 3 47.82 286.92 12 1 45 10.87 489.15 A 1313.47 B 13 C 1484.22 D 1920 E 77.30% F 4 G 77.30% Barcode stickers:- On return goods PL's sticker genration and pasting on Fabric (Both Small and big size) Open the bags adjust the fabric neatly ,place new tag and repack Open the bags adjust the fabric neatly ,place new tag and repack Goods coming from parties(PL/DPL) Take the jute bag ,open and take out the pieces(average 8 pieces,where 10 sub pieces in each piece in a bag) Goods coming from parties(Safari and suit length) Take the jute bag ,open and take out the pieces(average 30 pieces comes in 1 bag) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 6 Designation Proposed Manpower - - - 3 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 203.37 203.37 2 1 1 183.35 183.35 3 2 1 334.95 669.90 4 1 1 58.22 58.22 A 1114.84 B 13 C 1259.77 D 2880 E 43.74% F 3 G 87.48% The generation of delivery sheet and printing of invoice and delivery sheet for outsource job fabric and handing over of same to transporter. The reaching date of goods is fed into SAP for transporter evaluation. The print out of same is attached with with transporter bill. G Invoicing Printing of bills of 5 copy each (average 450 bills per day), remove the carbon papers, segregating the bills transportwise/agentwise/customerwise/extracopy/office copy. Tearing of same sheetwise and making the bundles separate as said above. The customerwise / agentwise segregated bundle is handed over to courier dispatch section. Extracopy and office copy is kept for further doing the needful. The extracopy of bill is attached with respective LR(350 LR average per day)and fed into the SAP for generation of schedule. The schedule is then printed and segregated partywise after removing the carbons.The schedule, LR Copy and extra invoice copy is attached and further checked. Then stamping of same is done brandwise e.g. grasim / graviera and signed. The bunch thus prepared is sent to courier dispatch section for its onward courier. Monitoring of pending LR's and ensuring that all LR's are received and fed into system timely. Old Warehouse Workmen Activity Description The dispatch details of previous day is collected by the person from domestic warehouse. Then the transportwise segregated bills are carried over to respective transporters and LR copy of previous day dispatch is collected from them. WLS No:LOG/05 WORK LOAD DETAILS SHEET Logistics Shifts A B C Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 6 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 30 3.21 96.30 2 1 4 35.65 142.60 3 1 2 132.87 265.74 4 1 10 6.43 64.30 5 1 332 0.25 82.06 6 1 1 67.73 67.73 7 1 356 0.26 93.21 8 1 490 0.73 357.86 A 1169.81 B 13 C 1321.88 D 2880 E 45.90% F 4 G 68.85% Putting Shipping Marka on case at the time of dispatch Sticker pasting on case and suit length polythene mouth closed at the time of dispatch,physical Stock taking for loose Time of Loading of loose / packed cases in any vehicle prepare record and will maintain as per instruction Activity Description Broken Cases - Opening of broken cases and arranging in racks quality and shade wise Sorting of packing slips and sent to sample, sales and maintaining the record and Peon work of old warehouse Checking the invoice case nos during dispatch the invoiced cases Chindi shorting -FRC, making / Packing House keeping / Cleaning of department Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) WLS No:LOG/06 WORK LOAD DETAILS SHEET Logistics Shifts A B Old Warehouse Workmen C G Old Warehouse Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Reprocess for sample cutting and any work in folding as inspection, convert in thans and refinish etc work,sampling Cutting as per instruction by reprocess and sticker generation Basic Workload per Shift ( in man minutes) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 14 Designation Proposed Manpower - - - 10 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 60 8.65 519.00 2 3 392 0.29 337.90 3 2 392 0.23 181.37 4 2 392 0.42 330.46 5 2 392 0.52 405.85 6 1 392 0.77 303.08 7 2 392 0.08 62.07 8 1 10 6.75 67.50 A 2207.22 B 13 C 2494.16 D 6720 E 37.12% F 10 G 51.96% Shifting cases to packing.Weighing and scanning of fabric for case preparation at packing station and generation of packing slip. Shifting of fabric on table alongwith packing slip Checking of packed case thru reading out details on stamping of than and comparing it thru packing slip. The signing of packing slip by checker if details are correct. One copy of packing slip will kept alongwith loose case and rest 3 copies will be kept at checkers end for Sampling / Marketing and Self Record. If details are not correct, will take up with higher authority. WLS No:LOG/07 WORK LOAD DETAILS SHEET Logistics Shifts A B Rest & Relaxation Allowances ( % ) Old Warehouse Packers n Checkers Activity Description Segregation of Fabric from racks for case preparation as per assortment and marketing advise and shifting it to packing station. Attend the Byers, case making, than fancy doing &keeping back to racks Take PP rolls to pack from stitching place Packing of prepared case in cartons / bags and stitching of bag after putting packing slip in the bag's pocket Put excise sealing onto each roll Marking of case thru packing slip kept in pocket of bag (e.g. case no. / quality no./no. of piece / gross weight / net weight etc Keeping the rolls at designated place Total Workload ( in man minutes ) Remarks: C G Packing Section Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 7 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 490 1.43 700.70 2 2 45 0.58 52.53 3 2 333 0.31 207.24 4 1 333 0.47 156.62 5 1 333 0.29 97.79 6 4 17 0.74 50.32 7 1 5 5.45 27.25 A 1292.45 B 13 C 1460.47 D 3360 E 43.47% F 4 G 76.07% Prepare and loose stitch the jute bags Sort and tie the waste carrying bags and place aside(16-17 bags comes on an average ) Bring empty jute bags from raw material section G Packing Section for Loose Adjust the trolley placed by rack monitor near the loose section Take than and load into jute bags (9 pieces in each jute bag) Old Warehouse Packers B WLS No:LOG/08 WORK LOAD DETAILS SHEET Logistics Shifts A Take the jute bags and place aside and mark the number on the bag C Activity Description Taping the mouth of loose fabric of Safari / PL / Suitlength Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 8 Sl. No Cre w Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 1/3 20.43 13.62 2 1 1/3 7.86 2.62 3 1 81 6.64 537.84 4 1 6 5.87 35.22 5 1 401 0.40 159.66 6 2 401 0.70 561.80 7 2 401 0.53 421.99 8 4 1/9 47.84 21.26 9 1 47 5.56 261.32 10 1 46 3.49 160.72 11 1 25 2.17 54.35 12 1 369 1.07 395.20 A 2625.61 B 13 C 2966.94 D 3840 E 77.26% F 8 G 77.26% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Prepare and stitch pocket on the rolls/cartons Cut plastic to be inserted inside the bags(for 15 bags at a time) Take jute and plastic ,stitch them on the m/c together and place aside Prepare and stitch the sheet of polythene to make it in a roll/carton form For making packing bags for loose (Hessian) Preparation of issue pass for issuance of packing material from the store and collection of packing material and taking them to its workstation Unlock the jute strips and take out the rolls and give for stitching Cut jute for bag formation(for 8 bags at a time) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: WLS No:LOG/09 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Bag Stitching Unlock the PP strips and take out the big roll Cut pieces (for 5 bags at a time) according to the required measurements and give inside for stitching Cut pocket for pocket formation(70-80 pockets at a time) Segregate and place aside Old Warehouse Workmen Activity Description For making packing bags for rolls and carton (HDPE's / LDPE's) Preparation of issue pass for issuance of packing material from the store and collection of packing material and taking them to its workstation ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 15 Designation Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 18 3.21 57.86 2 1 18 1.88 33.83 3 2 18 2.51 90.36 4 1 17 1.63 27.67 5 2 332 0.04 28.11 6 1 332 0.15 49.08 7 1 331 0.13 42.20 8 2 332 0.04 25.79 9 1 332 0.06 18.43 10 1 331 0.05 15.83 11 1 354 2.55 902.70 12 2 20 10.50 420.00 13 1 20 1.55 31.00 14 1 20 2.54 50.80 15 1 19 1.33 25.27 16 2 354 0.04 28.67 17 1 354 0.09 32.80 From stack to tuck door Destacking/loading bags on the back/shoulders of the workmen Return to take next load C) Loading rolls in truck Obtaining invoice from dispatch officer and marking (billwise/transportwise/partywise) on invoiced cases as advised by dispatch officer. B) Loading of loose packed goods for shifting them to domestic warehouse Destacking/loading bags on the back/shoulders of the workmen Carry the bags upto truck door From truck door to inside Loading the bags on the back/shoulders of the workmen Carrying inside the truck and dump Return to take next load D) From stacks to place near truck to load Load rolls onto the trolley(17 -19 rolls being loaded) Carry the rolls near the truck G Loading/Unloading Carry the rolls outside the warehouse Returning with empty trolley for next load Old Warehouse Loader / Marker Activity Description A) Shifting the packer rolls outside the warehouse Load rolls onto the trolley(17 -19 rolls being loaded) Unload all the rolls and stack/adjust the rolls WLS No:LOG/10 WORK LOAD DETAILS SHEET Logistics Shifts A B C Returning with empty trolley for next load Unload all the rolls and stack/adjust the rolls Carry the bags upto truck door ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 15 Designation Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Loading/Unloading Old Warehouse Loader / Marker Activity Description WLS No:LOG/10 WORK LOAD DETAILS SHEET Logistics Shifts A B C 18 1 353 0.08 28.00 19 2 354 0.04 29.97 20 1 354 0.06 22.60 21 1 353 0.05 16.30 22 1 2 3.67 7.35 23 1 2 1.38 2.76 24 2 2 2.61 10.44 25 1 2 1.21 2.42 26 1 10 11.83 118.30 27 1 10 1.45 14.50 28 2 10 2.66 53.20 29 1 9 1.32 11.88 A 2198.12 B 26 C 2769.63 D 7200 E 38.47% F 8 G 72.13% Returning with empty trolley for next load F) Shifting the rolls from one place to another Load rolls onto the trolley(17 -19 rolls being loaded) Carry the rolls to the desired place Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Carrying inside the truck and dump Return to take next load E) Shifting broken cases to packing section Load rolls onto the trolley(17 -19 rolls being loaded) Carry the rolls to the packing section Unload all the rolls and stack/adjust the rolls Returning with empty trolley for next load Unload all the rolls and stack/adjust the rolls From truck door to inside Loading the bags on the back/shoulders of the workmen Return to take next load Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 6 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 50 4.45 445 2 2 50 17.84 1784 3 1 1 119.87 119.87 A 2348.87 B 13 C 2654.22 D 3840 E 69.12% F 6 G 92.16% Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) WLS No:LOG/11 WORK LOAD DETAILS SHEET Logistics Shifts A B C G RMG Godown Sorting and picking of ordered material from the rakes is done. Picked item is packed into cartons by scanning the article, same is checked thru packing slip and put into bag, stripped and weighed for accuracy. The final weight is updated in SAP. Packing slip is kept in pocket of bag and marking of details happen on the bag e.g. case no. /weight / qualtiy / pcs etc. Packed cases are then kept at designated place for onward dispatch.(24 pieces in 1 carton) Printing of invoice copy - invoice copies are printed after invoicing by sales, two copies are handed over to transporter, one copy is handed over to invoice section for LR updation, one copy is handed over to sales and one copy is kept for record purpose Printing of delivery sheet and getting it signed by respective authority and arrange its availability at gate before physical dispatch of goods. New Warehouse Workmen Activity Description The RMG goods dispatched by vendor is Tallied as per documents at time of receipt, the cartons are opened, tally and segregate it quality / shade wise, inwarding of same by scanning each article ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 16 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 156.77 156.77 2 1 2 83.l6 166.32 3 1 1 45.65 45.65 4 1 18 13.33 239.94 5 1 18 135.55 2439.9 6 1 18 41.66 749.88 7 1 18 5.43 97.74 8 1 18 9.55 171.9 9 1 18 9.82 176.76 10 1 18 3.21 57.78 Press the pieces(12 shades) and bring to m/c Take the pieces to the m/c and cut them according to the requirements Place the small shades on base shades Collecting packs,covers and glue to fix the folder and paste the shades with glue,insert sticker on small samples and write transport no and quality no Final adjustment and place aside the final folder G Sample Sample preparation of window sample Prepare and note down quality/shades(15 qualities' average 12 shades) on to the paper the folder for sample making(pasting small windows on folders for inserting shades) Find the required quality's shades(whichever is available,average 12 shades per quality) and cut shades New Warehouse Sample Maker (Domestic) Activity Description Monitoring and sample sticker preparation as per packing slip and as required for record. Handing over of all stickers required in sampling to concerned workmen. Co-ordination with store and indentor for desired packing material for sample preparation.Co-ordination with sales and logistic team for preparation of samples as desired. Maintenance of racks of sample fabric as per quality and shade Preparatory Activities Bring and adjust the material required for sample making like glue,samle boards pins and other materials WLS No:LOG/12 WORK LOAD DETAILS SHEET Logistics Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 16 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Sample New Warehouse Sample Maker (Domestic) Activity Description WLS No:LOG/12 WORK LOAD DETAILS SHEET Logistics Shifts A B C 11 1 18 5.64 101.52 12 1 18 23.69 426.42 13 1 18 3.82 68.76 14 1 18 1.68 30.24 15 1 18 36.44 655.92 16 1 18 4.11 73.98 17 1 18 5.73 103.14 18 1 18 21.05 378.9 19 1 18 11.05 198.9 20 1 18 3.87 69.66 21 1 18 13.96 251.28 22 1 18 3.76 67.68 Sample preparation of Card Note down quality/shades on to the paper (15 quality's average 3 shades to be pasted in this case) Find the required quality's shades(whichever is available,average 3 shades per quality) and cut shades Bring covers,staple big sample as base of the hanger and small samples at the bottom of the hanger and adjust,paste stickers on the hanger and write quality details Final adjustment and place aside the final folder Press the pieces and bring to m/c Sample preparation of Hanger Note down quality/shades on to the paper (15 quality's average 2-3 shades in this case) Find the required quality's shades(whichever is available,average 2-3 shades per quality) and cut shades Press the pieces and bring to m/c Take the pieces to the m/c and cut them according to the requirements Take the pieces to the m/c and cut them according to the requirements Bring covers,paste big sample as base and small samples at the bottom of the card and adjust,paste stickers on the card and write quality details Final adjustment and place aside the final folder ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 16 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Sample New Warehouse Sample Maker (Domestic) Activity Description WLS No:LOG/12 WORK LOAD DETAILS SHEET Logistics Shifts A B C 23 1 2 24.65 49.3 A 6778.34 B 13 C 7659.52 D 7680 E 99.73% F 16 G 99.73% Proposed Manpower per shift Proposed Utilisation(%) Remarks: The bundles of record samples are made and kept to be picked up by desired person and in case of case samples, preparation of gate pass getting it signed by concerned authority and taking them to sample dispatch section at old warehouse for their further dispatch Basic Workload per Shift ( in man minutes) Net Available man-mins Present Utilisation(%) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 17 Designation Proposed Manpower - - - 10 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 349 3.21 2243.26 2 1 349 0.28 97.55 3 1 348 0.07 26.04 4 1 349 0.61 212.19 5 1 47 7.03 330.54 6 1 47 8.11 381.30 7 1 46 0.52 24.00 8 1 46 8.13 374.12 9 1 6 7.01 42.05 10 1 6 0.51 3.08 11 1 5 0.29 1.45 12 1 1 134.44 134.44 A 3870.01 B 13 C 4373.11 D 8160 E 53.59% F 10 G 91.11% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) WLS No:LOG/13 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Loose Opening Section Take out all the packets(average 9 in each pack) from the jute bags and place nearby Return to open next jute bag New Warehouse Workman Activity Description Opening of loose bags and arrange nearby in stack Opening of loose bag once unloaded by loaders Housekeep of section Return to take the next load Arrange all the pieces shade wise Shifting of made cases upto packing station. Loading pieces into the trolley(65-70 in one trolley) Carrying the pieces upto scanning section From stack to placing in racks Loading pieces into the trolley(65-70 in one trolley) Carry the pieces upto the rack and place the pieces quality wise and shade wise Attending of buyers, showing them the desired fabric, keeping the goods back in rakes and making of case as advised by buyers. In case of assortment, making the case as per packing instruction recvd from sales / LE. Keeping the residual fabric in rakes.Keeping of fabric in qualitywise /shadewise in rakes and ensuring proper upkeep and tracing of same as and when required. Maintaining agewise fabric in rakes and retrievel of same when required. Retun to take the next lot ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 24 Designation Proposed Manpower - - - 10 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 197.66 197.66 2 1 39 13.55 528.45 3 1 39 44.34 1729.377 4 1 39 8.87 345.93 5 1 39 18.14 707.265 6 1 39 2.51 98.0785 7 1 1 220.22 220.22 8 1 1 90.44 90.44 A 3917.42 B 13 C 4426.69 D 11520 E 38.43% F 10 G 92.22% Activity Description Opening of shirting, matching it with documents and stamping of each piece brandwise and cut wise and then keeping it in rakes sizewise and shade wise. Total Workload ( in man minutes ) The PL stickers is then removed by maker and generate new combo sticker in SAP and paste it on fabric. Insert shirting and PL in primary pack Write the details on the sticker ,bring big box and load average 13 primary packs in the box ,paster sticker and place aside Preparatory time(for bringing laces ,gum,cartons and other material) and proper maintenance and upkeep of Combo packing section.) Co-ordination with sales team / logistics for order processing and packing material respectively. B C G Combo Packing Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Bring shirting and PL from the respective sections(for making one big bag in which average 4-6 sub packs will come.In each sub pack a combination of 12 shirting,12 PL or 14 shirting,14 PL is being done) Pack shirting and PL in compact form and tie lace New Warehouse Workmen Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) WLS No:LOG/14 WORK LOAD DETAILS SHEET Logistics Shifts A ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 12 Designation Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 34 16.43 558.57 2 1 34 5.89 200.42 3 1 34 39.98 1359.43 4 1 34 18.27 621.18 5 1 1 240.55 240.55 6 1 3 90.00 270.00 A 3250.16 B 13 C 3672.68 D 5760 E 63.76% F 8 G 95.64% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) WLS No:LOG/15 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Suit Length / Safari Packing starts by scanning each piece and generating packing slip and checking of same for correctness and putting the polythene bag in primary box of safari which is made by folding the edges of raw primary box and keeping of primary box in secondary outers alongwith packing slip and leaving at designated place to be carried away for final packing by packing team Co-ordination with sales team / logistics for order processing and packing material respectively. Preparatory time(for bringing laces ,gum,cartons and other material) and proper maintenance and upkeep of Safari / suit length section.) Arrange the pieces on table Wrapping of fabric onto 15x7 patti and keeping it in one polythene bag and closing the mouth of same New Warehouse Workmen Activity Description Carrying (50 bundles at a time with 5 pieces in each) and opening of master pack of safari / suitlength and keeping them at designated place qualitywise, shadewise and cutwise. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 9 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 12 9.1595 109.914 2 2 46 9.33 858.36 3 1 46 3.46 159.16 4 1 304 5.45 1656.8 5 2 1 250.44 500.88 Activity Description Carrying and opening of master pack of PL and keeping them at designated place qualitywise, shadewise and cutwise.(40 PL packs where 8 PL pieces in each pack at a time) G PL Packing New Warehouse Workmen WLS No:LOG/16 WORK LOAD DETAILS SHEET Logistics Shifts A B C Scanning of bar code of each piece occurs in SAP and generation and printing of packing slip and making of PL case(80 PL pieces in one bag in an average) starts by keeping the pieces of different quality / shade together in one case The generated case no. is written on summary card and take away the generated cases at designated place for fancying and packing of PL case(80 PL pieces) There are two types of packing 2 fold or 3 fold. In case of 2 fold, the fabric is wrapped on 14x8 patti, one poster is kept onto it and inserted into one 9.5x15.5 polyhthene thaili. 10 pcs of each are then tied with ribbon and inserted in one 14x22 thaili. The packed cases are kept at desginated place to be carried away for final packing. In case of 3 fold packing, fabric is wrapped on 10x8 gatta and tied with ribbon, poster of 3 fold is kept onto it and inserted in 9.5x15.5 thaili. The thaili's are then kept into 5 ply outer and kept at designated place to be carried away for final packing by packing team Co-ordination with sales team / logistics for order processing and packing material respectively. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 9 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Activity Description G PL Packing New Warehouse Workmen WLS No:LOG/16 WORK LOAD DETAILS SHEET Logistics Shifts A B C 6 1 3 90.00 270 A 3555.11 B 13 C 4017.28 D 7680 E 52.31% F 9 G 92.99% Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Preparatory time(for bringing laces ,gum,cartons and other material) and proper maintenance and upkeep of PL section) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 6 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 6 43.65 261.90 2 1 6 2.22 13.32 3 1 12 45.55 546.60 4 1 12 2.57 30.84 5 2 1 218.98 437.96 6 1 3 90.00 270.00 A 1560.62 B 13 C 1763.50 D 2880 E 61.23% F 4 G 91.85% Activity Description Pack Good cut Segregate all the pieces rangewise / cutwise / qualitywise and brandwise .The lengths of the pieces include 91 cms,95 cms,1 mtr,1.05 mtr,1.10mtr and 1.14 mtrs G Good Cut / FRC New Warehouse Workmen Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) WLS No:LOG/17 WORK LOAD DETAILS SHEET Logistics Shifts A B C The sorted pieces cut wise and qualitywise are kept on one gatta of 30x8 and then inserted into one thaili of 17x35 (90 pieces being packed in each bag) alongwith one the summary card having details of packed pieces and kept at designated place to be carried away for final packing Pack FRC In case of Fent and Rags, opening of packet / bag and sorting the fabric rangewise / cutwise / qualitywise and brandwise.The lengths of the pieces include 120 cms,95 cms(chindi),21-44 cms(rag) and 45-90 cms(fant) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) The packed pieces are kept in one thaili alongwith summary card to be taken away for final packing. In case of chindi, stuffing of chindies in bags in according to their size and kept at designated place to be carried away for final packing. Co-ordination with sales team / logistics for order processing and packing material Preparatory time(for bringing laces ,gum,cartons and other material) and proper maintenance and upkeep of FRC section.) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 24 Designation Proposed Manpower - - - 18 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 342 0.46 313.04 2 2 342 0.46 313.84 3 2 342 0.78 535.57 4 2 342 0.92 628.71 5 1 342 0.80 273.09 6 1 342 0.78 268.01 7 2 342 0.07 47.99 A 2380.26 B 13 C 2689.70 D 11520 E 23.35% F 18 G 31.13% Stripping on the packed case manually / thru machine and mentioning final gross weight on case and keeping it at designated place Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Place the jute bags on stack and write the weight on bags Packing Section Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) New Warehouse Packers n Checkers Activity Description Weighing and scanning of fabric(11-12 pieces) in case of than packing at packing station and generation of packing slip. Shifting of fabric on table alongwith packing slip. Corner Making of packed case thru stitching for compactness and better handling at time of loading / unloading. Marking of case thru packing slip kept in pocket of bag (e.g. case no. / quality no./no. of piece / gross weight / net weight etc Checking of packed case thru reading out details on stamping of than and comparing it thru packing slip. The signing of packing slip by checker if details are correct. One copy of packing slip will kept alongwith loose case and rest 3 copies will be kept at checkers end for Sampling / Marketing and Self Record. If details are not correct, will take up with higher authority. Packing of prepared case in cartons / bags(11-12 pieces in one bag) and stitching of bag after putting packing slip in the bag's pocket WLS No:LOG/18 WORK LOAD DETAILS SHEET Logistics Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 10 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 342 0.04 27.93 2 1 342 0.39 132.35 3 1 341 0.366333 124.92 4 1 342 0.25 84.13 5 2 203 0.04 17.19 6 1 203 0.06 11.60 7 1 202 0.05 9.70 8 1 203 0.13 25.92 9 1 202 0.11 22.02 10 2 203 0.04 15.77 11 1 203 0.05 10.89 12 1 202 0.05 9.70 13 1 203 0.10 21.08 14 1 202 0.09 18.62 15 2 203 0.04 14.21 16 1 203 0.09 17.66 17 1 202 0.08 16.43 B) Unloading of loose packed goods and place them in the lower godown(Graviera) entry Destacking/loading bags on the back/shoulders of the workmen Carry the bags upto truck door C) Unloading of loose packed goods and place them in the upper godown(Grasim) entry Destacking/loading bags on the back/shoulders of the workmen Carry the bags upto truck door Return to take next load Return to take next load Carry the bags from truck door to inside godown Carry the packed cases to be placed inside the godown Stack/adjust the packed cases New Warehouse Loader / Marker Activity Description A) Shifting the packed cases inside the warehouse Destacking/loading packed cases on the back/shoulders of the workmen Returning with empty trolley for next load WLS No:LOG/19 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Loading/Unloading Carry the bags from lift to stack nearby Return to take next load Carry the bags from truck door to lift Return to take next load Upstation(Grasim) Destacking/loading bags on the back/shoulders of the workmen Return to take next load ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 10 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) New Warehouse Loader / Marker Activity Description WLS No:LOG/19 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Loading/Unloading 18 2 114 2.12 483.36 19 2 57 0.04 4.62 20 1 57 0.10 5.90 21 1 56 0.09 5.16 22 2 57 0.04 4.43 23 1 57 0.16 9.28 24 1 56 0.14 8.07 25 2 57 0.04 4.58 26 1 57 0.31 17.82 27 1 56 0.29 16.39 28 2 114 0.04 8.44 Return to take next load Carry the bags to lift E) Shift packed cases from upwards(Grasim) to be send for dispatch Destacking/loading bags on the back/shoulders of the workmen D)Loading marked cases for dispatch Printing of delivery sheet, case marka report and transportwise case report.Case marka report will handed over to marker to mark the dispatchable case for the day.The checker will check the cases at bay and permanent marka will be put before the loading of cases into the vehicle Carry the bags from lift to be placed for dispatch Return to take next load F) Shift packed cases from downwards(Graviera) to be send for dispatch Destacking/loading bags on the back/shoulders of the workmen Carry the bags outside the warehouse and place Downstation Destacking/loading bags on the back/shoulders of the workmen Return to take next load G) Load cheched and assembled cases into vehicle Destacking/loading bags on the back/shoulders of the workmen ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 16 Designation Proposed Manpower - - - 10 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) New Warehouse Loader / Marker Activity Description WLS No:LOG/19 WORK LOAD DETAILS SHEET Logistics Shifts A B C G Loading/Unloading 29 1 114 0.09 10.72 30 1 113 0.08 9.19 31 2 114 0.04 8.09 32 1 114 0.05 5.93 33 1 113 0.05 5.44 A 1187.53 B 26 C 1496.29 D 7680 E 19.48% F 10 G 31.17% Return for next case Return for next case Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) From door to inside vehicle Destacking/loading bags on the back/shoulders of the workmen Carry the bags inside vehicle and place Carry the bags upto vehicle and place ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 12 Designation Proposed Manpower - - - 9 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 3 22.41 67.23 2 1 3 7.58 22.74 3 1 3 179.55 538.65 4 1 3 32.50 97.5 5 1 3 9.97 29.91 6 1 3 131.62 394.86 7 1 3 14.48 43.44 8 1 3 20.98 62.94 9 1 3 7.64 22.92 10 1 3 93.03 279.09 11 1 3 162.50 487.5 12 1 3 10.21 30.63 13 1 3 112.10 336.3 14 2 1 240.54 481.08 15 1 1 206.97 206.97 16 1 1 248.76 248.76 C G Regrading / General New Warehouse Workmen Activity Description Cut and pack fresh into PL Load(60-70)fresh pieces on to the trolley and carry upto the scanning section,scan each piece and carry upto the FRC section WLS No:LOG/20 WORK LOAD DETAILS SHEET Logistics Shifts A B Fold the suit length in compact form Cut the pieces into 4 suit lengths Pack the suit lengths in poly bag with laces on both sides and paste sticker on them Packing material keeping with systematic way and deliver to respective user by one hand on daily basis Unload the pieces on the table in FRC section Cut the pieces into 10 PLs Unload the pieces on the table in FRC section Packing Slip sort out and give to concern department and other all peon work will do as per concer officer Monitor for Supervision of Graviear & Grasim Warehouse as inspection the work and making the requirment of packing material and monitior the store / Purchase work for avoide the any shortage of packing material. Paste stamp on the PLs Cut and pack fresh into Suit Length/Safari Load(60-70)fresh pieces on to the trolley and carry upto the scanning section,scan each piece and carry upto the FRC section Bring new SAP generated sticker from the computer Paste stickers on the PLs Tie 30 pieces together and send to PL. Bring new SAP generated sticker from the computer ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 12 Designation Proposed Manpower - - - 9 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) C G Regrading / General New Warehouse Workmen Activity Description WLS No:LOG/20 WORK LOAD DETAILS SHEET Logistics Shifts A B 17 1 3 90.00 270 A 3620.52 B 13 C 4091.19 D 5760 E 71.03% F 9 G 94.70% Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Preparatory time(for bringing laces ,gum,cartons and other material) and proper maintenance and upkeep of FRC section.) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani 14. THERMAL POWER PLANT ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani 14.0 14.1 I II III G T I II III G T 1 TPP ( Turbine Operation) Operator 1 1 1 - 3 1 1 1 - 3 2 TPP (Boiler Fuel Feeders) Operator 2 2 2 - 6 2 2 2 - 6 When Pet coke is used 3 TPP (Boiler Fuel Feeders)-PA Hopper Poking Operator 1 1 1 - 3 1 1 1 - 3 4 TPP (ESP & ASH Handling) Operator 1 1 1 - 3 1 1 1 - 3 5 TPP (Coal Handling Plant) Operator 7 7 7 - 21 7 7 7 - 21 When Indian Coal is used 6 TPP (Maintenance) Fitter / Asst. Fitter - - - 2 2 - - - 2 2 7 TPP (Maintenance) Helper - - - 5 5 - - - 5 5 8 TPP (Maintenance) Welder - - - 1 1 - - - 1 1 9 TPP (DM Plant Operation) Fitter - - - 2 2 - - - 1 1 10 TPP (DM Plant Operation) Helper - - - 2 2 - - - 2 2 11 TPP (DM Plant Operation) Chemist 1 1 1 - 3 1 1 1 - 3 Manpower Deployment THERMAL POWER PLANT Proposed Manpower Remarks S. No Section / Work area Designation Present Manpower _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani 14.0 14.1 I II III G T I II III G T Manpower Deployment THERMAL POWER PLANT Proposed Manpower Remarks S. No Section / Work area Designation Present Manpower 12 TPP (DM Plant Operation) Operator 1 1 1 - 3 1 1 1 - 3 13 TPP (House Keeping) Helper - - - 2 2 - - - 2 2 14 TPP/Wartsila Gardener & Sweeper - - - 2 2 - - - 2 2 15 Wartsila (Operation) Operator 1 1 1 - 3 1 1 1 - 3 16 ETP (Operation) Operator / Helper 2 2 2 - 6 2 2 2 - 6 17 TPP ( Electrical maintenance+Elect. B/D) Electrician / Asst. Foreman 1 1 1 - 3 1 1 1 - 3 18 18 18 16 70 18 18 18 15 69 Total _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani 14.0 14.2 14.2.1 I a) 14.2.2 I a) b) c) II a) b) III a) THERMAL POWER PLANT Proposed Changes & Observations Proposed Changes DM Plant-Mechanical Maintenance In view of low utilisation (37.62 %) it is recommended to deploy one fitter for DM plant maintenance activities instead of the present two personnel. In TPP-Temporary stores, where the materials like bed materials, lime stone which comes in bags was teared and spilled all around the entrance. It increases the workload of coal handling personnel as the materials has to be shifted from ground instead of bags. Observations TPP-Coal Handling It is observed that the coal handling areas like Vibratory screen area, magnetic separator, Crusher and belt conveyor walking pathways was not cleaned at regular intervals and causing threat to walk in that area for the mechanical checkups. It is recommended to maintain checklist to monitor the cleanliness in critical area for easy access to maintenance. In the belt conveyor pathways which is slide in nature and spilled materials are round in nature causes safety issues. In general, overall Coal handling plant and belt conveyor area to be improved in safety point of view like providing cross bars to prevent accidents, near magnetic separator(where magnetic separator operator works) adequate safety precautions to be provided. DM Plant -Mechanical Maintenance TPP Presently, open end small trolley is being used by DM plant mechanical helpers to shift salt bags from temporary stores to salt tank and to shift HCL chemical from storage tank to cooling tower. As the trolley is open (no boundary), two person is deployed during shifting of HCL chemical(one person front side and another person backside) and also causes spillage (if can falls). It is recommended to provide big trolley and recommended to tie the cans while moving. It also helps in reducing number of trips required to shift salt bags from stores to salt tank. Presently only 4 bags is shifted per shift. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani 14.0 14.3 S.No Area of work 1 TPP ( Turbine Operation) 2 TPP (Boiler Fuel Feeders) 3 TPP (Boiler Fuel Feeders) 4 TPP (ESP & ASH Handling) 5 TPP (Coal Handling Plant) 6 TPP (Maintenance)- Fitter/Asst.Fitter 7 TPP (Maintenance)-Welder 8 TPP (DM Plant Operation)-Fitter 9 TPP (DM Plant Operation)-Helper 10 TPP (DM Plant Operation)- Chemist 11 TPP (DM Plant Operation)- Operator 12 TPP (House Keeping)-Helper 13 TPP/Wartsila -Gardener &sweeper 14 Wartsila (Operation)-operator 15 ETP (Operation)-operator 16 TPP ( Electrical maintenance+Elect. B/D) TPP/W/06 TPP/W/07 TPP/W/08 TPP/W/09 TPP/W/10 TPP/ELEC/01 TPP/W/05 TPP/DM-MECH/02 TPP/DM-MECH/01 TPP/MECH/02 TPP/MECH/01 TPP/W/05 THERMAL POWER PLANT TPP/W/01 TPP/W/02 Workload Sheets Summary WLS Number TPP/W/04 TPP/W/03 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 a b c d 2 1 8 3.00 24.00 3 1 1 20.00 20.00 4 1 1/10 30.00 3.00 5 1 1 15.00 15.00 6 1 1/30 60.00 2.00 7 1 1/90 60.00 0.67 8 1 1 A 79.67 B 12 C 89.23 D 450 E 19.83% F 1 G 19.83% Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Cooling Tower fan checking Centrifuge operation checking Log Book Record Turbine Start Up and Normal Shut Down CW pump Suction strainer cleaning (Only in A Shift) Daily Check List Monitoring (Only in B Shift) ACW pump Suction strainer cleaning (Only in A Shift) Lube Oil and Control Oil Filter Checking Net Available man-mins Present Utilisation(%) * As the activity is observatory & monitoring in nature, not considered for calculating utilisation. Lube Oil and Control Oil Filter Cleaning (Only in A Shift) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Presently operator is being relieved by the shift incharge for the Tea break, Lunch break & personal needs during the shift hours. A shift person Utilisation comes to 16.09 %, B shift personal utilisation- 13.61%, C shift it is 9.87 % Monitoring of Turbine through DCS * Cooling Water pump -CW & ACW Pumps Checking WLS No: TPP/W/01 WORK LOAD DETAILS SHEET Engineering Shifts A B C 1 1 G TPP Control Room Turbine Operator Activity Description Turbine field parameter checking 15 15 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 2* 2 2 - Designation Proposed Manpower 2* 2 2 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 a 2 5 1/3 1.49 15.91 a 2 5 1/3 3.80 40.49 b 1 5 1/3 1.29 6.90 c 1 5 1/3 0.37 1.97 2 a 1 37 0.98 36.26 b 1 37 0.95 35.22 c 1 37 0.52 19.31 d 1 37 10.63 393.16 e 2 37 0.58 43.17 f 2 37 0.40 29.60 3 1 1 60.00 60.00 A 681.98 B 14 C 777.45 D 450 E 86.38% F 2 G 86.38% Move the empty trolley back to drain pipe area Net Available man-mins Present Utilisation(%) Total Workload ( in man minutes ) House keeping ground floor (area 900 sq meter by broom) Load the bags in the tractor Bed material screening is being carried out only when pet coke is used as fuel. When indian coal is used as a fuel, it is recommended to deploy one person per shift instead of two personnel. The utilisation of single personnel deployed would be around 54.73%. B Proposed Manpower per shift TPP G * Recommended manpower is for petcoke feeding Bed Ash drain:( 37 Trolley/Shift) Proposed Utilisation(%) Remarks: Activity Description Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Waiting for the operator to open the next pipe in computer Hit the pipe with the hammer & Collect ash Move the filled trolley to dumping yard and dump Screen the bed material through portable screen(2 level screening) Put the screened materials in the bags and tie Waiting for the ash to fill in the trolley Move the filled trolley to dumping yard for cooling Move the empty trolley back to drain pipe area WLS No: TPP/W/02 WORK LOAD DETAILS SHEET Engineering Shifts A PA Line drain:( Once in a day- 16 Pipes) C Boiler Fuel Feed Helpers ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 4 6.11 24.44 2 1 4 5.00 20.00 3 1 1 15.00 15.00 4 1 1 45.00 45.00 5 1 0.00 A 104.44 B 12 C 116.97 D 450 E 25.99% F 1 G 25.99% House keeping Boiler furnace area (area 900 sq meter by broom) (Only in A Shift) Monitor the Pocket fuel feeder operation and poke if feed get jammed Present Utilisation(%) Proposed Manpower per shift Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Proposed Utilisation(%) Remarks: Total Workload ( in man minutes ) Net Available man-mins WLS No: TPP/W/03 WORK LOAD DETAILS SHEET Engineering Shifts A B C G TPP Boiler Fuel Feed Helpers Activity Description PA mixing line, Fuel Feeding lines and vertical chute check & poke(if required).PA injector checking and hammering Monitor Bunker fuel Level by visual inspection once in a while Cleaning of Auxiliary & Equipments(Only in A shift) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Cre w Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 4 3.30 13.20 2 1 1 15.69 15.69 3 1 4 2.19 8.76 4 1 4 3.00 12.00 5 1 4 2.50 10.00 6 a 1 4 4.00 16.00 b 1 4 2.07 8.28 c 1 4 2.00 8.00 d 1 4 4.00 16.00 e 1 4 1.00 4.00 7 1 1 10.00 10.00 8 1 1 30.00 30.00 9 1 1 15.00 15.00 10 1 1/2 150.00 75.00 A 241.93 B 13 C 273.38 D 450 E 60.75% F 1 G 60.75% Net Available man-mins Present Utilisation(%) ( S.No 1-10) Rest & Relaxation Allowances ( % ) Proposed Utilisation(%)(S.No 1 -17) Remarks: The following data was collected from past record: Clean the ESP&Ash handling area ( Once in a day-A & B shift) Oct'2011- Dec'2011 - 207 Tractors, Oct'2011-Dec'2011 - 98 Trucks Proposed Manpower per shift Total Workload ( in man minutes ) Basic Workload per Shift ( in man minutes) Bring down the chute to place properly on the truck, Switch on Ash Sample Collection and Sending to Lab Monitor the Daily Check List parameter and fill the list(Only in B shift) Check the gearbox oil level and pumps, motors in ESP & Ash handling section Operator Activity Description Check the ESP and Ash handling plant during its operation, Check the compressor readings like pressure etc Clean the Compressor Suction Filter(2 Atlas + 2 Ingersoll rand) Fill the ash in truck from silo G TPP C Help in placing the truck in properly and note down the truck number in log book Switch on the air blower and switch off Observe the ash filling Hit the sides of the ash silo with hammer for proper flow Switch on the TR set room switches(once in every two hours) Switch off the TR set room switches(once in every two hours) Log book record keeping(once in every two hours) ESP&Ash Handling WLS No: TPP/W/04 WORK LOAD DETAILS SHEET Engineering Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7* 7* - - Designation Proposed Manpower 7 7 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 a 4 31 2.53 313.41 b 4 31 3.32 411.68 c 4 10 1.34 53.50 d 4 10 4.51 180.50 e 2 1 9.45 18.90 f 2 1 9.45 18.90 2 a 4 15 2.53 b 4 15 3.32 c 2 2 7.88 d 2 1 9.45 3 1 1 240.00 240* 4 1 1 240.00 240* Indian Coal(90%) + Cow dung ( 10 %) Waiting for the tractor to dump next load, in between poking Poke the grizzly screen after cow dung dumped by the tractor Waiting for the tractor to dump next load, in between poking Shift the Bed material from store to JCB (40 kg /bag)(30 bags/ JCB trip) Open the bed material bag and dump in the grizzly hopper(30 bags) Poke the grizzly screen after pet coke dumped by the tractor Waiting for the tractor to dump next load, in between poking One operator @ Grizzly hopper Bottom -While loading Shift the Limestone from store to JCB (60 kg/bag * 25 bags/JCB trip) Pet Coke(95%) + Lime Stone ( 5 %) Open the lime stone bag and dump in the grizzly hopper(30 bags) One operator @ Bunker Floor -While loading Poke the grizzly screen after coal dumped by the tractor Four operator @ Grizzly hopper Poking -While loading WLS No: TPP/W/05 WORK LOAD DETAILS SHEET Engineering Shifts A Remove the unwanted materials from the coal(running belt conveyor) near the magnetic separator Open the hopper outlet door manually to control the flow of the materials in the belt conveyor ( to avoid overflow & underflow in belt conveyor) One operator @ Magnetic Separator -While loading B C G TPP Coal Handling Helpers Activity Description ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 7* 7* - - Designation Proposed Manpower 7 7 - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) WLS No: TPP/W/05 WORK LOAD DETAILS SHEET Engineering Shifts A B C G TPP Coal Handling Helpers Activity Description 5 1 1 240.00 240* 6 1 1 30.00 30.00 7 2 1 120.00 240.00 8 2 1 45.00 90.00 9 1 1525 0.40 610.00 10 1 1 60.00 60.00 A 2026.89 B 16 C 2351.19 D 450 E 74.64% F 7 G 74.64% To get the workload, when petcoke is used as fuel, add S.No 2 a,b,c & d * Seven personnel per shift is deployed When indian coal is used as fuel. Six personnel per shift is deployed if petcoke is used as fuel. The study was done for indian coal feeding. Cow dung is used along only with indian coal. Present Utilisation(%) Clean the Coal Crusher, Screen, Belt BC-2, BC-3 and Coal Plant House Cleaning. Clean the Bunker BC4 Belt and Bunker floor Fuel spillage recovering from ground floor all over coal plant, put it on the JCB and transfer& house Keeping. ( Total Area-3050 sq meter. A shift - 3050/2 =1525 sq.mt) Water spraying to ground floor area in coal yard area Basic Workload per Shift ( in man minutes) Clean the Grizzly hopper and feeding area ,area opposite coke storage Seven operator is recommended because simultaneously seven operators are involved (during loading) Monitor the bunker level manually and inform the Control room for belt diverting once the level reached(like Bunker 1 to 2 or 2-3,etc) After loading over, all helpers clean the areas as group Proposed Manpower per shift Proposed Utilisation(%) Remarks: Lime stone is used along only with pet coke. Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Fitter +5 Helper Designation Proposed Manpower - - - 2 Fitter +5 Helper Fitter Helper 1 63.18 63.18 2 a 3.50 3.50 b 5.17 c 16.80 3 80.00 240.00 4 40.00 40.00 5 36.40 6 17.67 40.33 7 20.00 58.00 8 9.30 36.00 9 6.67 20.00 10 18.67 37.33 A 258.98 596.72 B 14 14 C 295.24 680.26 D 166 166 E 88.71% 81.76% F 2 5 G 88.71% 81.76% WLS No: TPP/MECH/01 WORK LOAD DETAILS SHEET Engineering Shifts A C G TPP & DM Rest & Relaxation Allowances ( % ) Total Workload ( in man hours ) Daily Works-Routine Checkup * Lubrication Works* Big Gear Box Oil Change ( 1 Fitter + 1 Helper) Mechanical Welder Small Gear Box Oil Change ( 2 Helpers) Small Breaing Greasing ( 1 Helper) Repair Work Roller Repair Basic Workload per month ( in man hours) B TPP Annual Shutdown works Kaizen Works-TPP Activity Description Assist Welder in carryout his activities (minor problems) Abnormalities-TPP Breakdown-TPP Wartsila Yearly Maintenance Breakdown maintenance,abnormalities,Kaizen works, Wartsila yearly Mt and TPP annual shutdown works data has been obtained for a period of two months and the same has been extrapolated for a month. The preventive maintenance data was collected for all the category of machines. Check studies on a sample basis were carried out to ascertain the process being followed for the preventive maintenance. The data gathered during check studies has been applied to the remaining preventive maintenance activities in that section. Net Available man-hours per month ( 26*8 *80% = 166 ) Present Utilisation(%) Total Time(Hours) /Month Proposed Manpower Proposed Utilisation(%) Sl. No Remarks: * For details See WLS-TPP/MECH/01 A & B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Fitter +5 Helper Designation Proposed Manpower - - - 2 Fitter +5 Helper WLS No: TPP/MECH/01 WORK LOAD DETAILS SHEET Engineering Shifts A C G TPP & DM Mechanical Welder B Repair work- The activity perform to resolve the running problems identified during daily check up. The timings was estimated based on the data collected from the past records & discussion with the workmen. The manpower has been computed with a loading factor of 80 % for the maintenance personnel. The 80 % loading has been considered to take into account the following: Bring tools/materials from store Ex: oil,grease,waste cloth, new parts Prepare attendance Roller Repair- The time spent in rectifying & replacing the damaged rollers in the belt conveyors. The timings was estimated based on the data collected from the past records & discussion with the workmen. Unavoidable delay. EX:New activity cannot start after 4.30 pm as only 30 mins left for that day Change dress Write logbook Arranging of tools & parts in tool room Efforts variation required Waiting for the machine for maintenance Clean the tool room daily morning Discard the waste cloth to the waste area daily after maintenance work ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - Designation Proposed Manpower - - - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 3 4 5 6 7 8 9 10 1 1 25.00 25.00 11 1 1 60.00 60.00 A 146.20 B 2.44 Check belt conveyor rollers(BC1,3&4) 1 1 61.20 CW pump,ACW pump coupling, sound checking Vibratory screen,V belt, Crusher checking CT fan gearbox oil level checking HP Dosing pump and LP dosing pump checking Check the bunker floor belt conveyor motor Check the DEB floor WLS No: TPP/MECH/01 A WORK LOAD DETAILS SHEET Engineering Shifts A Basic Workload per Shift ( in man hours) Basic Workload per Shift ( in man minutes) ETP pump gland and compressor oil, sound level checking Check belt conveyor rollers(BC2) B C G TPP Check Pocket feeder floor and check oil level TPP Mechanical Activity Description Drag chain feeder, gearbox oil, nut & bolt checking 61 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre - - - Designation - - - Sl. No Crew Size Numbe r of parts Freq/ Month Basic Time (Hour) Total Time (Hour) 1 1 F+1 H 4 1/12 2.00 0.67 1 F+1 H 2 1/12 2.00 0.33 1 F+1 H 2 1/12 2.00 0.33 1 F+1 H 4 1/12 2.00 0.67 1 F+1 H 1 1/12 2.00 0.17 1 F+1 H 1 1/12 2.00 0.17 1 F+1 H 1 1/12 2.00 0.17 1 F+1 H 1 1/12 2.00 0.17 1 F+1 H 4 1/12 2.00 0.67 1 F+1 H 1 1/12 2.00 0.17 3.50 2 2 8 1/6 0.50 1.33 2 4 1/6 0.50 0.67 2 4 1/6 0.50 0.67 2 2 1/6 0.50 0.33 2 1 1/6 0.50 0.17 2 1 1/6 0.50 0.17 2 1 1/6 0.50 0.17 2 1 1/6 0.50 0.17 2 1 1/6 0.50 0.17 2 8 1/6 0.50 1.33 5.17 3 1 2 1 0.15 0.30 1 2 1 0.15 0.30 1 2 1 0.15 0.30 1 8 1 0.15 1.20 1 4 1 0.15 0.60 1 4 1 0.15 0.60 1 3 1 0.15 0.45 1 3 1 0.15 0.45 WLS No: TPP/MECH/01 B WORK LOAD DETAILS SHEET Engineering B C G TPP A TPP Mechanical Activity Description BC - 4 - 1 No. Gearbox oil change (Small) Pocket feeder gearbox - 8 Nos. Drag chain gearbox - 4 Nos. Lub oil changing - 1 No. Total Workload per month Gearbox oil change (big) PA fan bearing greasing - 2 Nos. ID Fan bearing greasing - 2 Nos. FD fan bearing greasing - 2 Nos. Pocket feeder bearing greasing - 8 Nos. C.W Pump motor bearing greasing - 3 Nos. Motor Bearing & Plumber Block Bearing and all bearing greasing C T Fan Gearbox - 4 Nos. HMDC Gear Box - 2 Nos. Ash Silo Air blower - 2 Nos. ETP Air blower - 4 Nos. BC - 1 - 1 No. BC - 2 - 1 No. BF - 1 - 1 No. Total Workload per month Shifts Present Manpower Proposed Manpower Lime stone feeder gearbox - 4 Nos. BF - 2 - 1 No. RBF - 1 - 1 No. BC - 3 - 1 No. Collecting rapping gearbox - 4 Nos. Rotor feeder gearbox - 2 Nos. Drag chain feeder bearing greasing - 4 Nos. Lime stone feeder greasing - 4 Nos. CT fan motor bearing greasing - 3 Nos. RBF - 2 - 1 No. ETP Plant gearbox - 8 Nos. RBF - 3 - 1 No. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre - - - Designation - - - Sl. No Crew Size Numbe r of parts Freq/ Month Basic Time (Hour) Total Time (Hour) WLS No: TPP/MECH/01 B WORK LOAD DETAILS SHEET Engineering B C G TPP A TPP Mechanical Activity Description Shifts Present Manpower Proposed Manpower 1 2 1 0.15 0.30 1 1 1 0.15 0.15 1 4 1 0.15 0.60 1 4 1 0.15 0.60 1 2 1 0.15 0.30 1 4 1 0.15 0.60 1 2 1 0.15 0.30 1 1 1 0.15 0.15 1 1 1 0.15 0.15 1 1 1 0.15 0.15 1 1 1 0.15 0.15 1 4 1 0.15 0.60 1 9 1 0.15 1.35 1 9 1 0.15 1.35 1 3 1 0.15 0.45 1 4 1 0.15 0.60 1 30 1 0.15 4.50 1 2 1 0.15 0.30 16.80 Rotary feeder motor gearing - 2 Nos. BC-1 Motor - 1 No. BC-2 Motor - 1 No. BC-3 Motor - 1 No. BF-2. RBF-1, RBF-2, RBF-3 Motor-4 Nos. Screen arm bearing - 4 Nos. Screen small bearing - 30 Nos. Crusher bearing greasing - 2 Nos. Total Workload per month BF-1 Motor - 1 No. F- Fitter , H - Helper BC tail pulley bearing greasing - 9 Nos. BC head pulley bearing greasing - 9 Nos. BC counter belt bearing-3 Nos. A.C.W Pump motor bearing greasing-2Nos. G.D motor bearing greasing - 1 No. Emmiting rapping motor - 4 Nos. Collecting rapping motor - 4 Nos. HMDC Motor greasing - 2 Nos. Air blower motor greasing - 4 Nos. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 1 Designation Proposed Manpower - - - 1 Sl. No Total Time(hours) /Month 1 6.67 2 2.67 3 8.00 4 22.66 5 3.66 6 4.67 7 36.40 A 84.72 B 14 C 96.58 D 166 E 58.04% F 1 G 58.04% Proposed Manpower C Proposed Utilisation(%) Basic Workload per month ( in man hours) Remarks: The activities performed under abnormalities, breakdown and Kaizen works was collected from the past record and workload per month was arrived. Minor Problems attended daily Activity Description Abnormalities Attended-TPP The past data of minor activities was collected from the past records. The data gathered during check studies has been applied to the remaining preventive maintenance activities. Rest & Relaxation Allowances ( % ) Total Workload ( in man hours ) Net Available man-hours Present Utilisation(%) G TPP & DM Mechanical Welder TPP Annual Shutdown Abnormalities Attended - DM Breakdown Activities - TPP Kaizen Works-TPP Kaizen Works-DM WLS No: TPP/MECH/02 WORK LOAD DETAILS SHEET Engineering Shifts A B ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 1 Sl. No Crew Size Freq/ Month Basic Time (hours) Total Time (hours)/ Month 1 2 1.00 3 1.00 4 2.67 5 8.00 6 6.00 7 79.04 A 110.71 B 14 C 126.21 D 166 E 37.92% F 1 G 75.84% Breakdown maintenance,abnormalities,Kaizen works data has been obtained for a period of two months and the same has been extrapolated for a month. Running maintenance data has been collected by detailed discussions with the incumbents and the supervisory personnel and compared with check studies and estimated. Check the raw water tank pump, Trail run the standby Total Workload ( in man hours ) Net Available man-hours Present Utilisation(%) Proposed Manpower The preventive maintenance data was collected for all the category of machines. Check studies on a sample basis were carried out to ascertain the process being followed for the preventive maintenance. The data gathered during check studies has been applied to the remaining Abnormalities Attended WLS No: TPP/DM-MECH/01 WORK LOAD DETAILS SHEET Engineering Shifts A C G TPP Breakdown Activities Check PAC tanks,hypodosing tank and refill oil B 13 1 26 0.5 DM Plant Fitter Activity Description Check polyelectrolyte tank agitator motor and refill the oil Lubrication Works- Gear box oil change Small (6 Nos) Check the degassing tank pump Apply grease in clarifier chain link Check the clarifier motor and its oil level Check RO&softener feed tank pumps Check the DMF pump The manpower has been computed with a loading factor of 80 % for the maintenance personnel. The 80 % loading has been considered to take into account the following: Pump motor bearing greasing( Raw Water-2 nos, Jockey Pump-2 nos, Fire pump-2 nos) Kaizen Works Minor Problems attended daily Basic Workload per month ( in man hours) Rest & Relaxation Allowances ( % ) Remarks: Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 1 WLS No: TPP/DM-MECH/01 WORK LOAD DETAILS SHEET Engineering Shifts A C G TPP B DM Plant Fitter Bring tools/materials from store Ex: oil,grease,waste cloth, new parts Prepare attendance Unavoidable delay. EX:New activity cannot start after 4.30 pm as only 30 mins left for that day Dress change Write logbook Arranging of tools & parts in tool room Efforts variation required Waiting for the machine for maintenance Clean the tool room daily morning Discard the waste cloth to the waste area daily after maintenance work ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 60.00 60.00 2 1 1 30.00 30.00 3 a 2 7 2.03 28.42 b 2 28 0.33 18.48 c 2 7 2.51 35.09 d 2 28 1.12 62.77 4 a 1 5 1.00 5.00 b 1 5 3.37 16.85 c 2 3 5.40 32.40 5 2 1 5.00 10.00 6 2 1/3 120.00 80.00 7 2 1 5.00 10.00 8 2 1 5.00 10.00 9 2 1 10.00 20.00 10 a 2.31 b 21.54 c 36.92 d 21.53 e 165.85 A 667.16 B 14 C 760.57 D 480 E 79.23% F 2 G 79.23% Proposed Utilisation(%) Remarks: As the helpers have routine works, other than maintenance, 480 min is taken as available time. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Minor Problems attended daily Abnormalities Attended Move the filled can to cooling tower & come back Shift chlorine from Dm plant to cooling tower (2 cans/day- 2 cans/trip) Breakdown Activities Clean the salt preparation tank 1 & 2 Shift hypo chemical from mechanical room to near the tank ( 100 kg/day-40 kg/can- 3 can per trip) Lubrication Works & Gear box oil change Small Bring the empty can to sulphuric acid tank Fill the acid in can from the tank Move the loaded trolley back to salt tank Place the bag from trolley to salt tank top Shift PAC bag from mechanical room to near the tank (50kg/day- 25 kg/bag- 2 bags/trip) Kaizen Works Shift the caustic to near the tank & mix (100kg/day-50kg/bag-2 bags/trip) Assist the fitter in the repair work in DM plant Sulphuric Acid can shifting (250 Kg/ day - 50 Kg per can- 2 cans per trip) DM Plant Mechanical Helper Activity Description Clean the DM plant (under the shed area) (office,DM plant,mechanical office) Place the bag on the trolley from the floor TPP Clean the outside area of the DM plant Shift the salt bag from store to salt mixing tank ( 1100 Kg/Day- 40 Kg per bag- 4 bags per trip) Move the empty trolley to the store area WLS No: TPP/DM-MECH/02 WORK LOAD DETAILS SHEET Engineering Shifts A B C G ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 17.83 17.83 2 1 1 7.17 7.17 3 1 1 10.00 10.00 4 1 1 9.50 9.50 5 1 1 9.50 9.50 6 1 1 8.00 8.00 7 1 1 45.00 45.00 8 1 1 50.83 50.83 9 1 1 50.83 50.83 10 1 1 35.00 35.00 11 1 1 40.00 40.00 12 1 1 20.00 20.00 13 1 1 45.00 45.00 A 348.67 B 13 C 393.99 D 450 E 87.55% F 1 G 87.55% WLS No: TPP/W/05 WORK LOAD DETAILS SHEET ENGINEERING Shifts A B C G THERMAL POWER PLANT DM PLANT, RO PLANT, COOLING TOWER CONTRACT CHEMIST Activity Description Sample collection from Boiler Sample collection from cooling Tower sample collection from softener Sample collection from DM Plant Sample collection from Mix bed Sample collection from R.O.Plant All sample testing Fuel feeder fuel Testing Eco.APH, Bed and Ash silo ash sample testing Chemical solution Preparation Test report preparation and pass it Shift in charge Log book maintaining Chemical dosing in cooling tower,LP and HP tanks Basic Workload per Shift ( in man minutes) Remarks: Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 1 Designation Proposed Manpower 1 1 1 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 1 50.83 50.83 2 2 1 20.00 20.00 3 2 1 20.00 20.00 4 2 1 30.00 30.00 5 2 1 8.60 8.60 6 2 1 40.00 40.00 7 2 1 60.00 60.00 8 2 1 45.00 45.00 9 2 1 30.00 30.00 10 2 1 25.00 25.00 A 329.43 B 13 C 372.26 D 450 E 82.72% F 1 G 82.72% WLS No: TPP/W/06 WORK LOAD DETAILS SHEET ENGINEERING Shifts A B C G DM PLANT TECHNICIAN JOB CONTRACT OPERATOR Activity Description DM plant operation through PLC Boiler chemical preparation &charging cooling water chemical preparation & dosing Net Available man-mins All dosing point clarifier, R.O. DM Plant chemical preparation and dosing in points clarifier sludge draining DMF Back wash DM PlantRegenration/Softener Regeneration/R.O.Cleaning System update Logbook Record keeping Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: * General shift operator position is not required Check list monitoring Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 2 100.83 100.83 2 1 1 55.83 55.83 3 1 1 70.00 70.00 4 1 1 30.00 30.00 5 1 1 35.00 35.00 6 1 3 45.00 45.00 7 2 1 54.00 54.00 8 2 1 22.50 22.50 9 2 1 7.50 7.50 A 420.67 B 13 C 475.35 D 480 E 99.03% F 2 G 99.03% WLS No: TPP/W/07 WORK LOAD DETAILS SHEET ENGINEERING Shifts A B C G THERMAL POWER PLANT TPP, WARTSILA,ETP HELPER(Houeskeeping) Activity Description House keeping work in TPP and Wartsila ( cleaning area3840 sq meter by broom and water) TPP control room cleaning (area 112 sq meter by water and broom) TPP 4.0M,12 Mand 8M level cleaning . (1980 SQ meter by broom) Water spraying on all TPP area Unwanted scrap materials removing from TPP and shifting. Tee and water arrangement for staff. Machine cleaning of Turbine,ejector,and cooling tower Control room and office cleaning in TPP Dust removing from dust bin Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 2 Designation Proposed Manpower - - - 2 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 1 80.83 80.83 2 1 1 84.17 84.17 3 1 1 65.00 65.00 4 1 1 20.00 20.00 5 1 1 5.33 5.33 A 255.33 B 13 C 288.53 D 480 E 60.11% F 2 G 60.11% WLS No: TPP/W/08 WORK LOAD DETAILS SHEET ENGINEERING Shifts A B C G THERMAL POWER PLANT Total Workload ( in man minutes ) TPP Sweeper &Gardener Activity Description House keeping work on Road in TPP Wartsila. And ETP plant. (Area 4000 sq meter by broom) Handling of garden in TPP. Toilet cleaning in TPP WTP area. Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Remarks: Water spraying on all Green area. Unwanted grass removing from green area. Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 40.00 40.00 2 1 1 15.33 15.33 3 1 1 12.00 12.00 4 1 1 25.00 25.00 5 1 1 20.00 20.00 6 1 1 8.00 8.00 7 1 8 1 9 1 1 7.00 7.00 10 1 1 10.00 10.00 11 1 1 8.36 8.36 12 1 1 10.00 10.00 A 207.69 B 13 C 234.69 D 450 E 52.15% F 1 G 52.15% WLS No: TPP/W/09 WORK LOAD DETAILS SHEET ENGINEERING Shifts A B C G WARTSILA WARTSILA OPERATOR Activity Description Engine aux,skid cleaning. All parameter checking of aux. skid. Water supply checking of cooling tower and fiber dying HFO and LO separator start and cleaning done steam line checking ,steam traps checking from TPP and fiber dying Log book parameter records. Wartsila start and stop activity done. 1 52.00 52.00 Wartsila trial taken every day. Lube oil cleaning and taken in line. HFO and LO truck unloading. HFO sludge removing. Air filter cleaning. Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 9.52 9.52 2 2 14 trips 35.00 35.00 3 2 14 trips 44.80 44.80 4 2 4 40.00 40.00 5 1 22.50 6 1 1 43.33 43.33 7 2 2 30.00 30.00 8 1 5.00 9 1 1 3.45 3.45 10 1 4 12.00 12.00 11 2 1 20.00 20.00 12 1 1 5.00 5.00 13 1 1 5.00 5.00 14 1 2 10.00 10.00 15 1 8 0.96 0.96 A 286.56 B 13 C 323.82 D 450 E 71.96% F 1 G 71.96% WLS No: TPP/W/10 WORK LOAD DETAILS SHEET ENGINEERING Shifts A B C G THERMAL POWER PLANT ETP OPERATOR Activity Description Sample testing in lab. Pre treatment dosing. Chemical shifting. Chemical preparation every two hrs. water pump and tank level monitoring. All drain cleaning House keeping in ETParea Chemical line cleaning Air blower operation. Tube settler draining Drain sludge taken in decanter/filter Treated water sending to TPP CT and garden ETP R.O plant operation. Back of ACF and MGF RO plant flushing. Proposed Manpower per shift Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower 1 1 1 - Designation Proposed Manpower 1 1 1 - Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 1 20.00 20.00 2 1 1/7 17.14 17.14 3 1 1 20.83 20.83 4 1 1 30.00 30.00 5 1 1 12.00 12.00 6 1 1 12.50 12.50 7 1 1 30.00 30.00 8 1 1/7 21.43 21.43 9 1 1/7 8.57 8.57 10 1 1/7 8.57 8.57 11 1 1 10.00 10.00 12 1 1/7 2.86 2.86 13 1 1/7 2.14 2.14 14 1 1 motor in a 30.00 30.00 15 1 1 8.00 8.00 A 234.05 B 13 C 264.47 D 360 E 73.46% F 1 G 73.46% WLS No: TPP/ELEC/01 WORK LOAD DETAILS SHEET TPP Shifts A B C G ENGINEERING TPP,WARTSILA,ETP, WTP ELECTRICIAN/ASST. FOREMAN Activity Description All energy meter reading. Cleaning of electrical panels. All electrical equipments monitoring. Load checking in all motor Log book parameter records. TPP synchronization with grid and Wartsila. All lighting work. Filter cleaning of all AC total 16 nos. Checking all connection of all motor and panels. Checking water levels in batteries. Check Transformer oil level and temp. Check condition of Battery charger. start and stop of 1250 kv DG set. And fire pump Keep ready of all stand by motor, drives for emergency. Control the aux. cons. in TPP Proposed Utilisation(%) Remarks: Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) Net Available man-mins(450*80%) Present Utilisation(%) Proposed Manpower per shift ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 15. YARN GODOWN ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 15.0 15.1 I II III G OR T I II III G OR T 1 BTM GODOWN - - - 8 - 8 - - - 4 - 4 2 ELEGANT GODOWN - - - 8 - 8 - - - 4 - 4 3 FIBRE GODOWN - - - 8 - 8 - - - 8 - 8 4 OUTSIDE YARN GODOWN - - - 11 - 11 - - - 6 - 6 Total 0 0 0 35 0 35 0 0 0 22 0 22 YARN GODOWN Proposed Manpower Remarks YARN GODOWN S. No Section / Work area Designation Present Manpower Manpower Deployment _________________________________________________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 15.0 15.2 15.2.1 a) b) c) YARN GODOWN Proposed Changes & Observations Proposed Changes BTM godown - Deploy 4 personnel instead of the present deployment of 8 personnel based on workload and simultaneous requirement ELEGANT godown - Deploy 4 personnel instead of the present deployment of 8 personnel based on workload and simultaneous requirement Outside yarn godown - Deploy 6 personnel instead of the present deployment of 11 based on workload and simultaneous requirements ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani 15.0 15.3 S.No 1 2 3 4 YARN GODOWN Workload Sheets Summary Area of work WLS Number Fibre godown YAG/03 Outside yarn godown YAG/04 BTM godown YAG/01 Elegant godown YAG/02 ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 122 0.04 9.39 2 1 122 0.13 16.02 3 1 121 0.12 13.96 4 1 5 1.56 7.80 5 1 122 0.04 4.43 6 1 122 0.19 23.71 7 1 121 0.18 21.70 8 1 122 0.08 9.23 9 1 4 1.56 6.24 10 2 55 0.04 3.87 11 1 55 0.18 9.82 12 1 54 0.16 8.89 13 1 3 1.21 3.63 14 2 55 0.03 3.81 15 1 55 0.11 6.07 16 1 54 0.10 5.26 17 1 2 1.21 2.42 18 2 55 0.04 4.07 19 1 55 0.12 6.81 20 1 54 0.10 5.51 Return for the next load From dump to truck De-stack and load the bags on head or shoulder Auto driver return for next transfer Carry the bags upto the door of the truck Return for next load Return for the next load From auto to godown Destack and load the bags on head or shoulder Auto driver shifted to godown Auto driver shifted to Open compound From auto to dump De-stack and load the bags on head or shoulder Carry the bags and dump to the ground Stacking/adjusting the bags inside the godown B) To move the yarn from Godown to open compound and then loading the yarn for job weaving / sale. De-stack and load the bags on head or shoulder Carry the bags upto the auto and dump on it Carry the bags inside the godown and dump Return for next load Auto driver return for next transfer A) Yarn Shifting from packing to godown. De-stack and load the bags on head or shoulder Carry the bags upto the auto and dump on it BTM Loaders/Unloaders Activity Description Return for next load WLS No:YAG/01 WORK LOAD DETAILS SHEET BTM Yarn Godowns Shifts A B C G Packing Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) BTM Loaders/Unloaders Activity Description WLS No:YAG/01 WORK LOAD DETAILS SHEET BTM Yarn Godowns Shifts A B C G Packing Section 21 2 55 0.06 6.11 22 1 54 0.05 2.68 23 2 70 0.04 5.65 24 1 70 0.20 14.13 25 1 69 0.16 11.35 26 1 3 3.87 11.61 27 2 70 0.04 5.02 28 1 70 0.16 11.15 29 1 69 0.14 9.95 30 1 2 3.87 7.74 31 2 50 0.04 3.90 32 1 50 0.17 8.43 33 1 49 0.15 7.24 34 1 50 0.09 4.72 35 1 1 62.87 62.87 Carry the bags upto the auto and dump on it From auto to place inside the Weaving deptt De-stack and load the bags on head or shoulder Return for the next load D) To shift yarn bags from one place to another place in same godown. De-stack and load the bags on head or shoulder Auto driver return for next transfer Return for the next load E) Lot wise and shade wise stock taking in different godowns. To verify lot no and shade no of bags and note verified bag in stock register Auto driver shifted to Weaving Deptt Carry the bags inside godown and dump Carry the bags to a place inside the same godown Return for the next load Stacking/adjusting the bags inside the godown C) To deliver yarn bags from godown to weaving. De-stack and load the bags on head or shoulder Carry the bags from the door of the truck to inside the truck and adjust Return for next load ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) BTM Loaders/Unloaders Activity Description WLS No:YAG/01 WORK LOAD DETAILS SHEET BTM Yarn Godowns Shifts A B C G Packing Section 36 1 192 3.86 741.12 A 1086.30 B 26 C 1368.74 D 3840 E 35.64% F 4 G 71.29% F) For Marking on yarn bags. To note and verify bag no and lot no of packed yarn from packing report and to note and verify bag no and lot no of yarn to be issued or to be despatched Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 2 124 0.04 8.85 2 1 124 0.15 18.33 3 1 123 0.13 16.24 4 1 5 1.87 9.35 5 1 124 0.04 4.67 6 1 124 0.20 24.53 7 1 123 0.18 22.18 8 1 124 0.08 9.42 9 1 4 1.87 7.48 10 2 62 0.04 4.46 11 1 62 0.16 10.16 12 1 61 0.15 8.88 13 1 3 1.65 4.95 14 2 62 0.04 4.98 15 1 62 0.11 6.88 16 1 61 0.10 5.86 17 1 2 1.65 3.30 18 2 62 0.04 5.04 19 1 62 0.11 7.05 20 1 61 0.09 5.74 Return for the next load From dump to truck De-stack and load the bags on head or shoulder Auto driver return for next transfer Carry the bags upto the door of the truck Return for next load Return for the next load From auto to godown Destack and load the bags on head or shoulder Auto driver shifted to godown Auto driver shifted to Open compound From auto to dump De-stack and load the bags on head or shoulder Carry the bags and dump to the ground Stacking/adjusting the bags inside the godown B) To move the yarn from Godown to open compound and then loading the yarn for job weaving / sale. De-stack and load the bags on head or shoulder Carry the bags upto the auto and dump on it Carry the bags inside the godown and dump Return for next load Auto driver return for next transfer A) Yarn Shifting from packing to godown. De-stack and load the bags on head or shoulder Carry the bags upto the auto and dump on it Elegant Spinning Loaders/Unloaders Activity Description Return for next load WLS No:YAG/02 WORK LOAD DETAILS SHEET Elegant Spinning Godowns Shifts A B C G Packing Section ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Elegant Spinning Loaders/Unloaders Activity Description WLS No:YAG/02 WORK LOAD DETAILS SHEET Elegant Spinning Godowns Shifts A B C G Packing Section 21 2 62 0.06 8.00 22 1 61 0.05 3.03 23 1 60 0.03 2.08 24 1 60 0.16 9.87 25 1 59 0.15 8.57 26 1 3 3.87 11.61 27 2 60 0.04 4.44 28 1 60 0.16 9.76 29 1 59 0.14 8.48 30 1 2 3.87 7.74 31 2 50 0.04 3.87 32 1 50 0.17 8.43 33 1 49 0.16 7.88 34 1 50 0.09 4.63 35 1 1 60.66 60.66 Return for the next load D) To shift yarn bags from one place to another place in same godown. De-stack and load the bags on head or shoulder Auto driver return for next transfer Return for the next load Return for next load Auto driver shifted to Weaving Deptt Carry the bags inside godown and dump C) To deliver yarn bags from godown to weaving. De-stack and load the bags on head or shoulder Carry the bags to a place inside the same godown Return for the next load Stacking/adjusting the bags inside the godown E) Lot wise and shade wise stock taking in different godowns. To verify lot no and shade no of bags and note verified bag in stock register Carry the bags upto the auto and dump on it From auto to place inside the Weaving deptt De-stack and load the bags on head or shoulder Carry the bags from the door of the truck to inside the truck and adjust ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 8 Designation Proposed Manpower - - - 4 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) Elegant Spinning Loaders/Unloaders Activity Description WLS No:YAG/02 WORK LOAD DETAILS SHEET Elegant Spinning Godowns Shifts A B C G Packing Section 36 1 184 4.87 896.08 A 1243.47 B 26 C 1566.78 D 3840 E 40.80% F 4 G 81.60% For Marking on yarn bags. To note and verify bag no and lot no of packed yarn from packing report and to note and verify bag no and lot no of yarn to be issued or to be despatched Remarks: Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) Total Workload ( in man minutes ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Present Manpower - - - 8 Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 4 46 2.16 398.11 2 3 23 0.65 45.09 3 1 23 0.96 22.09 4 1 22 0.56 12.26 5 1 10 1.26 12.61 6 1 10 1.83 18.30 7 1 9 1.66 14.94 8 3 20 0.74 44.56 9 2 20 1.56 62.44 10 2 19 1.18 44.75 11 3 20 2.12 127.20 12 2 20 1.50 59.85 13 2 19 1.21 46.09 14 1 20 1.26 25.18 15 1 20 1.84 36.76 C) Issue of Fibre Bales from Go down to BTM Carry from back and load the bale on trolley Carry the bale and place inside upto the processing point Return for next transfer D) Issue of Fibre Bales from Go down to Fibre Dyeing Load two bales on forklift Carry the bales to the fibre dyeong entry pt. and dump Return for next transfer Return for next transfer From elegant entry to the process point Load the bale on trolley Carry the bale and place inside upto the processing point Return for next transfer Carry the bales to the elegant entry pt. and dump B) Issue of Fibre Bales from Go down to Elegant Load two bales on forklift G Packing Section Pull and make pair of bales Carry the bales inside the godown with forklift and adjust Yarn Bags Movement Loaders/Unloaders Activity Description A) Unloading of Polyester / Viscose / Wool Fibre Bales to Go down Destack unloading the bales and place on the ground Work Centre Designation WLS No:YAG/03 WORK LOAD DETAILS SHEET Fibre Godowns Shifts A B C ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Present Manpower - - - 8 Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Packing Section Yarn Bags Movement Loaders/Unloaders Activity Description Work Centre Designation WLS No:YAG/03 WORK LOAD DETAILS SHEET Fibre Godowns Shifts A B C 16 1 19 1.14 21.67 17 3 20 0.65 39.10 18 2 20 0.38 15.22 19 2 19 0.20 7.42 20 2 90 0.21 38.49 21 1 90 0.09 8.33 22 2 90 0.06 9.99 23 1 90 0.15 13.31 24 1 89 0.13 11.51 25 2 45 0.06 5.00 26 1 45 0.25 11.21 27 1 45 0.13 5.91 28 4 5 8.79 175.80 29 2 45 0.04 3.48 30 1 45 0.09 4.25 31 1 44 0.08 3.49 32 4 4 5.65 90.40 33 2 45 0.04 3.65 Return for next transfer Carry the fibre bag and place at the required position Note down the weight and other details in register G) Issue of Fibre Bags from Dye House to BTM deptt. Destack/load bags on head/shoulder Return for next transfer E) Shifting of dyed fibre bags to Go down from Dye House Take the bag upto the weighing m/c,weigh Return trolley for next transfer Return for next transfer Trolley transfer to Elegant deptt. Tie knot on the bags and carry the trolley to elegant deptt. Load the bag on head/shoulder F) Issue of Fibre Bags from Dye House to Elegant deptt. Destack/load bags on head/shoulder Carry the bags and load on to the trolley Return for next transfer Unload the bags inside the deptt Destack/load bags on head/shoulder Return for next transfer Carry and dump at the required place From fibre dyeing entry pt to place stackwise nearby Load the bale on trolley Carry and stack nearby ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Present Manpower - - - 8 Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Packing Section Yarn Bags Movement Loaders/Unloaders Activity Description Work Centre Designation WLS No:YAG/03 WORK LOAD DETAILS SHEET Fibre Godowns Shifts A B C 34 1 45 0.25 11.42 35 1 44 0.15 6.50 36 4 5 4.01 80.24 37 2 45 0.04 3.66 38 1 45 0.13 5.83 39 1 44 0.09 3.98 40 4 5 3.04 60.85 41 1 20 18.87 377.40 42 2 8 0.95 15.14 43 6 8 4.34 208.32 44 1 7 0.43 2.99 45 4 10 2.22 88.80 46 3 5 0.71 10.61 47 1 5 0.98 4.90 48 1 4 0.58 2.31 49 2 55 0.04 4.46 J) Loading & Unloading Job Fibre A/c Destack unloading the bales and place on the ground Pull and make shadewise bunch of Bales. Carry the bales inside the godown with forklift and adjust Return for next transfer K) Shifting of dyed fibre bags to Shade wise stackling in the deptt Destack/load the bags on head/shoulder Return for next transfer Return for next transfer Trolley transfer to BTM deptt. Tie knot on the bags and carry the trolley to elegant deptt. Unload the bags inside the deptt Destack/load bags on head/shoulder Carry and dump at the required place Return for next transfer Carry the bags and load on to the trolley Return trolley for next transfer H) Handling & Packing of Fibre Waste / Empty Bags and delivered to as per direction of deptt. I) Loading of Fibre waste Sale Put waste bales putting on trolly for loading. Moving the bales through Trolly to the truck. ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Present Manpower - - - 8 Proposed Manpower - - - 8 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Packing Section Yarn Bags Movement Loaders/Unloaders Activity Description Work Centre Designation WLS No:YAG/03 WORK LOAD DETAILS SHEET Fibre Godowns Shifts A B C 50 1 55 0.19 10.28 51 1 54 0.16 8.88 52 1 55 0.09 5.07 53 1 27 1.45 39.15 A 2389.23 B 26 C 3010.43 D 3840 E 78.40% F 8 G 78.40% Carry the bags to the nearby place and dump L) Arranging fibre samples to dye house for testing Stack/adjust the bags Return for next transfer Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 11 Designation Proposed Manpower - - - 6 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) 1 1 115 0.21 24.36 2 2 115 0.03 7.97 3 1 115 0.06 7.44 4 1 114 0.05 5.28 5 1 115 0.30 34.62 6 1 114 0.26 30.04 7 1 115 0.09 10.83 8 2 60 0.03 4.10 9 1 60 0.28 16.69 10 1 60 0.22 13.23 11 1 3 0.76 2.29 12 2 60 0.04 4.42 13 1 60 0.13 7.56 14 1 60 0.10 5.81 15 1 2 0.76 1.53 16 2 60 0.04 4.46 17 1 60 0.11 6.74 18 1 59 0.10 5.77 Auto driver shifted to Open compound From auto to dump De-stack and load the bags on head or shoulder Carry the bags and dump to the ground Return for the next load From dump to truck De-stack and load the bags on head or shoulder Auto driver return for next load Return for next load Stacking/adjusting the bags inside the godown B) To move the yarn from Godown to open compound and then loading the yarn for job weaving / sale. De-stack and load the bags on head or shoulder Carry the bags upto the auto and dump on it Return for the next load Return for next load Carry the bags from the door of the truck to inside the godown G Packing Section De-stack and load the bags on head or shoulder Carry the bags upto the door of the truck Yarn Bags Movement Loaders/Unloaders Activity Description A) Unloading the outside yarn without weighment. Checking of bag lot and shade wise from challan . WLS No:YAG/04 WORK LOAD DETAILS SHEET Outside Yarn Godowns Shifts A B C Carry the bags upto the door of the truck Return for next load ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 11 Designation Proposed Manpower - - - 6 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Packing Section Yarn Bags Movement Loaders/Unloaders Activity Description WLS No:YAG/04 WORK LOAD DETAILS SHEET Outside Yarn Godowns Shifts A B C 19 2 60 0.06 6.64 20 1 59 0.05 2.84 21 2 62 0.04 4.57 22 1 62 0.26 16.08 23 1 61 0.26 15.68 24 1 3 4.87 14.62 25 2 62 0.04 4.77 26 1 62 0.15 9.52 27 1 61 0.14 8.77 28 1 2 4.87 9.74 29 2 10 0.03 0.69 30 1 10 0.27 2.75 31 1 9 0.26 2.31 32 1 1 2.46 2.46 33 2 10 0.04 0.72 34 1 10 0.21 2.12 35 1 9 0.18 1.65 Return for the next load To deliver the yarn from godown to BTM Spinning/ Packing/ Fibre Dyeing & shifting back to godown. De-stack and load the bags on head or shoulder Return for the next load Auto driver shifted to Respective godown De-stack and load the bags on head or shoulder Carry the bags inside the godown and dump Return for the next load Return for the next load Carry the bags upto the auto and dump on it C) To deliver yarn bags from godowns to weaving. De-stack and load the bags on head or shoulder From auto to place inside the Weaving deptt De-stack and load the bags on head or shoulder Carry the bags from the door of the truck to inside the truck and adjust Return for next load Auto driver return for next load Auto driver shifted to Weaving Deptt Carry the bags inside godown and dump Carry the bags upto the auto and dump on it ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 11 Designation Proposed Manpower - - - 6 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Packing Section Yarn Bags Movement Loaders/Unloaders Activity Description WLS No:YAG/04 WORK LOAD DETAILS SHEET Outside Yarn Godowns Shifts A B C 36 1 1 2.46 2.46 37 2 85 0.04 6.55 38 1 85 0.17 14.14 39 1 84 0.15 12.26 40 1 85 0.08 6.90 41 1 1 55.35 55.35 42 1 177 5.66 1001.82 43 1 1 277.88 277.88 44 1 30 5.54 166.20 45 1 90 0.95 85.17 46 2 90 0.04 7.26 E) Lot wise and shade wise stock taking in different godowns. To verify lot no and shade no of bags and note verified bag in stock register For Marking on yarn bags. To note and verify bag no and lot no of packed yarn from packing report and to note and verify bag no and lot no of yarn to be issued or to be despatched F) To colloect the sample cones from yarn bags and deliver the SQC for testing and pick up from SQC and repack the same. To deliver four cones of each lot to SQC dept. And one cone lot wise to FIBRE DYEING for checking from new consignment. After checking collect the tested cones from respective depts and placed at appropriately. G) For Repacking of the return yarn bags. I) To lift the bags from wvg dept. to loose godown De-stack and load the bags on head or shoulder Auto driver return for next load D) To shift yarn bags from one place to another place in same godown. De-stack and load the bags on head or shoulder Carry the bags to a place inside the same godown Return for the next load Stacking/adjusting the bags inside the godown H) For loading and unloading issue from loose and job return godown. To note and verify bag no and lot no of yarn at the time of receipt and issue ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm ________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani Department Section Work Centre Present Manpower - - - 11 Designation Proposed Manpower - - - 6 Sl. No Crew Size Freq/ Shift Basic Time (Mins) Total Time (Mins) G Packing Section Yarn Bags Movement Loaders/Unloaders Activity Description WLS No:YAG/04 WORK LOAD DETAILS SHEET Outside Yarn Godowns Shifts A B C 47 1 90 0.28 24.96 48 1 89 0.26 23.26 49 1 4 3.24 12.96 50 1 90 0.04 3.23 51 1 90 0.24 21.98 52 1 89 0.23 20.57 53 1 3 3.24 9.72 A 2051.72 B 26 C 2585.16 D 5280 E 48.96% F 6 G 89.76% Return for the next load Auto driver return for next load Return for the next load Auto driver shifted to Respective godown De-stack and load the bags on head or shoulder Carry the bags inside the godown and dump Carry the bags upto the auto and dump on it Remarks: Total Workload ( in man minutes ) Net Available man-mins Present Utilisation(%) Proposed Manpower per shift Proposed Utilisation(%) Basic Workload per Shift ( in man minutes) Rest & Relaxation Allowances ( % ) ________________________________________________________________________________________ National Productivity Council, Bangalore. 6oteo uth the oemo versoo o| Io||x Prc PDf 6d|tcr Jo remove ths ootce, vst: uuu.ceo.com/oolock.htm