A.

BACKGROUND OF THE STUDY

Introduction

The 20th century World’s globalization and development invited the citizens to

reside in urban areas favoring lifestyles in the vicinity of their work, schools and comfort;

in 2008, for the first time in history, more than half of humanity was living in urban areas.

Behind national development, the construction sector was the engine of growth, along

with of productivity that serves as one of the vital aspects of the construction industry.

To the antique brick, composed of sand and clay; constructions, especially

in the Philippines, preferred the Concrete hollow block having as components sand and

cement. The concrete hollow block, compared to the brick is preferred because of its

durability, sound and fire resistance, rapid production, thermal insulation and for its low

cost. Statistically, CALABARZON region has been ranked 5th in the Philippines in terms

of number of constructions. In line with this, with the non-stop cities’ development and

the construction industry is in its growing phase, the demand for concrete hollow blocks

is also arising.

R.Y. Saligvera Builders Construction and Supply Corporation is a fast-growing

construction company that has a strong focus on business development and value.

They started with small projects to large Government projects which gave the company

the opportunity to introduce itself in construction industry, afterwards, the company also

decided to arise batching plant and produce their own CHB products. The company

consisted of a JIT production, as it is also a contractual company; the first semester of

CHB production implementation went smooth, however, due to lack of standardization,

various problem successively, were found in: workplace condition, work performance,

job allocation, work flow organization, management operation, unsynchronized

production work flow, lack of standard operating procedure. The company’s

performance, didn’t meet the actual demand.

A. Data of the Monthly Production and Demand

The production line of hollow block making process in Calamias has six workers who

are assigned to produce the product.

Three concrete hollow blocks are produced within a process cycle. Finished goods have

an average weight of 8.5 kilograms each. The Architect stated that the company is

having difficulties in coping with increasing demand of hollow blocks to supply the

company for construction services given in the data.

18000
16000
14000
12000
10000
8000
6000
4000
2000
0
Jan' Feb' Mar' Apr' May' Jun' Jul' Aug' Sep' Oct' Nov' Dec' Jan' Feb'
18 18 18 18 18 18 18 18 18 18 18 18 19 19

Demand Output

Figure 1. Monthly Output and Demand of Concrete Hollow Block

 Figure 1 illustrates the monthly production and demand of concrete hollow blocks

from January 2018 to February 2019. It can be seen that the company’s demand is not

constant since the product is produced depending on customer’s order. It is also

presented that the company was not able to meet the demand noticeably by month of

March 2018 up to February 2019. Considering other factors such as number of labor

and days of work, it still clearly show given the monthly demand, company is having

difficulties that needs improvement.

B. Process Flow

The company’s CHB production relies on 3 main equipment producing different

size of Concrete Hollow Blocks, namely Equipment A, Equipment B and Equipment C.

Equipment A produces CHB 4 (Concrete Hollow Blocks 4 inches long and 3

inches wide) used in small construction and the raising of small rooms like bathrooms.

On the other hand is equipment B that produces CHB 5 (Concrete Hollow Blocks 5

inches long and 3 inches wide) used in private and residential projects. Lastly is the

equipment C producing CHB 6 (Concrete Hollow Blocks 6 inches in length and 3 inches

in width) that it is used in government constructions since it is the standard approved by

the government for schools and other government buildings.

The production of hollow blocks consists of four basic processes: mixing,

molding, drying and stacking. In mixing, the raw materials are put together with the

proportions such as 2/3 palanas, 1/3 cement and undefinable quantity of water in the

mixer. Steel pallets are then put inside the equipment, they will serve as the blocks’

bases.
 The process of producing Concrete Hollow Blocks consists of four basic

processes: Preparation, Oil Coating, Mixing, Molding, Drying and Stacking. The current

process is the standard processes used by Ry Saligvera Builders Construction And

Supply Co.

Figure 4. Process of producing cement concrete hollow blocks

Process Description

The following are the process description on producing Concrete Hollow Blocks:

Step 1: Preparation of Materials and Equipment

The process consists of preparing all the raw materials needed from the area

provided such as palanas, cement and water. Applying oil coating on the equipment

was included in the process to provide smooth service where the mixture will be placed.

Steel pallets are placed inside the equipment molder which will serve as the blocks’

bases.

Step 2: Mixing

Raw materials consists of two thirds of palanas, one third of cement and

indefinable amount of water were combined together to produce the mixture.

Step 3: Molding of mixture

The produced concrete mixture will be placed on the rectangular steel container

that lets the concrete mixture dispense gradually inside the equipment’s molder. The

operator will turn on the equipment that will give uniform vibration which sets the mixture

to the pallet. Simultaneously with the vibrating equipment, the operator will perform the

repetitive sliding motion of pushing and pulling of steel container to fully dispense the

mixture into the mold.

Step 4: Compaction of Concrete Hollow Blocks

 When the molds are done, the concrete is compacted by the weight of the upper

part of the molding equipment to fully shape the hollow blocks.

Step 5: Drying

The compacted blocks are pushed upward from the molder and transported to

the material handling facility for drying process. It will take one to three days for the

hollow blocks to be dry and the pallets to be removed.

Step 6: Stacking

After drying the concrete hollow blocks within one to three days, the hollow

blocks will be transferred to the stacking area.

Figure 3. Process flow chart per element
The researchers used the Fishbone Diagram or the Ishikawa Diagram, to identify the

causes behind the unmet demand.

Source: RY Saligvera Corp.

Figure 4. Fish bone diagram of unmet demand

Among the 6 Ms Method and Measurement resulted to be the root causes behind

the problem. In measurement, is presented the absence of standard time: the observers

recorded ten different records, once compared, high standard deviation was found, this

concept is a obstacle to optimal productivity. Second, no standard ratio between the

mixture’s components is followed: the mixture should be composed of 2/3 of palanas,

1/3 of cement and unquantifiable water; during the process itself, the operators

unattentively tend to add the components regardless the standard measures causing

then, wastage of material. Third, lack of equilibrium of tasks: tasks are not equally
divided among the operators, forcing at times severe duties to some operators, while

effortless activities to the others.

Based on Fayol’s principle of management, the company lacked on division of

work, as the operators’ qualifications were not taken in consideration: sometimes drivers

were used in the assembling of CHB, their fatigue factors not taken in consideration and

lack of ergonomically design equipment; unity of direction because no specific order nor

plan were assigned to the operators: they didn’t have target output to encourage or

pressure the operators, tasks not well observed and initiative because based on the

interview with the supervisors, it was observed they had good ideas to improve the

production performance, but they were not listened to.

B.Statement of the Problem

The company consists of a JIT production model, human power number is

allocated depending on the need, the company lacked on standardization of process

and proper organizational flow. As a result, the company encountered series of

production incapability as emphasized by 6996 units of shortage corresponding to an

average of 10% unfulfilled demand.

C.Research Objectives

The aim of this research is to maximize productivity of Concrete Hollow Block

(CHB) Making Process in R.Y. Saligvera Builders Construction and Supply Corporation.

Specifically, it will address the following objectives:

1) To improve the efficiency of CHB Making process by means of simplifying and

eliminating unnecessary actions and procedures via’ Value Stream Mapping;
2) To determine the effective resource allocation by constructing Capacity Design
that will maximize production capacity;

3) To conduct time study to determine standard time, performance rating and to

set standard operating procedure for the process;

4) To assess the efficiency of the established Standard Operating Procedure

compared to the Actual Operating Procedure of the process by performing Work
Sampling Technique;

5) To prove the significance of the proposed methodology given the following

objectives:

i. H0: There is no statistically significant difference between the

productivity level of the process performing the Actual Operating
Procedure and the productivity level of the process simulating the
established Standard Operating Procedure.

ii. H1: There is a statistically significant difference between the

productivity level of the process performing the Actual Operating
Procedure and the productivity level of the process simulating the
established Standard Operating Procedure.
D.Theoretical Framework

Source: https://www.visual-paradigm.com

Figure 5. Theoretical Framework

The theoretical framework in Figure 5 illustrates the Business Process Re-

engineering’s (BPR) flow on how to improve business process effectively. The process

management capability of BPR can help a business design, plan and asses the process

though process map. Business Process Re-engineering will able the company to

redesign process, eliminate hours of unnecessary movements or process and make

more efficient use of valuable time.

Business Process Re-engineering initial step is the mapping and analyzing of the

current process. In analyzing the existing process, Motion and Time Study, Work
Measurement and Value Stream Mapping (VSM) are used. The steps included in

method study are select the work, record the data by presenting charts, diagrams and

models to examine the data and develop a more economical way. Work measurement

is the assessment of human effectiveness by selecting and defining the method to be

used by breaking down the jobs into elements measuring the quantity of work involved

in the methods by direct observation and using time study synthesis. With the methods

to be used, process or workflow will be analyzed and wastes, non-value adding or

inefficiencies will be identified. After that is to redesign new process to visualize desired

business process and solve the problems identified, also with the use of VSM.

Redesigned new process may import the current process map to make changes or start

from scratch. The utilization of Value Stream Mapping (VSM) will be of consideration.

Value stream mapping is a lean management tool that helps visualize the steps needed

to take from product creation to delivering it to the end-customer. The VSM allows the

company to see a top-down overview of the business processes. Method study

improves the methods of production to simplify work. Redesigning is followed by Gap

Analysis with the use of different Industrial Engineering tools such as Flow process

chart, Gang chart, Yamazumi chart etc. Things that will be identified include areas of

changes, gaps to be studied and solutions to address the gaps. Identifying project

works comes next to classify the set of work packages and structure the work leading to

efficient and effective implementation of re-designed process. Subsequently,

implementation plan will be formulated to list the activities to be performed by assigning

the right person to complete the work and setting of completion date for the particular

work. Lastly is the performance assessment wherein KPI for performance measurement
will be identified and conducted on an on-going basis. Assessing the improved working

processes, utilization of machines, materials, and manpower will result to productivity.

E. RELATED LITERATURE

A country's growth engine is the construction industry, along with productivity that

serves as one of the building industry's essential aspects. The construction industry

serves as one of the most important and significant sector that supports a country's

socio-economic development is the construction industry. Approximately 8-10 percent

on average contributed to different countries ' economies as well as fostering growth,

creating jobs for the masses, and creating a link between the economy and other

industries (Dixit et al., 2018). Therefore, improving the building productivity is of critical

importance. Improving the productivity of construction industry is a key issue for

companies and nations to increase profitability, reduce costs, create and maintain

competitive advantage. In order to remain world-class players in a highly competitive

global market, construction decision-makers need to promote individual productivity

strategies that meet business needs.

In line with the industry are the sectors including construction services and

construction manufacturing of masonry units. One type of building construction that can

be used for the construction of residential and commercial buildings is concrete

masonry units specifically the precast material, cement concrete hollow block. Cement

concrete hollow blocks (CHB) are modern building materials and are used as such in all

buildings such as residential, commercial and industrial buildings. The CHB varies in

different sizes and shapes and were widely used in developing countries, including the
Philippines, for masonry work. With the growing phase of modern construction, demand

for materials arises thus higher production is of significant importance. In manufacturing

the cement concrete hollow blocks, raw materials including sand, cement, fine gravel

and water were used. The process of producing CHB consists of four basic processes

such as mixing, molding, drying and stacking. In manufacturing, especially with

construction industry, several problems were encountered thus recognizing the industry

as laggard. Some problems in manufacturing include no standard operating procedures,

poor working environment, lack of man power, low productivity and so on.

Productivity in the production is one of the primary issues that a manufacturing

industry is focused on. Production is any process or procedure developed to transfer a

set of inputs in proper quality and quantity into a specified set of outputs thus achieving

an industry's goals.

According to Palop 2016, the term "productivity" has different meanings for

different people. Depending on who explains productivity, whether he is a politician,

accountant, economist, industrial engineer or construction manager, the term

"productivity" will have a wide variety of meanings. Some will define it as the rate of

production, efficiency, efficiency, performance or production alone. Palop defined

productivity generally as the average direct labor hours required to install a unit of

material. It is said that perfect productivity can be achieved with a 40-hour work week,

with people taking all the holidays and vacation days as planned, all of the engineering

drawings would be 100% complete and no delays of any kind during construction;

everyone would work safely; everything would fit perfectly the first time; the weather

would be 70 degrees F; and there would be no litigation at the end of the project. The
study can be associated with manufacturing in construction industry specifically

production of precast materials were working condition, processes and standards are of

critical evaluation and subject for productivity improvement.

On the other hand, Moktadir et al., 2017 defined productivity as the ratio between

wealth output and resource input used during the production process. Moreover,

measurement of productivity turns output comparison to inputs by calculating a

productivity index.

Output
Productivity =
Input

It is also mention on the study conducted by Moktadir and co-researchers that

productivity can be used to measure the extent to which a specific output from a given

input can be extracted. Moreover, increasing productivity is one of the key issues to

boost more profit from the same resource types. Improving productivity helps satisfy

customers and reduce the time and costs involved in developing, producing and

delivering products. Moktadir et al., also added that productivity includes an effective

relationship to performance measurement for method use, method output, product

prices, and process inventory and time delivery levels. Productivity is regarded as a

profit growth. It is clearly stated that improvement of productivity can be accomplished

by sorting elimination, repairing ineffective processes, simplifying the method,

optimizing the system, reducing variation, maximizing quality or responsiveness of

turnout and reducing set-up time. Productivity can also be achieved by increasing the

value-added content of products or by lowering the unit cost of manufacturing or

reducing the unit cost of manufacturing or decreasing the work content of manufacturing

or line balancing or combining all. Improving productivity is the ongoing process of

improving any type of activity.

Improvement of productivity can be achieved by using Lean Manufacturing.

According to the study conducted in a printing industry by Saihong et al., lean

manufacturing is a popular tool to be implemented in the fields of the printing industry to

achieve successful production goals and is a well-organized method of eliminating

waste or non-value-added activities. Lean Manufacturing is made up of various tools

such as 5S, Motion Study, Work Measurement, VSM, TPM, Kanban, Kaizen and others.

The tools are applicable in any industry including manufacturing in construction industry.

In achieving productivity, a well organized and systematic approach of executing

lean tools must be followed. Business Process Reengineering (BPR) is a powerful

approach to bringing an organization's output to extraordinary improvements. By

improving performance such as speed, cost, shareholder value, customer orientation,

quality and service this approach focuses on business process optimization (Boonsiri,

2016).

One of the researchers that utilize the Business Process Re-engineering

approach is Agunshinta et al., (2015). The research shows that existing business forms

in a clinical research center situated in Bekasi are still run physically. It requires a great

deal of investment to accomplish more procedures, particularly in client administration

and obtainment units. These wasteful procedures are broke down here. Be that as it

may, the utilization of data innovation must be offset with the availability of existing
assets to work. Without supporting assets, particularly HR accessible, data innovation is

nothing. The Business Reengineering Process strategy used to fathom the current

business process, decides procedures to be reengineered, examines elective update,

reenacts the current business forms and the proposed business forms, plays out an

investigation of reproduction results, and looks for corporate open doors utilizing data

innovation. This Business Process Reengineering (BPR) investigate helped the clinical

research center particularly in client administration and acquirement in improving the

productivity and adequacy of existing procedures that will at last diminish cost and time.

Results demonstrated that business forms increment with data innovation use and limit

the utilization of workers.

Moreover Chin-Tsai' et al., (2011) also uses the Business process Re-

engineering. Reseachers stated that “In the changing worldwide condition, so as to

endure, ventures must almost certainly alter their unique business forms.” BChin-Tsai’

and company recognized business process reengineering (BPR) as an effective device

for undertakings to upgrade their inward and outer correspondence and capacity. In the

study conducted, investigation proposes a BPR model for provider choice in hardware

industry. This investigation utilizes a case of the biggest motherboard producer in

Taiwan. The BPR model furnishes chiefs with another perspective about business

forms. In this original copy, the BPR model for buy furnishes chiefs with another

perspective. In the buying office, undertakings dependably put a great deal of exertion

into sparing expenses and avoiding misuse. A way to deal with putting orders

objectively spares working hours for representatives as well as keeps away from

maltreatment in buying conduct. The BPR model gave in this examination should
consolidate the ERP idea and data innovation for augmenting its comfort and

helpfulness. The BPR model offers another thought for procedure improvement; the

ERP idea coordinates purchasers (request) and providers (supply); the IT device

assumes the job of accelerating this reengineering activity. It is evident in the research

that the approach benefits the company by systematic method given by Business

Process Re-engineering.

Corresponding to the use of Business Process Re-engineering as an approach is

the different lean tools to be executed. Work Study, Work Measurement, Methods Study

and Value Stream Mapping are the common tools used in improving a process in a

manufacturing industry. These tools play a significant role in providing innovative ways

and solution to increasing the efficiency of production for a certain industry.

Work study, according to Moktadir et al., (2017), is the investigation process, by

means of a consistent system of the work done in an industry, in order to attain the best

possible use of the men, machines, materials, available in the building at present.

Tapiwa et. al, (2013) also defined work study as the specific examination of the

techniques for doing exercises in order to improve the persuasive utilization of assets

and to set-up benchmarks of execution for the exercises being completed. It is one of

the most useful assets that administration can use to improve efficiency. The

implementation lists of each work think about procedure should yield improved

profitability, improved quality, improved proficiency, diminished personal time, improved

worker resolve, decreased turnover and non-attendance. The term ‘work study’

embraces method study and work measurement. Method study, being the systematic

recording and critical examination of ways of doing things in order to make

improvements whereas work measurement, involves application of techniques. Lack of

maintenance policy to guide the engineering section on how they operate contributed to

most of the challenges being experienced. The reason for a maintenance structure is to

limit or lessen the span of breakdowns in this way expanding plant accessibility. A

compelling support framework will meet or outperform organization targets

In addition, work study can be divided into method study and work measurement

according to Pisuchpen et al., (2014). It is used to systematically study and improve

human working methods by considering all factors that affect the working efficiency and

conditions. After the job of interest has been selected, time study can be examined by

recording all information about the job, breaking the job down into elements, examining

those elements and determining the sample size, recording the time to perform each

element using a stop-watch, assessing the speed of working, converting the observed

time to basic time, determining the allowances, and determining the standard time.

In the study that Moktadir and co-researchers have conducted year 2017 in the

leather industry, improvement of productivity is an important issue. The leather products

industry's profit earning largely depends on improving productivity. The study proves

how the production process and operations gap can be found. Increased productivity

was achieved by implementing work study and method study and establishing new

effective processes for specific operations. The study illustrates in particular the

improvement of productivity in the assembly line of the manufacturing industry of leather

products. Line balancing is the key point in increasing productivity for specific products.

The study also shows the improvement in productivity by reducing work content and

balancing line. A combination of lean and work study technique could be used to carry
out further research. Time study has been taken by stop watch and determined the

basic time for all operation sequences and the capacity of each workstation per day has

been calculated.

In earlier the work content per piece was 80.04 minutes. After line balancing and

critical analysis the work content was 71.03 minutes. So, that the work content reduced

to 9.01 minutes after line balancing and critical method work. In this proposed line the

standard output at 100% efficiency was 656 pieces bag per day. Input of this proposed

line was 582 pieces bag per day. The proposed method helps to increase productivity to

12.71% with reduction of work content and line balancing applying method study and

work measurement.

Moreover, a study entitled Modifying production line for productivity improvement:

A Case Study of Vision Lens Factory (Pisuchpen., et al.,2014) states that improved the

bottleneck process in a lamp assembly line using the basic concepts of work study,

ECLS, and line balancing. The result shows the improvement for both product and

operator. The reduction in production time resulted in better productivity. Khalid and

Saleh (2011) studied the manufacturing process in the automobile industry both before

and after the improvement had been made, by using an operation process chart. The

bottleneck of the process was selected to study and improve to increase manufacturing

capacity.

Also, there are many components that impact the productivity of an assembling

line. The most broadly handled issue is the means by which to improve effectiveness

and efficiency. Motion and time study about system is one of the productivity
improvement strategies utilized in many assembling organizations. Motion and time

consider is characterized as a logical examination strategy intended to decide the most

ideal approach to execute the redundant undertaking and to quantify the time spent by a

normal laborer to finish a given task in a fixed work environment. The points of these

frameworks are to make items at creation rates in the briefest time, in the most

profitable way, economically and with the quality required. The points of the examination

are improving the productivity and processing the effectiveness of a mechanical

production system in little and medium industry. The goals are to re-structure the format

to improve the line execution (Reddy, et. al 2016).

Motion and Time study as a component of Work Study to be considered for a

well execution of productivity improvement. One of the successful researches

conducted by Cury and Saraiva (2018) utilizes the Motion and Time study. The study is

all about the application of motion and time study in the production line of organic

lenses in Manaus Industrial Hub. Researchers stated that the time and motion study

enables continuous improvement within organizations to be developed. A technique

developed in conjunction with the Lean Manufacturing philosophy in the Toyota

Production System, it enables production processes to be optimized, ensuring flexibility,

lower costs and faster delivery of the products to customer.

Work Study can result to Work Standardization which is one of the tools that can

be applied in the continuous improvement of the organization. Standardized work is one

of the most powerful but least used lean tools. By documenting the current best

practice, standardized work forms the baseline for kaizen or continuous improvement. It

reduces the variations of the process and improves the quality of products and
processes. In this contribution is described 5S method, which is used in organizations to

eliminate, respectively elimination of waste in the workplace through five steps. Mĺkva et

al., (2016)

Standardization can, on the other hand, weaken the employees’ choice by

guiding them to operate uniformly and follow instructions in order not to make errors.

But according to Nissinboim et al., (2018) standardization creates and strengthens

situations of choice because employees decide the extent to which they adhere and

execute said standardization. The standard data acquired will be applicable in one of

the lean manufacturing tools to be implemented in the improvement of a certain process

like for example the value stream mapping.

Another lean manufacturing tool is the Value Steam Mapping (VSM). Singh et. al,

(2015) states that “Value Stream Mapping is the visualization and work processes are

streamlined using Lean Manufacturing tools and techniques”. VSM helps in the

processes to identify, demonstrate and decrease waste. Waste is any activity not

adding value to the final product.VSM can serve as a lean manufacturing blue print.

A case study of value stream mapping (VSM) of Rope Manufacturing conducted

by Yuvamitra et al., (2017) states that “In today’s competitive market, in order to

maintain a returning customer base, manufacturing companies must apply continuous

process improvement. One way to achieve constant process improvement is by using

value stream mapping. Value stream mapping is used to visualize the current process

for easier understanding and problem identification. Throughout this case study, Lean

concepts have been applied to the rope manufacturing process. The goal was to
decrease the overall time required for the company to get the customer’s order.” In the

study, lean concepts were applied by changing the setup sheets for all departments, the

processing time will be reduced by an estimated 68%. Reducing the process time will

also affect the waiting time for each order. This case study applied Lean changes to the

information flow system, as well as the material flow system, to reduce the total time

required from the time an order is received to the time the rope is shipped to the

customer.

In addition to this study by Yuvamitra et al., (2017), the material progression of

assembling was likewise considered and it demonstrates that the floor format can make

the entire procedure progressively proficient. 6.5 minutes can be spared in material

taking care of by changing the assembling floor setup to make the material stream

progressively sorted out. This is an absolute investment funds of 33% for material

dealing with time. This contextual analysis likewise demonstrates that having a security

supply of material will also decrease the hanging tight time for the procedure by

evaluated 88%. Executing changes in both the data stream framework and the material

stream framework will spare an expected 75% for the assembling time of the rope. At

the end of the day, the proposed changes will reduce the time it takes to produce the

rope and ship the request from 36 days to 9 all out days.

Another case study is the Value stream mapping in glide manufacturing of Insti-

Tools in Zimbabwe. The case study was performed by Dzanya et. al, 2015. According to

the study, the Glides are basically plastic components manufactured for supporting

beds and sofas (legs). Due to globalization and rapid advances in manufacturing

technology, Small to Medium Enterprises (SMEs) involved in manufacturing of Glides

also needs to improve and be able to adopt new situations and Value Stream Mapping

is the tool for that. Value Stream Mapping (VSM) is a tool for Lean Manufacturing which

is used in mapping and identifying all specific actions required to remove the non-value

activities in manufacturing process. This paper aims to eliminate and improve the quality

in the production of Glides by applying Value Stream Mapping. The current state map

(CSM) was designed, analyzed and suggestions were then given to improve the

operational process whereas the future state map (FSM) was drawn for lean

implementation.

In line with the study of glides, lean production means continuous improvement.

Value Stream Mapping (VSM) have been established to be a useful tool to eliminate

some waste in a cycle and find that there are more waste for you to eliminate in next

cycle. The CSM helped to identify the areas of potential improvement while the FSM

suggest ways to reduce waste and increase throughput. As a result of this study entitle

Value stream mapping in glide manufacturing: A case study of Insti-Tools in Zimbabwe ,

the lead time was reduced by 60.88%, there was no reduction in WIP, Processing time

was reduced by 4% and there was a reduction in manpower of 25%.

Guzel et. al, (2018) case study of textile industry utilizing Value Stream Mapping

implemented increase productivity and effectiveness by removing 64% of lead time with

the use developing a value stream map for a textile producer to find the resource of the

wastes, non-value added steps and look for the appropriate solution for these. Lean

techniques such as 5s, takt time, JIT were applied in this company and the results were

shared with managers of the company. Production Lead Time (PLT) downed from 14.5

days to 5.2 days.

 In addition, the study conducted by Sunk et al., (2015) improving productivity by

deriving and defining target conditions in the value stream of packing also uses VSM.

The authors planned logistic processes, the Operation Sequences of Forklifts of the

Methods-Time-Measurement minutely detailed method descriptions of logistic

processes and transport sequences and applied them as a result, productivity increased

by 36%. The study operated also helped the company to attach itself to continuous

improvement.

With the proper execution of lean manufacturing following the Business Re-

engineering approach, higher productivity will be achieved. The benefit that

organizations can gain after implementing such tool are ensuring better product quality,

reducing equipment breakdown, reducing total costs, utilizing resources properly, line

balanced production, creating a working environment that is full of motivation, and

improving employees ' working attitude. Most organizations that was able to achieve the

result of improvement to minimize any equipment breakdown, lessen idle time, utilized

resources properly and provides a systematic flow resulting to a higher productivity such

considered as improved productivity.

F. Significance of the Study

The study will provide information and available data that could help reduce non

value adding, lessen idle time and improve the productivity to increase the production

capacity of the workers of the Concrete Hollow Block Making process of RY Saligvera

Builders and Construction Supply Company. The results of the study will benefit the

following:

For the society

The findings of the study will contribute to the benefits of the society as

productivity pays a great role in everyone’s life. The study revolving around the

promotion of sustained economic growth, higher levels of productivity and technological

innovation will belong to a step nearer to the goal of achievement full and productive

employment, and decent work, for all women and men by 2030. Promoting sustainable

industries, and investing in scientific research and innovation, are all important ways to

facilitate sustainable development. The ethical implementation of the study’s

fundamentals will contribute to a responsible consumption and production, guiding the

company’s manufacture to output only the adequate amount.

For the workers

The research will set standards, their tasks and responsibilities toward the goal

will be established producing a sense of accountability, responsibility and harmony. The

operators’ tasks will be allocated, avoiding too much stress, evaluating their physical

conditions and limiting their tasks accordingly. Job allocation will avoid confusion

between the operators and through their collaboration, the target goal then will be more
reachable. this study would enable the laborers to improve their methods of working

thus increasing their productivity

For the company

This study will benefit the company to increase the productivity of Concrete

Hollow Block Making Process in RY Saligvera Builders and Construction Supply Co.

Since the demand of the CHB in construction firm is not stable and the company is

lacking to meet the target output, the productivity improvement will have a great impact

to the company. Company workers would also benefit, through the accomplishment of

the goals of the company, the workers could have more motivation and incentives in the

future.

For the researchers

This study will be helpful to the researchers to have more knowledge and

experience in managing and dealing with different problems of the company and how it

can be solved. The study will also help the researchers to be more familiar with different

Industrial Engineering tools and use it in a real-world situation. Also, the researchers will

be able to learn how to have collaboration, time management and commitment to

everything that they do. This study will also enhance the knowledge such as logical and

intellectual skills of the researchers that they can apply in the future. As the researcher’s

experiences broaden through this study, the overall personality of the researchers

would be enhanced.

For the future researchers

 The study will be helpful to the future researchers as it can be used as guide in

conducting their research. For future ideas, this research can serve as a basis for

further improvement of the study giving various ideas that would enhance their

knowledge. The theories, concepts, frameworks, recording and tools used for analyzing

problems can also be used as reference in conducting future study of researchers.

G. SCOPE AND LIMITATIONS

The study will focus on eliminating idle time to improve productivity incurred by

the workers on the line. The study will include the process on producing cement

Concrete Hollow Block; tools will be evaluated to suggest ways on how to improve the

performance and productivity of the company. In conducting time study, the

performance of the workers under the line which produces Model Size number six (#6)

cement Concrete Hollow Blocks used in buildings will only be observed.

Other product of cement Concrete Hollow Block including Model Sizes numbers

four (#4) and five (#5) will not be covered on this study. The proposed improvement

would only cover the five workers on the production line of CHB #6. The study will not

comprise other factors that cause inefficient production such as, poor organization

management, employee absenteeism, employee turnover and dissatisfaction, employee

personal problems and work environmental factors.

Operational Definition of Terms

 All the terminologies listed are used in this paper based on the following

operational definition:

Cycle Time. The amount of time from the moment the operation started of making

Concrete Hollow Blocks (CHB) up to the time it was stacked.

Idle time. The ineffective or unproductive time of the workers and machines in

producing the cement Concrete Hollow Blocks (CHB).

Palanas. Mixed sand and fine gravels that are used as one of the raw materials in

making cement Concrete Hollow Blocks (CHB).

Productivity. The measure on production efficiency of how the target outputs of cement

Concrete Hollow Blocks (CHB) being met in Saligvera Builders Construction and Suppy

Company.

Production. The process of making Concrete Hollow Blocks (CHB) wherein the raw

materials used is mixed to become as finished goods that is then delivered to the

customers.

Time Study. The method which involves direct observation and the measurement of the

operators’ work using a stopwatch to determine the time required for the completion of

producing cement Concrete Hollow Blocks (CHB).

Work Standardization. The method used to efficiently organize the sequence of job

elements for each worker in making cement Concrete Hollow Blocks (CHB).

Flow Process Chart. The tool used to study the process in detail to identify the areas

of possible improvements in the process of making Concrete Hollow Blocks (CHB).

Gang Process Chart. The tool used to illustrate the relationship of the manual work

performed by the workers and the equipment involved in making cement Concrete

Hollow Blocks (CHB).

Value Stream Mapping. The tool used for lean manufacturing to analyze and improve

the flow of information or materials required to produce cement Concrete Hollow Blocks

(CHB).

Yamazumi Chart. The stacked bar chart used to show the balance of cycle time

workloads between the five operators of the Model Size #6 production line of cement

Concrete Hollow Blocks (CHB).