Enhancing productivity through work study - A case of electric power pole cross arm fabrication

In the area of globalization any manufacturing industry must be competent in terms of productivity, quality, cost and delivery. A fundamental improvement in production is necessary to succeed in the international markets. Work study is one of the earliest scientific management methods used to determine the best way to perform production tasks in order to reduce idle time and worker fatigue as a result, increase productivity. Kombolcha Steel Products Industry, the member of MIDROC Ethiopia Technology Group, producing a variety of metal and engineering products, such as steel poles, steel structures, structural hot dip galvanization, corrugated sheet metal, etc. The company's main focus was meeting the delivery deadlines, with little attention to implementing standard working method and procedures during the production. The inefficient method of piercing the holes in the u-channels to fabricate the electric pole cross arms is causing a drop in productivity. The primary objective of the current study is to identify the bottlneck in the process of electric power poles cross arms fabrication, to set standard time for the process and reduce the cycle time. Time and method studies were used to identify the flaws in the current fabrication process and layout design. The efficient technique to manufacture the product has been replaced by redesigning and implementing a new layout. This arrangement accelerated the process by reducing the idle time for the three punching machines that undertake the piercing operations. The modified layout raised production from the target daily production of 420 pieces to 720 pieces in 8 h, resulting in a 71 % reduction in the previous work cycle from 65 to 39 s. After a time and method study, a simple change in the layout with no capital investment not only increased the company's productivity and profitability, but it also reduced worker fatigue due to extra material handling operations of raw materials and intermediate products.