The work was carried out in the metal production company of Las Tunas "Israel Santos Santos", commercially called DURALMET and its general objective is: To develop a working method to increase the use of the working day in the door assembly workshop of the DURALMET company. For the development of the research, direct observation techniques were used as well as the documentary review, which allowed to collect the greatest amount of real information about the company in terms of organization and demonstrate that there is a low use of the working day in the workshop object of study. Taking into account the above, a work method was proposed that allows eliminating the difficulties detected,increase the level of work organization and aims to increase the use of the working day, guaranteeing the delivery of the finished product on time and with the required quality.
Introduction
The Metallic Productions Company, DURALMET belongs to the Las Tunas Construction Business Group. Appointed by Resolution 1161/002, it is established in the City of Las Tunas, Camino del Oriente s / n Zona Industrial. From its creation to the present, it has registered significant levels of economic, professional and commercial growth. It has a Quality Management System, following the model of the International Standard NC ISO 9001: 2008.
Although the company's achievements are notorious, during the investigation some organizational problems were detected that directly influence the use of working hours in the door assembly workshop, which is located in the production UEB. This can be based on studies carried out from 2009 to 2011, which resulted in a 59.72% use of the working day in 2009, 72% in 2010 and 71.25% in 2011, these results were obtained through the application of collective photography, based on this, in the interest of the company, studies were carried out on working hours and regulatory adjustments were made in the workshop based on the results obtained through the application of the timing technique, by university researchers.
Taking into account the aforementioned, it was determined to continue with the studies on the use of the working day based on the interest of the company in continuing to improve the performance of the workers and with it the productivity of the same.
Applying specific tools of industrial engineering that are mentioned later, it was also detected that the organization of jobs does not meet all the requirements for workers to work comfortably without the need for loss of time during their working hours, in addition there is no production flow that guarantees the logical and orderly sequence of operations as well as the proper division and cooperation of work.
The general objective of this research is: To develop a work method to increase the use of the working day in the door assembly workshop of the company DURALMET.
And as specific objectives:
- Determine the causes that have the greatest impact on the use of the working day (AJL) Determine a production flow that guarantees greater production volume without affecting product quality Determine the most efficient work method for the organization of the workplace and the use of the working day.
Materials and methods
Design of the investigation
Research Idea: Study of the working day in the door assembly workshop of the company DURALMET.
In accordance with the above, it is defined as a Scientific Problem: How to increase the use of the working day in the door assembly workshop of the DURALMET company?
To solve the scientific problem raised, the following hypothesis is formulated: if a work method is determined that allows better organization of work, it will be possible to contribute to increasing the use of the working day in the door assembly workshop at the company DURALMET, Las Tunas.
The object of the research: the organization of work.
The field of action: the use of the working day.
As a general objective: To elaborate a work method to increase the use of the working day in the door assembly workshop of the DURALMET company.
The following are set as specific objectives:
- Determine the causes that have the greatest impact on the use of the working day (AJL) Determine a production flow that guarantees greater production volume without affecting product quality Determine the most efficient work method for the organization of the workplace and the use of the working day.
To achieve the objective, different methods of scientific research were applied, including techniques and tools of Industrial Engineering.
The empirical method used was: observation.
The historical method was used as a theoretical method: to compile all the information from the beginning of the Work Organization to the present day. Analysis-synthesis: to be able to establish regularities of the behavior of the Work Organization established theoretically by the different authors and the hypothetical-deductive: to be able to make scientific conjectures during the different stages of the investigation and to be able to reach logical conclusions that respond to the problem raised.
The production process that is analyzed is the assembly of simple galvanized doors with tongue and groove cover. To carry out this process, the company has a workshop dedicated exclusively to this activity. 20 workers work in the workshop.
In the workshop, 6 jobs are currently working that close doors, that is, they carry out the operations of placement of chirrys, assembly of frames, placement of key and accessories, as well as the union of the leaf and the frame, 1 position of work for the welded joint of the hinges to the vertical frame, 1 workstation for the placement of crossbars to the leaves and a drilling machine to open the key hole.
The raw material is supplied by the cutting and forming workshop.
The production structure is online or by item because in each job a logical order is followed to carry out the operations, although there is no production line in the workshop and the type of production is massive because there is a reduced nomenclature of items. a large volume of production and the jobs will carry out the same technological operation.
The production process goes through different stages, starting with the issuance of the production order, the request for materials, continuing in the cutting and shaping, assembly and finishing processes until reaching a finished product or carpentry ready for commercialization.
The results of the visits to the workshop gave rise to important reflections on the situation of the workshop and allowed to elaborate and propose solutions that will greatly favor the development of the company.
Among the problems that affect the proper development of the production process in the workshop are lighting, ventilation, noise is present but for this there is protection through ear muffs, on the other hand lighting and ventilation are not enough, since the The premises are a bit closed and in the afternoon the heat becomes stronger, the existing fans do not satisfy the needs of the workers. Although the luminaires that are assigned are in good condition in all the workstations, it should be noted that it is not enough for the characteristics of the aforementioned area. On the other hand, it is necessary to point out indisciplines such as smoking during work hours, constant departures from the job and even from the workshop, late arrivals,In the collective photograph taken at one of the jobs, a 71.25% use of the working day was obtained as a result.
Photography Summary
Calculation of the use of the working day
During the exchange with the workers it was learned that sometimes there are delays in the delivery of raw material from the cutting and forming workshop and other times they have to wait for the welder to have their frame legs ready with the hinges. The workers also show dissatisfaction with the payment system, which is by collective piecework and feel unmotivated, although some say that it is better this way because even if they do not work much, they still pay them and the stimulus depends on everyone. They also show disagreement due to the delay in the delivery of the toilet, as well as the poor quality of the gloves. The workers in this workshop are exposed to contact with sharp and pointed objects, falling to the same level, poorly conceived work processes, poor handling of objects, flying particles that come off,collision with moving objects, collision with immobile objects, blows by tools deficient for use, entrapment by equipment (forklifts), contacts with energized lines (open PGD), noise in the work environment, electric shocks due to not being insulated, not to use properly MPI, possibility of fire, explosion in hoses and pneumatic equipment.
Behavior of the elements of work organization in the workshop.
Division and cooperation of labor
The form of division of labor is by function because there is a separation between processing jobs and preparatory jobs, or between basic jobs (drilling, chirrys, assembling) and auxiliary jobs (tool setting). This is because the workers who participate in the process do not carry out the same work, there are direct workers (the carpenters) and indirect workers (the workshop manager), the former are those who carry out the work properly, those who directly transform the raw material until it becomes a finished product, the seconds are those who prepare the work. It is important to note that an excessive division of labor results in an increase in the monotony of work and an increase in the degree of fatigue both physically and mentally,these things that influence the worker's state of mind and health. In the door workshop, as indicated above, there are 6 tables that carry out the same operations, this results in the workers taking less advantage of the work time since the operations are sometimes very complex, in addition they must change the augers and nozzles of the squeaker every time they are going to change operation, which requires an expenditure of time that, despite not affecting the use of the working day, if it is eliminated, it could offer better productive results.This results in the workers making less use of their work time since operations are sometimes very complex, and they must also change the augers and chirp nozzles every time they change operations, which requires an expense of time. that despite not affecting the use of the working day, if it is eliminated it could offer better productive results.This results in the workers making less use of their work time since operations are sometimes very complex, and they must also change the augers and chirp nozzles every time they change operations, which requires an expense of time. that despite not affecting the use of the working day, if it is eliminated it could offer better productive results.
The form of cooperation is within the brigade, this can be categorized as specialized, since they are made up of workers who practice the same trade.
Organization and service to the workplace
Organization of the workplace
In the workshop under study there are manual and mechanical-manual jobs, individual and collective. In the workshop, a supply to the workplace with all the necessary means to carry out the activities is not guaranteed. The equipment is arranged in each work station in such a way that it does not affect the good performance of the workers, but the means such as augers and chirrys have to look for them in the warehouse, and when an auger is damaged or the chirrys end they workers find it necessary to stop production to go out and find these means, which causes delays in the process and sometimes indiscipline because the workers leave the position and take longer than necessary to fulfill this task,In addition, sometimes the scarf or the workshop manager who is in charge of supplying these products is not at his job. Each position is guaranteed the necessary means of protection as they are; gloves, ear muffs, boots and clothing to ensure worker safety, although these are not always adequate and do not have the quality required for the work carried out.
On the other hand, the cutting and shaping workshop sometimes does not deliver the raw material in time and form, which causes delays in the production process.
Service to the work media
The company has a Preventive Maintenance Plan that is designed and implemented at the company level in order to maintain the ability to supply products that meet the established requirements. In addition, corrective maintenance is carried out when necessary.
In the workshop under study, the maintenance and conservation of these equipment and working means are carried out against failure, and there is also a scheduled maintenance plan that is carried out to the column drill every three months, as well as to the welding machine and the emery stone, in the case of tools such as drills and grinding machines they only go to the maintenance area when they suffer serious damage, in the case of small breakdowns the same workers repair them.
Oil is assigned to each workstation to lubricate its work tools before starting the activity every day. This workshop has individual air compressors due to the great demand it has and they are checked once a month. The documents with which each job is operated are within the reach of the worker. The space for the location of the tools is quite comfortable, it does not make it difficult at all to have them. However, although there is a maintenance plan, sometimes the production process is paralyzed or slowed down due to breaks in the air hoses that sometimes occur due to the carelessness of the worker who drills it with the bit, in these cases it is necessary Find the technician in the maintenance area and wait for him to change the hose.
Service to work objects
Efficient handling of work objects is carried out. The movement of the objects is correct, since there are no crossings or setbacks in the flow of circulation. There are no long journeys, unnecessary transshipments, repeated or supplementary movements in the handling of materials. The projection of the movement of materials is in a straight line, this allows the worker not to deviate from his path. The movement system is quite safe, which does not mean that accidents can occur during handling, so it is necessary for workers to be very disciplined, use their means of protection correctly and be cautious during their movements.
Service to the workforce
The organization works on the implementation and certification of a Occupational Health and Safety System with the aim of eliminating or minimizing risks for workers and other interested parties that may be exposed to risks related to their activities.
The company has a medical post, the workers' dining room where food preparation is regular. The premises to satisfy the biological needs are located inside the workshop, so the workers do not have to leave their workplace to satisfy their personal needs, they are kept clean and in optimal conditions. The workers are guaranteed the service of special clothing and means of personal protection such as gloves, earmuffs and aprons, in the case of the gloves they state that they are not of good quality and the aprons in previous years were not lacking but are currently being presented problems with the supply of these, since they are not enough to change them periodically,This means of protection is very important due to the risks faced by the workers in this workshop.
The MICONS is in charge of supplying the means of protection, but sometimes the company has to assume the shortages of boots and other means that it acquires through the Cuban fund of cultural property.
Method and procedures of the job
In the workshop the activities are classified into manuals and mechanical - manuals so we can say that the working methods correspond to the existing technology.
It is important to note that this research allowed us to know that in this workshop, given the form of division of labor, the production process is not organized in the form of flow. What causes some workers to finish first than others and take less advantage of the working day, indiscipline is very frequent and the process tends to be less organized.
Through the measurements made in the workshop during the investigation, it was possible to determine through stopwatches, clocks and other means, the duration times of each of the activities carried out in the door assembly process. These data allowed us to know the capacity of the workers in each of the jobs and arrive at the conclusion that they are underutilized because the analysis of the activity that constitutes the limiting point showed that the workers have the capacity to make 204 doors daily, it is clear that this number for a duo of workers is a bit strong, but if they had the proper organization of the workshop this would be possible. In addition, the working method of this activity was analyzed, which constitutes the limiting point that is the placement of 3 × 10 chirrys,in one of the jobs and the result was positive, that is, the workers correctly apply this method of work, although it is important to note that all jobs do not apply the same method, which causes differences in the pace of work and This is one of the reasons why some finish first than others and also lack of discipline and leaving the job, factors that greatly affect the use of the working day.factors that greatly affect the use of the working day.factors that greatly affect the use of the working day.
For example, in some jobs we could observe that the workers develop another method for this operation, that is, in batches; The worker who works with the drill drills a batch of 5 doors and waits for the worker with the squeaker to finish those 5 doors to start the next batch of 5 again, this of course generates a TITO within the working day. In the collective photograph taken in this job, the previous approach is demonstrated. The workers who perform this method state that it is faster and that it allows them to take more rest during the activity.
Other jobs carry out the work method in this way: the workers begin with the adjustment of the tools in 5 seconds, then the worker who works with the drill looks for the door leaf that only takes 1 second because it is found correctly located near the station, it opens the holes in 49 seconds and passes the blade in one second to the worker who works with the chirriadora, he places the chirrys in 65 seconds and places the blade in position for the next operation, this takes 1 second. The analysis of this method allowed us to know that this activity can be carried out 204 times a day, so that is precisely the volume of production that can be obtained in the workshop in one day, since this is the operation that constitutes the limiting point.
Assessment of working conditions
Audiometry and temperature studies carried out in the workshop under study by other researchers yielded the following parameters that are above the permissible level, that is, the average noise level was approximately 90 decibels, to protect themselves the workers use ear muffs that reduce the noise considerably. There is a hygienic-sanitary service in the workshop, the company has a medical post for emergencies as well as a workers' dining room for snacks and lunch, they also have cold water in the workshop.
There are problems with lighting and ventilation caused by the lack of fans, in addition to the fact that the place is very closed and the operations are quite strong. On the other hand, the workers are not exposed to dust or toxic substances.
The workshop is characterized by being generally clean and organized, workstations are easily accessible, all workers use their work clothes properly, as they have overalls, boots and gloves and aprons although these are not in good condition. conditions, as the company does not have to replace them.
Labor discipline
Through the collective photograph taken in one of the workstations of the workshop under study, a 71.25% use of the working day was obtained as a result, this result is mostly given by the high percentage of TIDO, which is given for late arrivals, early departures, for the tendency of workers to be distracted from their work, to leave their position, to smoke, to talk during working hours.
Below is the calculation of the use of the working day:
With the elimination of the aforementioned time losses, an increase in productivity would be obtained, reflected in the increase in the use of the working day:
The increase in total productivity would be 55.5%
All these elements previously analyzed are closely linked, we must not see them separately but as a very close relationship, since one leads to the other.
This study allowed to know the degree of use of the working day that the workers who work in the door assembly workshop of the DURALMET company have and the analysis of the elements of the work organization revealed the causes of this insufficient result.
Based on the analysis carried out previously, the general problem-solving method was applied in order to determine what is the fundamental problem that is affecting this workshop, what are the causes that generate it and how it can be solved. The results using this tool are shown below.
General troubleshooting method
I: Main Problem
Insufficient use of the working day of 71.25%, in the door assembly workshop of the company DURALMET, Las Tunas, in 2011.
Desired State: achieve a better use of the working day in the door assembly workshop of the company DURALMET, Las Tunas in 2012.
II: Potential causes
- Insufficient division of labor Neglect of the workers when using the tools Supply to the workplace with all the necessary means is not guaranteed Indiscipline of the workers Loss of time by TITO, TIDO Delay in the delivery of raw material Poor quality of means of protection. (Gloves) Inconformity of the workers due to the poor quality of the means of protection (gloves and aprons) and due to delays in their delivery All jobs do not carry out the same work method There is no production flow in The workshop Existence of noise, heat, poor lighting Indisciplines for (late arrivals, early departures, smoking, talking during the activity.)
These problems are summarized in the cause-and-effect diagram below.
III- Alternative solutions
- Divide work by technology that establishes the distribution of workers in correspondence with the technological division of the production process, that is; by activities or operations, through this form the specialization of the work is achieved.Guarantee workers the necessary means of work in their position to avoid delays caused by the change of bit, to look for chirrys.Take measures to guarantee that all positions carry out the work method correctly Carry out a study in the cutting workshop to adjust their double shift so that the raw material can be supplied without difficulty to the two workshops Encourage the sense of belonging in the workers, so that they take care of their means of work.Putting into practice a production flow in the workshop that favors the increase in the daily production volume and also contributes to a better organization of work in the workshop, and to the better use of the capacities of both workers and equipment. windows in the workshop Strengthen ideological work with the workers, to guarantee that each worker contributes more to the production process, so that he feels closer and closer to the process as a whole, that the fruits of his work materialize in the finished product, this means that the worker does not lose the incentive for work and feels that his work is important.Open more windows in the workshop Strengthen the ideological work with the workers, to guarantee that each worker contributes more to the production process, so that he feels closer and closer to the process as a whole, that the fruits of his work materialize immediately In the finished product, this means that the worker does not lose the incentive for the work and feels that his work is important.Open more windows in the workshop Strengthen the ideological work with the workers, to guarantee that each worker contributes more to the production process, so that he feels closer and closer to the process as a whole, that the fruits of his work materialize immediately In the finished product, this means that the worker does not lose the incentive for the work and feels that his work is important.
IV- Selection and planning of the solution.
Put the analyzed work method into operation in each of the workstations and ensure that it works correctly and as described below:
This method begins with the adjustment of the tools in 5 seconds, then the worker who works with the drill looks for the door leaf that only takes 1 second because it is correctly located near the post, it opens the holes in 49 seconds and passes the sheet in a second to the worker who works with the chirriadora, he places the chirrys in 65 seconds and places the sheet in position for the next operation, this takes 1 second. The analysis of this method allowed us to know that this activity can be carried out 204 times a day, so that is precisely the volume of production that can be obtained in the workshop in one day, since this is the operation that constitutes the limiting point.
AR = time before round
NR = number of rounds
P = Dynamics of productivity
As can be seen in the calculations, productivity increases by 13.3% with the performance of this work method.
Conclusions
The organization of work in the door assembly workshop of the company DURALMET, Las Tunas is very complex, since there is no production flow that guarantees the continuity of the production process.
The proposed work method allows to obtain a greater volume of production and better organize work.
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