BMFI 2112 WORK SYSTEM DESIGN

(ASSIGNMENT 1)

WORK SYSTEM DESIGN TIME AND MOTION STUDY

Prepared by: JAKAN A/LSATHIYANANDAN ELANGOVAN

(B051920058)

Checked by: PROFESOR MADYA DR SERI RAHAYU BINTI KAMAT

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TABLE OF CONTENT

NO CONTENT PAGE

1 Introduction 2

2 Problem Statement 2

3 Challenge 2-3

4 Literature Review 3-4

5 Solution 5

6 Result 6
Activity Chart 7
Worker Multimachine Activity Chart 7
Time Study Analysis 8-9

7 Conclusion 10

8 References 11

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1.0 INTRODUCTION

Productivity Improvement Through Motion and Time Study

A Manufacturing or Service Industry's productivity is impacted by a variety of factors.

How to increase productivity and efficiency is the topic that is most frequently
discussed. Many manufacturing or service organization businesses employ the motion
and time research technique as a productivity development tool. How to increase
productivity and efficiency is the topic that is most frequently discussed. Many
manufacturing businesses employ the motion and time study technique as a
productivity development tool. This assignment's goal is to explore motion and time
study implementation-related concerns and how they affect service industry Lazada
Warehouse productivity development. Lazada is an international e-commerce company
or can state as a Service Industry. The activities of this organization are workers should
be responsible for performing an array of duties such as receiving and processing
incoming stock and materials, picking and filling orders from stock, packing and
shipping orders, or managing, organizing, and retrieving stock.

2.0 PROBLEM STATEMENT

• Poor in facility layout of warehouse which the environment were unmanageable.

• Ergonomic Factor
a. Awkward posture
b. Repetition motion
c. Static posture
d. Human error
• 80% were used human energy exclude the sorting which result to delay in shipping the
things to customer and deliver the item wrongly to the customer due to exhaustion.

3.0 CHALLENGE

Lazada claimed that the employment opportunities they provide are "not your standard
warehouse positions," requiring different scales of operation including using a forklift

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 and transporting huge boxes to pick, pack, and ship goods. According to Dylan Hunt's
book Logistics of Logistics, there are three key warehouse competencies: speed;
productivity should be continuously evaluated by management on an individual basis
for each employee. Accuracy: any mistakes made in the warehouse could be very
expensive for the business to repair.

Although the public's preference for Lazada has grown in recent years due to its
convenience over direct purchasing, which can save time, it obviously has an impact
on the employee who works in the Lazada warehouse because, because of the high
demand, the quantity of items in the warehouse is high and bulky due to the facility's
inconsistent layout. Where the employee is required to work for an extended period due
to those issues, as well as ergonomic issues that cause the item to be delivered to
customers late.

The temperature in the warehouse is quite high, which could lead to worker discomfort
and injuries. It could also impact the products, which might break or sustain other
damage, especially ones that must be kept in good shape. The workplace is unsafe for
the personnel because of the high temperature, which puts their health at risk and could
cause heat stroke due to improper ventilation.

4.0 LITERATURE REVIEW

A quick peek at the fundamental components of a warehouse system might assist in

choosing the appropriate deployment to better comprehend this creative application and
to realize significant benefits.

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Receiving: This procedure itself can be divided into smaller ones as follows (placing a
purchase order, preparing space in the warehouse, unloading (manual or automated),
verification, filling in the database.

Put away: Distributing things to the best location in the warehouse. Here, it's crucial
to correctly identify each SKU (stock keeping unit) and place it in the appropriate
location. To ensure the security of the items and the workers, storage conditions are
equally important.

Picking: Process of retrieving products from a storage location in accordance with a

customer's order. It is considered to be the most expensive, time-consuming, and error
prone. Voice systems and portable scanning equipment can greatly cut down on errors
and save a bunch of time in this situation. Consider using one of the picking techniques,
such as cluster picking, zone picking, wave picking, etc.

Packing: Assembling the specified components, ensuring their quality, and preparing
the final product for shipping. It's critical to have all the relevant information about the
order at this time, along with the type and quantity of packing material needed for each
order.

Shipping: Delivering products to the customer and ensuring their security and
punctuality. Again, in this case, meeting consumer needs requires proper scheduling,
labour management, and tracking systems.

Returns: It is important to correctly identify, classify, and handle returned units,

whether that means restocking them, sending them for repair, tossing them in the trash,
returning them to the vendor/seller or manufacturer, etc.

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5.0 SOLUTION

Although Lazada is well known E-Commerce company but there are things should be
improved to make sure the well-being of employee and working environment of
warehouse. Here there are some ideas for the solution to overcome the problems that
faced in the warehouse. Vertical lift storage modules system’s warehouse management
system was concept of with automated height adjustments depending on items, no space
is wasted between trays. Reduced footprint and storage area mean lower energy costs,
more efficient processes, and cleaner operations. It more save which can less the
ergonomic hazard among the operators and keep the warehouse tinnier, wider, and
clean as well. Besides it minimizes the error during work in shifting the carton in each
station and avoid accidents in arranging loads at the rack by using ladder or hydraulic
jack

Before came with idea for the solution After came with idea for the solution by
installing Vertical lift storage modules
system

Basically, from this solution it would bring a huge impact on motion and time study for
productivity after introducing the concept like Vertical lift storage modules system’s
warehouse management system. Where it manages in more than 40000 goods according

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 to city that have being ship for, after the sorting process. The goal of motion and time
study is to eliminate superfluous labour and develop methods and procedures that are
the most efficient, demand the least amount of work, and are appropriate for the
employees who will be utilizing them. The improvement of this warehouse will provide
tools for measuring work to calculate a task's performance or productivity index.

6.0 RESULT

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 6.1 ACTIVITY CHARTS
Shading Color Activity

Black Blue Operation: Performing an operation. Worker operating on or

handling material at workplace, Machine performing an
operation on automatic or mechanized.
Grey Yellow Inspection: Worker performing an inspection an inspection, to
check for either quantity or quality.
White (Blank) White Idle time: Worker or machine is idle, waiting, or stopped

Diagonal lines Green Moving: Worker walking outside immediate workplace

Horizontal lines Red Holding: Worker holding an object in fixed position without
performing any work on it.

6.2 WORKER-MULTIMACHINE ACTIVITY CHART

Sequence Work Element Description Worker Worker Machine Machine Cumulative
chart Time chart Time Time (min)
(min) (min)
1 Employees receive the
goods from the seller or
vendor. Then checking the
condition of the items and 15 (Idle) 15
scan it proceed next process
sortation.
2 Sorting the items according (Idle) 10 25
to the location the items.
3 Distributing items to the
location in the warehouse by
identify each SKU (stock (Idle) 18 43
keeping unit) and place it in
the Vertical lift storage
modules system
4 Take off the product from the
storage location with (Idle) 5 48
accordance with customer
order’s date
5 Specified components,
ensuring their quality, and 20 (Idle) 60
preparing the final product
for shipping
6 Delivering products to the
customer and ensuring their 720 (Idle) 780
security and punctuality
7 Identify and handle returned
units, whether that means 60 (Idle) 840
restock it or send to seller for
repair.

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 6.3 TIME STUDY ANAYSIS

Lazada Warehouse as per study consists of 7 processes exclude 2 process which is

improvement of solution for warehouse. The results of the time study's initial sample of one
observation are displayed in the following table. Each component's performance rating factor
(PR) is displayed, and the total workers allowance is 9% and machine allowance is 4% of the
total normal time.

Performance rating: The analyst or pace of the worker is typically used to evaluate
performance in relation to the organization's notion of standard performance.

Standard Performance (PR) = 100%

Slower Pace than Standard (PR) < 100%
Faster Pace than Standard (PR) > 100%

In this case the worker helped to do this analysis is skilful workflow process that did by
employee such as pick and pack service.

Allowance: The allowance given to this situation:

• Personal allowance – 5%
• Standing allowance – 2%
• Awkward allowance – 2%
• Machine allowance – 4%

Standing allowance for this work because most of the picking and processing is done while
standing. Due to the fact that workers must slightly bend their bodies, an awkward allowance
(bending) is then supplied. Additionally, several process steps have been completed with the
aid of machines. Finally, workers are provided personal allowances to help them with personal
concerns.

Compute average time

Job Observed Time Performance Average

Element Rating time (min)

1 15 15 13 1.0 14.3
2 10 11 10 1.1 10.3
3 18 17 18 0.9 17.7

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 4 5 6 5 1.0 16
5 20 20 19 1.0 19.7
6 720 710 715 0.8 715
7 60 55 62 0.6 59

Compute normal time

Normal Time = Average Time x Performance Rating

Normal Time Element 1 = 14.3 x 1.0 = 14.3 minutes

Normal Time Element 2 = 10.3 x 1.1 = 11.33 minutes

Normal Time Element 3 = 17.7 x 0.9 = 15.93 minutes

Normal Time Element 4 = 16 x 1.0 = 16 minutes

Normal Time Element 5 = 19.7 x 1.0 = 19.7 minutes

Normal Time Element 6 = 715 x 0.8 = 572 minutes

Normal Time Element 7 = 59 x 0.6 = 35.4 minutes

Total Normal Time = 684.66 minutes @ 11.41 hours

Standard Time

Standard time = Total Normal time (1 - Apfd)

Standard time = Tn (1-Apfd)

= 684.66 (1 + 0.13)
= 773.66 minutes

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7.0 CONCLUSION

As a conclusion the time studies and efficiency improvements might be crucial for employee
welfare. It can aid in the development of better, safer work environments. By discover and
reduce redundant and potentially unsafe movements and actions on the plant floor, thereby
lowering the work required to complete jobs by making some improvement it in it, and Lazada
is the finest example. Standard time is a very helpful statistic for industrial engineers. It allows
them to evaluate their plant’s efficiency with industry norms. These may include real-time
inventory visibility, decreased costs, error-proofing, productivity, or efficiency increases. It’s
true that expenses vary from solution to solution based on the needs. Basically, this assignment
to find out the problems Lazada warehouse and to make improvement working environment
especially the worker that to avoid ergonomics hazards as by make upgrade the environment
of warehouse, also to identify the entire time study and motion of each process flow in the
warehouse and analysis it to find the normal and standard time.

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8.0 REFERENCES

• Mohd Razali Muhamad 1 & Wan Hasrulnizzam Wan Mahmood 2, Productivity

Improvement Through Motion and Time Study.
http://eprints.utem.edu.my/id/eprint/11217/1/Productivity_Improvement_Through_M
otion_And_Time_Study.pdf

• Joel Pinaroc, Benefits a logistic engine for Lazada (November 2, 2022).

https://golocad.com/blog/benefits-of-a-logistics-engine-for-lazada/

• Mordor Intelligence, Warehouse Automation Market - Growth, Trends, Covid-19

Impact, and Forecasts (2022 - 2027).
HTTPS://WWW.MORDORINTELLIGENCE.COM/INDUSTRY-
REPORTS/WAREHOUSE-AUTOMATION
MARKET?GCLID=CJWKCAIA7IGCBHA8EIWAFFUDSSOH42DYVIMVORILM
IWHMAVZIXJW51MLFW78DPCXKEI_NAWWUUMVWBOCJ_EQAVD_BWE

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