Abstract:
Work study tools are vital in labor intensive industries such as garment, electronic and footwear industries to improve the processing time of tasks, labor productivities, motion of workers and materials and efficiencies of the assembly line. The main aim of this study was to standardize and balance the workload of all workstations in the selected stitching and lasting assembly lines in order to enhance line efficiency and labor productivity. The methodology for this study was incorporated critical investigation and examination of the existing production using work study tools by prioritizing the most important study areas in the factory. The allowance and performance rating factor has been determine based on the work conditions. The normal and standard time for stitching and lasting lines are determined. Daily production capacity of workstations, for stitching and lasting assembly lines has found. To compromise the bottleneck workstations, rearrangement of workstations has been performed considering three important factors such as production capacity and time, machine type and labor efficiency of workstations. Due to balancing the work stations ,improvements have been achieved in line efficency,labor productivity of stitching and lasting lines and increasement of out put rate. In stitching line ,the line efficiency and labor productivity has enhanced from 49.09-61.75% and 5.31-7.55% respectively.With the same method of balancing the lasting line efficiency and labor productivity has been enhanced from 28.56-51.51% and 5.6 -12.17%. Generally, this study has increasesed the overall efficiency of the company from 39 to 49.66%. In addition to rearranging the stitching and lasting assembly lines, implementation framework was developed to adopt the new rearrangement. Through conducting motion study for the movement of leather , non value added activities have been minimized hence the distance and time has reduced by 25m and 41minute respetively. By rearranging the work stations labor productivity and assembly line efficiency have been increased.On the other hand by rearranging the stations capacity of stitching and lasting lines, 2 and 7 workers are reduced respectively.Hence 22,500 ETB of labor cost has reduced per year .