CHAPTER 1

INTRODUCTION AND RESEARCH DESIGN OF THE STUDY

Sr. No Title

Page

No.

1.1 Statement of the Problem 1

1.2 Need of the Study 5

1.3 Objectives of the Study 6

1.4 Assumptions of the Study 7

1.5 Hypothesis of the Study 8

1.6 Significance of the study 9

1.7 Research Design 10

1.7.1 Area and scope of the study 11

1.7.2 Period of the Study 13

1.7.3 Sample and Sample Size 14

1.7.4 Sources of Data Collection 16

1.7.4.1 Primary Data Collection 17

1.7.4.2 Secondary Data Collection 18

1.7.4.3 Techniques of data collection and its justification 18

1.8 Statistical tools and techniques used 19

1.9 Data Interpretation and Analysis 20

1.10 Limitations of the Study 20

1.11 Terms and definitions of study 21

1.12 Chapter Plan 25

1

CHAPTER 1

INTRODUCTION AND RESEARCH DESIGN OF THE STUDY

1.1 Statement of the Problem:

This study is about labour productivity improvement through application of

stopwatch time study method and MOST in Skoda Auto India Private Limited. The

measurement of the work is in terms of productivity of material, money, method and

labour. Labour is prime in any manufacturing company as it determines its

performance, growth and quality of progress. To know the productivity performance

it s essential to apply certain work measurement techniques to measure the work

performed by the labour. Hence work study and its measurement is an important

management tool to achieve higher productivity. It is related to human work, method

of doing work and standard of performance. The survival of any organization is

dependent on use of latest technology and efficient methods of production. To

improve efficiency of production it needs effective utilization of plant, equipment and

labor. This is achieved by using work study which studies method and evaluate the

performance. It divides work into smaller elements, studies it, and rearranges it to get

same or higher productivity at reduced cost. According to International Labor

Organization (ILO) work study is the technique of method study and work

measurement employed to ensure the best possible use of human and material

resources in carrying out a specified activity. Thus the work content has two

constituents. Work measurement is the application of a set of techniques intended to

establish quantum of work to be done by an operator in a given time of a specified

task, under specified conditions and at defined level of performance.

The measurement of the work in terms of productivity of material, money,

method, labours and ultimately overall management is prime in any company which

determines its progress and growth. Time study is the technique of work measurement

to establish time for a qualified labour to carry out specified task under specified

conditions and at defined levels of performance. Therefore an attempt has been made

in the present study to measure and analyse the performance of the labour for

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maximum productivity improvement. This must be linked with the time study hence;

time study is the technique of work measurement to establish time for a qualified

labour to carry out specified task under specified conditions and at defined level of

performance. There are multiple productivity improvement techniques such as

productivity indices (Labour, Machine, Material), Japanese productivity improvement

technique (Kaizen, TQM, JIT, Quality circles etc.), Work study techniques (Method

study and Work measurement), Work measurement techniques (Time study, MOST,

Work sampling etc.) Thus an attempt is made to measure and compare the

performance of time study and MOST technique for productivity improvement

purpose.

Productivity is some relationship between output and input. It is quantitative

relationship between what we produce and what we have spent to produce. On the

other hand, according to International Labour Organisation productivity is the ratio

between the volume of output as measured by production indicates and the

corresponding volume of labour input' as measured by production indices and the

corresponding volume of labour input as measured by employment indices1.

In countries where capital and skill are short, while unskilled labour is

plentiful and poorly paid, it is especially important that higher productivity

(improved) should be looked for by increasing the output per machine or piece of

plant or per skilled worker. Improving productivity means increasing or raising

productivity with the help of using same amount of materials, machine time, land,

labour or technology.

One of the oldest tools used by industrial engineers in work measurements is

stopwatch time study2.

Time study that originated by Taylor and developed by

Gilbreths was used mainly for determining time standards and motion study. Time

study is the technique of establishing an allowed time standard to perform a given

task, based upon measurement of work content of the prescribed method, with due

allowance for fatigue and personal and unavoidable delays3.

3

According to Rice (1977) 4

, over 89 percents of the companies that perform

work measurement used time study. The technologies are rapidly growing everyday

but there are still no tools that can replace time study method completely. They only

invented equipment that can improved the tools and made it users friendly. According

to Niebel (1993)5, computers produce standards from fundamental motion data up to

50 percents faster than manual methods. The computers also provides a simple and

convenient way to make time studies, monitor and measure machine and equipment

performance, make work sampling studies, and perform other data-gathering

activities. Even though there are many techniques and equipments to perform the

time study, but basically the concept is just the same. In manufacturing industries,

especially for industries that implement 90 percents of manual production time

study is very crucial because time study can reduce and control costs, improve

working conditions and environment and motivate people.

On the other hand, MOST stands for Maynord Operation Sequence Technique

is one of the important techniques used for improvement in labour productivity. Work

measurement is a sound management tool to be used as a basis for planning,

scheduling, estimation of costs and evaluation of performance. Work is displacement

of mass. For every type of work displacement of object is common denominator under

which work can be studied. MOST is a system to measure work and concentrates on

the moving objects. Efficient, smooth, productive work is performed when the basic

motion patterns are tactically arranged and smoothly, choreographed. Movements of

objects follow certain consistently repeating patterns such as Reach, Grasp, Move and

position the object. These patterns were identified and arranged as a sequence of the

events called sub activities manifesting the movement of object. A model of this

sequence is made and acts as a standard guide to analyze the movement of an object.

General move sequence, Controlled move sequence, Tool use sequence, Manual crane

sequence are MOST work measurement techniques. Earlier all studies shows that

there is positive relationship of productivity with work measurement as shown in

Figure1.1.

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Figure 1.1

Relationship between higher Productivity with Work Measurement

In the above scenario an attempt is made by the researcher to seek the answer to the

following questions.

1. Whether labours are aware of stop watch time study method and MOST

technique?

2. Whether labours are aware of training related to stop watch time study method

and MOST technique?

3. To what extent labours received training related to stop watch time study method

and MOST technique?

4. Whether labour creates any socio- technical barrier in application of stop watch

time study method and MOST technique. If „Yes‟ then to what extent?

5. How to measure the performance of productivity on the basis of stop watch

method and MOST technique.

6. What is the procedure of stop watch time study method and MOST technique?

7. What happens if stop watch method and MOST technique are applied in

manufacturing industry for productivity improvement?

8. Whether labours are ready to adapt the changes in existing productivity

improvement technique?

9. Does application of MOST leads to higher productivity improvement as

compared to stop watch times study method?

10. What are the differences with respect to various variables related to stop watch

time study method and MOST technique application leading to productivity

improvement?

Method Study Work

Measurement

Higher

Productivity Work

5

11. Is there any research gap in existing literature about application of MOST

technique to improve productivity in manufacturing industries?

Assuming that it is essential for any organization to realize and adopt

advanced work measurement technique as compared to traditional work measurement

technique to achieve higher productivity improvement, attempts is made here to

Study, Measure and compare the labour productivity through the application of

Stopwatch time study method and MOST technique. Therefore the statement of

problem is as under

‘A Study of Labour Productivity through application of Stop Watch Time Study

Method and MOST in Skoda Auto India Private Limited.’

1.2 Need of the Study:

1. The company aims to maintain its leadership in the industry by exploring the

cutting edge of technology; they stand prepared to compete with other global

competitors. Work measurement has important place in productivity

improvement. The productivity improvement directly corresponds to the growth

of the company and in turn gaining the market share. Productivity can be

maximized only when there exists a standard method of accomplishing a task and

time to perform a task according to a standard method can be measured. At

present, studied company measures productivity as per traditional time study

method and MOST is advanced technique of work measurement; it is helpful to

understand the performance of labour and material time. Hence there is need to

understand which work measurement method performs better to result in higher

productivity.

2. There are many reasons to carry out this study apart from getting idea about how

much time it takes to carry out the whole process of material distribution to

production, stores and line feeding. Also it is helpful to determine the overall

working hours, setting the production goals, and functional cost. Hence this study

is needed to determine the manpower required for the future expansion.

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3. Following are the purposes which can be fulfilled with the result obtained from

this study analysis: (i) Determine total labour cost in working area (ii) Determine

the total number of worker needed (iii) Determine the number of machine needed

(iv) Determine the total amount of the delivery time for material (iv) Determine

the total amount of delivery time for material (vi) Determine the overall working

schedule (vii) Check the departmental or individual efficiency.

4. The goal of Skoda Auto is to improve the quality of manufacturing and products,

expand the product range, build and optimize the dealer network, and

systematically reinforce the Skoda brand image. Therefore it is essential for Skoda

Auto to determine the performance of productivity by application of time study

and MOST work measurement technique so as to go for application and practice

of efficient work measurement technique to achieve increased productivity.

5. Since material flow at Skoda Auto India is from Czech Republic to India it is

worth to examine time and work study of method followed by Skoda such as

MOST and time study. Hence, this is needed to understand the relationship

between work study and productivity improvement.

6. The study is needed to take measures for further productivity improvement of

labour, material, machine and processes.

7. To improve productivity it is necessary to understand the existing method,

production process, resource usefulness and measure the performance of standard

time of selected company; resulting in higher profitability.

8. Cost reduction and cost control is one of the important functions of organization.

It is necessary to eliminate unnecessary activities resulting into waste of time and

cost. This study helps in this direction.

1.3 Objectives of the Study:

The following are the main objectives of the study:

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1. To study and assess the extent of awareness, training, training received and socio

technical barriers related to application of stop watch time study method among

labour respondents.

2. To study and assess the extent of awareness, training, training received and socio

technical barriers related to application of MOST technique among labour

respondents.

3. To study and understand the stop watch time study method and MOST technique

application procedure.

4. To study and assess the labour productivity performance by application of stop

watch time study method.

5. To study and assess the labour productivity performance by application of MOST.

6. To compare the labour productivity of stop watch time study method and MOST

application.

7. To recommend the most appropriate work measurement technique.

1.4 Assumptions of the Study:

Following are the assumptions of the study:

1. SAIPL will adopt the Basic MOST method in future to measure the work in the

company.

2. SAIPL will expand its base in India and provide employment opportunities to

labour class.

3. Awareness of SAIPL labour towards method and training related to stopwatch

time study is more than that of Basic MOST.

4. Socio-technical barriers faced by SAIPL labours related to stopwatch time study

method is more than that of Basic MOST method.

5. Time taken by Basic MOST method to measure the work performed by labour

respondents in unloading, TFA and catwalk section is less than stopwatch time

study method.

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6. Basic MOST method saves the time of labour respondents performing the

activities in unloading, TFA and catwalk section of logistic department than

stopwatch time study method.

7. Basic MOST method improves the productivity of labours in unloading, TFA and

catwalk section than that of stopwatch time study method.

1.5 Hypothesis of the Study:

In the light of the above cited objectives, the following hypothesis has been

formulated by the researcher for the testing purpose:

1. Awareness of SAIPL labour towards stopwatch time study method is higher than

that of Basic MOST method.

2. Awareness of SAIPL labour on training related to stopwatch time study method

is higher than that of Basic MOST method.

3. Social barriers faced by SAIPL labour associated with the application of

stopwatch time study method is less than that of Basic MOST method.

4. Technical barriers faced by SAIPL labour associated with the application of

stopwatch time study method is more than that of Basic MOST method.

5. Time taken (Standard Time) by SAIPL labour to perform unloading activity in

unloading section under application of stopwatch time study method is high than

that of Basic MOST method.

6. Application of Basic MOST method saves the time of unloading activity

performed by labour than that of stopwatch time study method.

7. Application of Basic MOST method improves the labour productivity in

unloading section than that of stopwatch time study method.

8. Time taken (Standard Time) by SAIPL labour to perform trolley filling activity

in TFA section under application of stopwatch time study method is high than

that of Basic MOST method.

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9. Application of Basic MOST method saves the time of trolley filling activity

performed by labour than that of stopwatch time study method.

10. Application of Basic MOST method improves the labour productivity in TFA

section than that of stopwatch time study method.

11. Time taken (Standard Time) by SAIPL labour to perform activity in Catwalk

section under application of stopwatch time study method is high than that of

Basic MOST method.

12. Application of Basic MOST method saves the time of activity performed by

labour in catwalk section than that of stopwatch time study method.

13. Application of Basic MOST method improves the labour productivity in catwalk

section than that of stopwatch time study method.

1.6. Significance of the study:

1. There are various work measurement techniques used to improve productivity that

are adopted by manufacturing industries. The application of adequate and correct

work measurement technique is of at most importance for higher productivity

improvement. This study helps to know and understand the adequate and correct

application procedure of stop watch time study method and MOST technique for

higher productivity improvement.

2. Even for large manufacturing organization it is possible to implement simple and

easy work measurement techniques that can result into improved productivity with

minimum input resources. This study shows how a simple stop watch time study

technique can result in establishment of standardize and improved procedures to

enhance the productivity of the activity with minimum input resources and march

ahead towards application and adoption of advanced work measurement technique

such as MOST technique.

3. For any organization it is important for the employees and management to

understand the need for change in existing work measurement and its importance

to adopt and implement for higher productivity improvement. Therefore this study

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helps to understand the attitude and awareness of employees towards the adoption

of advanced work measurement techniques for productivity improvement.

4. Productivity can be maximized only when there is optimum utilization of all the

available resources. This study is useful to determine the optimum utilization of

manpower in three section of Logistic division by reducing non value added

activities.

5. For a manufacturing industry where time is one the most crucial and important

factor, implementation of time study to measure work will surely result into

optimized job performance.

6. Measurement of time along with the operation sequence of worker gives scope to

improve productivity in workers performance as well as improved job procedure.

Application of MOST is useful to utilize workers time effectively and greater

improvement in job procedure followed in company.

7. Application of all the work measurement techniques provides scope of

improvement in the productivity in their own ways. It is essential to understand

which work measurement technique will give maximum productivity

improvement results. This study is useful to compare the results obtained from

application of stop watch time study method and MOST technique as better option

for productivity improvement.

1.7. Research Design:

This is survey and experimental based research and hence to achieve the

above cited research objectives and hypothesis, following research design/

methodology was employed as shown in chart 1.1.

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Chart 1.1

Research Design

Research Purpose To measure, analyse and compare the labour productivity

results after application of Stop watch time study method

and MOST at SAIPL

Research Method

Survey

Simple, Random and Convenient Survey Method

Research Design Quantitative Research

Research Sample Logistic department, Unloading, TFA, Catwalk, Labour

Sample Size Total Labour respondents in Unloading, Catwalk and TFA

section = 43, Sample Size selected = 25 (57%)

Sampling Technique Random Sampling and Purposive sampling

Data Collection Primary and Secondary Data sources

Primary Data

Collection

Questionnaire, Observation and Personal Interview as well

as discussion with the experts

Secondary Data

Collection

Books, Journals, SAIPL Management Report, Skoda Annual

Report, Website

Statistical Tools used Chi-square test, Frequency Distribution, Standard Time,

Average Time, Percentage, Graphs, MOST Index Values

and MS-Office Suite.

Conclusion Summary of Findings, Conclusion and Suggestions

1.7.1 Area and scope of the study:

Figure. 1.2 shows the diagrammatic view scope of the study for the research.

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Figure 1.2

Scope of the Study

Shendra, Aurangabad has been selected as geographical study area. Skoda

Auto India Private Limited, an automobile company operating in MIDC area of

Shendra, Aurangabad is selected as study sample. There are 7 departments in SAIPL.

These 7 departments are treated as universe of the study. Out of 7 departments, 1

department i.e. Logistic Department is selected as study area. Logistic department

consist of 5 subsections namely PPC, MPO, ECM/BOM, Logistic Planning, Stores/

RFD. Out of these 5, 2 subsections namely Logistic Planning and Stores are selected

for study purposes which consist of unloading, Trolley Filling Area (Supermarket)

and Catwalk area are selected purposefully as study area and scope.

Logistic Department

PPC MPO ECN/

BOM

LOGISTIC

PLANNING

STORES/

RFD

Aurangabad:

Shendra MIDC

SAIPL

Supermarket

/ TFA

Catwalk Unloading

Labour working in Unloading,

TFA and Catwalk Section

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1.7.2 Period of the Study: 2011-2012

Data collection was started from January 2011. The period of data collection is from

September 2011 to March 2012. It is shown in the chart 1.2.

Chart 1.2

Period of the study and schedule of data collection

Sr.

No

Period of

Schedule

Scope of Work

1 Jan to June 2011 Topic finalization and Review of Literature

2 July 2011 General area visit and observation at SAIPL

3 August 2011 Pilot survey of the departments and discussions with

concerned officers at SAIPL

4 September 2011 Secondary Data Collection related to SAIPL

5 October 2011 Final selection of Logistic Department with consulting of

HR , Logistic officers and guide

6 November 2011 Questionnaire finalized in consultation with guide and

officers of Logistic department

7 December 2011 Questionnaire distributed

8 January 2012 Observations of activities performed by labour in Unloading

, TFA and Catwalk section of Logistic department

9 February 2012 Recording of time required to perform activities by labour

in Unloading, TFA and Catwalk section for time study and

MOST purpose

10 March 2012 Interview, Discussions and questionnaire collection

11 April 2012 Data Processing

12 September 2012 Data verification , collection of some more data as per

required study

During this period, the data was collected by means of observations, interview,

questionnaire survey and discussion with labours and officers of selected department.

Before that in the month of August 2011, pilot survey was conducted in the study area

and final sample was fixed for study purpose. The chart shows the schedule of data

collection for the study purpose.

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1.7.3. Sample and Sample Size:

The study area consists of Skoda Auto India private Limited located in

Shendra, Aurangabad. The plant consist of 7 departments namely HR, Quality,

Logistics, Production, Marketing and Sales and IT department. Out of these

departments, one department namely logistic department is selected as sample

department. Logistic department consist of 5 subsections namely PPC, MPO,

ECM/BOM, Logistic Planning and Stores/ RFD. Within this subsections Logistic

planning and stores are selected which consist of unloading, TFA or supermarket and

catwalk section. Figure 1.3 shows detail of sample selected for study purpose.

Chart 1.3 shows the sample selection process for study purpose. As discussed

above, out of 7 department of SAIPL considered here as universe, only 1 department

i.e. Logistic department, contributing to 14.28 Percent of the universe is selected

purposefully as sample department. Further, this logistic department consists of 5

subsections which is considered as universe. Out of this, 2 subsections i.e. Logistic

planning and Stores, contributing to 40 Percent of the universe is selected

purposefully as sample.

The selected subsections of logistic department i.e. logistic planning and stores

consist of unloading, Trolley Filling Area or supermarket and catwalk area where

different activities of logistic are performed. This is sample and scope of the study.

This sample size from area is 14.28 Percent and 40 Percent. Further the labours that

are working in this three sections or area are included in the study as sample. The

selection of labour respondents is done by using random sampling technique.

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Figure 1.3

Selection of Samples for Study

Chart 1.3

Selected Sample and Size from Department

Sr.No Universe Area Selected Sample Percent sample

Size to Universe

1 7 Department of

SAIPL

1 Department i.e.

Logistic

14.28

2 5 Subsections 2 Subsections i.e.

Logistic Planning

and Stores

40

Skoda Auto India Private Limited, Aurangabad

Human

Resource

Dept.

Quality

Dept.

Logistic

Dept.

Production

Dept.

Marketing

& Sales

Dept.

Finance

Dept.

IT Dept.

Loading &

Unloading

Section

Super

Market

Section

Catwalk

Section

Labours working in Unloading, TFA and

catwalk section

PPC MPO ECM/BOM Logistic

Planning

Stores/RFD

16

Chart 1.4 shows number of labour considered as sample size for unloading,

TFA and catwalk section was to the extent of 71 Percent, 29 Percent and 100 Percent

of sample. Unloading section consist of total 21 labours considered here as universe.

Out of 21 labours, 15 labours are selected by random sampling as sample labour

respondents which contribute to 71 percent of universe. Similarly for TFA section, out

of total 17 labour, 5 labour respondents are selected randomly as sample size

contributing to 29 percent of universe. Catwalk section consists of 5 labour and all the

labour are selected as respondents contributing to 100 percent of universe. Overall, it

can be seen that, out of total labour (i.e. 43 labour) from unloading, TFA and catwalk

section, 25 labour are selected as sample size contributing to 57 percent of the

universe.

Chart 1.4

Selection of Sample Size from section/ Area

Sr.No Section/Area Universe

(Total Labour)

Selected

Sample

Percent

sample to

Universe

1 Unloading 21 15 71

2 TFA 17 5 29

3 Catwalk 5 5 100

Total 43 25 57

1.7.4. Sources of Data Collection:

Primary as well as secondary data is collected by the researcher from different

sources to study the productivity improvement through application of Stop watch time

study and MOST technique in Skoda Auto India Private Limited, Aurangabad. Figure

1.4 shows sources of information of data collection.

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Figure 1.4

Sources of Data Collection

1.7.4.1 Primary Data Collection:

The primary data is collected on the basis of interviews and observations

through personal visits, telephone as well as mobile interview by using questionnaire.

Discussion, mobile talks, internet and questionnaire were used to collect data from

requisite respondents. The survey and experiment was conducted in Skoda Auto India

Private Limited, Aurangabad in Unloading, TFA and catwalk section of logistic

department. The researcher has approached personally to all the concern individuals

of the selected study area, had detailed discussions with the respective labour and

officers.

Sources of Data Collection

Primary Data Secondary Data

Questionnaire Books, Thesis, Annual

Reports

Personal Interview Websites

Observations/ Discussions Magazines & Journals

Analysis & Interpretation

Conclusion & Suggestions

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1.7.4.2 Secondary Data Collection:

Secondary data is collected from various references that already exist and

published such as books, Project reports, theses, newspapers, magazines, productivity

research journals and articles, websites, internet and e-information, Annual report of

Skoda auto and departmental management reports of Skoda Auto India. Chart 1.5

shows the sources of secondary data collection for study purpose.

Chart 1.5

Main Sources of Secondary Data Collection

Sr.No Source Place of Visit

1 SNDT Women‟s University Library Churchgate and Juhu

Campus, Mumbai

2 Mumbai university Library Kalina Campus, Mumbai

3 National Institute of Industrial Engineering (NITIE)

Library

Lake Vihar, Powai, Mumbai

4 Indian Institute of Technology (IIT-B) Library Powai, Mumbai

5 Veermata Jijabai Technological Institute (VJTI)

Library

Matunga, Mumbai

6 Indian Institute of Industrial Engineering (IIIE)

Library

Belapur, Navi Mumbai

7 National Council of Quality Management (NCQM)

Library

Vikhroli, Mumbai

8 Tata Institute of Social Sciences (TISS) Deonar, Mumbai

9 Skoda Auto India Private Limited (SAIPL) Library Shendra, Aurangabad

10 Dr. Babasaheb Ambedkar Marathwada University

(BAMU) Library

Aurangabad

11 Government College of Engineering Aurangabad

12 Pune University Pune

1.7.4.3 Techniques of data collection and its justification:

The study is survey and experimental based. Survey was conducted and

questionnaire was administered, one to one discussions and interviews was done with

concerned officers and labour respondents. Chart 1.6 represents the technique used for

collecting data:

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Chart 1.6

Techniques of Data collection

Sr.No Technique Respondents Class Justification

1 Observation Labour - Activities performed by individual labour

in one shift

- Measurement of labour performance in one

shift using Time study & MOST technique

2 Questionnaire Labour To collect primary information and opinion

of labour related to awareness, training,

barriers and application of stopwatch time

study method and MOST technique

3 Interview Labour and

Officers

To collect information on implementation of

Time study and MOST technique in Skoda

Auto India Private Limited.

4 Secondary

Data

Libraries, Journals,

Books, Websites

Books. Journal, reports and thesis are

referred to gain theoretical and evaluation

knowledge on time & motion study and

MOST technique.

5 Discussion Guide, Experts,

Labour and Officers

To clarify various issues in application of

stop watch time study method and MOST

technique

1.8 Statistical tools and techniques used:

Data collection is followed by the process of data analysis and interpretation.

It is one of the most important parts of research study. The data is analyzed using

various statistical tools to interpret the results of the study. It is extremely important

to analyze the data collected by the right statistical tool as this will affect the accuracy

of the results that are interpreted for study. Wide ranges of statistical tools are

available and used to analyze data that is collected for research purpose. Various types

of statistical tools used for analysis of data includes: Mean, Median, Mode,

Dispersion- Standard deviation, Excel and other spreadsheet programs, distributions

and descriptive statistics – Mean and Percentage, correlations and regression

techniques and statistical software packages - SAS, SPSS and Stata.

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The data here is interpreted with the help of statistical tools such as frequency

distribution, average, Observed time, Normal time, standard time, percentage, graph,

comparative approach, index Values for MOST, TMU for MOST and time study &

MOST technique, MS Office-MS-Word, MS-Excel and Chi- square test.

1.9 Data Interpretation and Analysis:

For research purpose data collected by any method is called raw data. This

data is processed, analyzed and interpreted to arrive at certain results.

The data was collected by the researcher through the questionnaire,

observation, discussion, interview etc on specific selected department with a specific

object in specific sections. The collected raw data was coded and tabulated to

facilitate the analysis and interpretation. The data is interpreted, concluded and

presented in terms of average time, standard time, TMU, graphs, charts, tables,

percentage as well as Chi-square test is used.

1.10 Limitations of the Study:

The study suffers from certain limitations as under:

1. The study is conducted on logistic department of Skoda Auto India Private

Limited and hence results and benefits are limited to logistic department only.

Thus the study is on micro level, it is not applicable at macro level.

2. It may not be representative for all the departments and sections of Skoda Auto

India Private Limited.

3. Random error is inevitable while using sampling technique.

4. The study is conducted for only three sections of logistic department due to data

constraints.

5. For Study purpose, work measurement is done using Stop watch time study

method and MOST only. No other work measurement technique is used to

perform study such as TQM, TPM, and Lean etc.

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1.11 Terms and definitions of study:

1. Skoda Auto India Private Limited (SAIPL):

Skoda Auto India is a fully owned subsidiary of Skoda Auto, Czech Republic. The

plant is located at Shendra Industrial area, five Star MIDC, Aurangabad, Maharashtra.

SAIPL started its operations from November 2001 and has the annual production

capacity of 40,000 units.

2. Logistic Department:

Logistic department of SAIPL performs planning, implementing, and controlling the

efficient, effective flow and storage of goods, services and related information flow to

serve the customers. It is divided into various other sub departments performing

functions that are integrated to logistic functioning of SAIPL mainly: PPC, MPO,

ECN/BOM, Logistic planning and stores/ RFD.

3. Unloading section:

Unloading section is the area in logistic department of SAIPL where containers which

come from the Mumbai port dock at this section to unload the material and car body.

4. Trolley Filling section (TFA):

TFA or trolley filling area is the section in logistic department of SAIPL where

activity of filling the trolley from supermarket is performed as per the demand of

assembly line. This section is also known as Supermarket area since material is

stocked in this area to fill the trolley as per the requirement.

5. Catwalk section(KLT):

The catwalk or KLT is the stores section in logistic department of SAIPL which

contains most of the parts which area below predefined cubic volume. The section is

the previous stage of the supermarket & therefore the filling of the supermarket is

basically done from catwalk storage section.

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6. Element:

An activity consists of parts known as elements that are broken down as per the

analysis needs to be performed.

7. Work Study:

Work study here is to measure the work performed by the labours in unloading,

trolley filling and catwalk section of logistic department which includes the

examination of the method to perform the activity and ultimately to measure the time

required to perform the activity elements by application of stopwatch time study

method and Basic MOST technique.

8. Work Measurement:

Work measurement here is the process to measure and determine how long it takes to

perform the assigned activity for an average labour in unloading, trolley filling and

catwalk section under normal conditions by application of stopwatch time study

method and Basic MOST technique.

9. Time Study:

Time study here is the technique used to measure the time by application of stop

watch time study method and determine the rate of working for the elements of the

activities performed by the labours in unloading, trolley filling and catwalk section of

logistic department.

10. Stop watch time study method:

Stopwatch time study is the method of time study used in the study to measure the

time required for an average worker to complete the activity at a normal rate.

11. Maynard operation Sequence technique (MOST):

MOST is the system used in the study to measure the work performed by the labour of

SAIPL which concentrates on movement of the objects.

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12. Basic MOST method:

Basic MOST method is one of the methods of MOST used in the study by the

researcher to measure the work performed by the labours of SAPlL.

13. Basic MOST General Move Sequence Model:

The material displacement of the activities performed by the labour of unloading,

trolley filling and catwalk section of logistic department follows spatial displacement

or unrestricted path through the air under manual control and thus this process is

named as general move sequence model which is used in the study.

14. Labour Productivity:

i) Labour productivity means standard time taken by labours to perform assigned

activity.

ii) Time taken by labour to perform assigned job or activity is called labour

productivity

iii) Standard time taken by labour to perform unloading, trolley filling and catwalk

activity in SAIPL is referred here as labour productivity.

(a) Standard time taken by labour to perform or complete unloading activity of

logistic department in SAIPL is called labour productivity.

(b) Standard time taken by labour to perform or complete trolley filling activity of

logistic department in SAIPL is known as labour productivity.

(c) Standard time taken by labour to perform or complete catwalk activity of logistic

department in SAIPL is known as labour productivity.

15. Observed Time (OT):

The time taken by an average labour to perform the activity in unloading, trolley

filling and catwalk section of logistic department is taken as observed time in the

study. The average time is calculated by taking 10 numbers of observations for all the

selected respondents.

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OT = t1+ t2+ t3 +t4+ t5+ t6+ t7+ t8+ t9+t10 / 10

16. Normal Time (NT):

Normal time here is the product of observed time (OT) and the performance rating (R)

calculated for each labour of unloading, trolley filling and catwalk section of logistic

department.

NT = OT * R

17. Standard Time (ST):

The standard time is the sum of Normal time and allowances determined for each

labour of unloading, trolley filling and catwalk section of logistic department.

ST = NT + Allowances

18. Allowances:

20 Percent allowance was added to the normal time as per SAIPL policy book since

no labour can work continuously.

19. Performance Rating:

Performance rating is the rate at which the labour is performing the work with respect

to the standard. Synthetic rating method is used to determine standard performance

rating for each Labour as it gives consistent results.

20. Parameter Index:

The parameter Index is the series of letters representing various activity elements

performed by labour of unloading, trolley filling and catwalk section of logistic

department. The parameters of the Basic MOST General Move Sequence consist of 5

step pattern as below:

A B G A B P A

Where: A = Action Distance

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B = Body Motion

G = Gain Control

P = Placement

21. (Time Measuring unit) TMU:

Time measuring unit is the time calculated in units by application of Basic MOST

method. This time in TMU can be converted into corresponding time in hours by

multiplying TMU value with 0.00001hrs.

1.12 Chapter Plan:

Chart 1.7 shows the chapter plan for the research study as under:

Chart 1.7

Chapter Plan

Sr.No Chapter

1 Introduction and Research Design of the Study

2 Review of Literature

3 Productivity improvement techniques and its relationship

with the work study

4 Stop watch time study method and MOST: Work

measurement techniques

5 Skoda Auto: An Overview

6 Labour Productivity through Application of Stop Watch Time

Study Method in SAIPL: Data Analysis and Interpretation

7 Labour Productivity through Application of MOST in SAIPL:

Data Analysis and Interpretation

8 Comparative Analysis of Labour Productivity between Stop

Watch Time Study Method and Basic MOST method

9 Summary of findings, conclusion and suggestions

26

Reference

1. International Labour Organisation (ILO), „Introduction to Work Study‟, Universal

Publishing Corp., India. , Third Revised Edition, 1986.

2. Nor Diana Hashim, „Time Study Method Implementation in Manufacturing

Industry‟, A B.E Report, Universiti Technikal Malaysia, Melaka, 2008.

3. Niebel, B. W, „Motion and Time Study‟, Richard D. Irwin, Inc., Homewood,

Illinois, 1962.

4. Rice, 1977, in „Time Study Method Implementation in Manufacturing Industry‟,

A B.E. Report, Universiti Technikal Malaysia, Melaka, 2008, PP. 1.

5. Niebel, 1993, in „Time Study Method Implementation in Manufacturing Industry‟,

A B.E Report, Universiti Technikal Malaysia, Melaka, 2008, PP. 1.