Table No:4.

3
Sr.
no

Type of
material

Weight's

Time for each truck

incoming

Finished
goods boxes

(1016 kg)

2.002.30

outgoing

1.30hr

Truck capacity
(units/truck)
incoming

14001500

outgoing

total
No of workers required from loading to stacking
unloading

loading

4(truck)+
2(dock)
+1(pallet truck)
+1(reach truck)

4(truck)
+( 4dock)
+1(pallet truck)
+1(reach truck)

10001200

Standard time for one pallet in

sec
Loading

No of units per pallet

Dimensions of unit
(Dimensions in cm)

Unloading

31.5x23.8x18.0

450

384.72

48 or 60 or 72

33.8x23.6x19.3

36x30x22.5

CLD
(corrugated
boxes)

Wrapper rolls

10kg

13.9 kg

4050min

3035min

4045min

2025min

300350

250300

250300

150200

Total=8

Total=10

2(truck)
+3(dock)
+1(pallet truck)
+1(1 reach truck)

2(truck)
+2(dock)
+1(pallet truck)
+1(reach truck)

Total=7

Total=6

1(truck)
+2(dock)
+1(pallet truck)
+1(reach truck)
Total=5

Stiffener

17.5kg

1530min

30min

250300

150200

1(truck)
+2(dock)
+1(pallet Truck)
+1(reach truck)

390

345.12

24

66x40x17

320.04

291.132

5460

Dia=4042
Height=1112

446.376

386.264

4045

Dia=71.5
Height=7

Total=5

1(truck)
+2(dock)
+1(pallet truck)
+1(reach truck

1(truck)
+2(dock)
+1(pallet truck)
+1(reach truck

Total=5

Total=5

47

soap noodle
bags
(20CNO)

Salt

50kg

25kg

2hr

2hr

1hr30min

300400

300400

250300

6(truck)
+
2(dock)
+
1(pallet truck)
+
1(reach truck)

4(truck)
+
2(dock)
+
1(pallet truck)
+
1(reach truck

Total=10

Total=8

6(truck)
+
2(dock)
+
1(pallet truck)
+
1(reach truck)

389

2226

96.5 x 67 x12

338.124

2226

80x43x12

338.124

2226

80x43x12

290.868

265.392

Total=10

AOS
(Sodium
7

AlphaOlefin
Sulfonate)

25kg

2hr

300400

6(truck)
+
2(dock)
+
1(pallet truck)
+
1(reach truck)
Total=10

noodle bags
(15 CNO)

1(truck)
1(crane operator)
+1(pallet truck)+
1(reach truck)
1T

1hr

1hr

1820

1(truck)
1(crane operator)
+1(pallet truck)
+1(reach truck)

Total=4

Total=4

48

9.

Lauric acid

25kg

2hr

300400

6(truck)
+
2(dock)
+
1(pallet truck)
+
1(reach truck)

338.124

2226

80x43x12

395.86

24

96.5 x 67 x12

338.124

2226

80x43x12

Total=10

10

Anhydrous
sodium
sulphate

50kg

2hr

100200

6(truck)
+
2(dock)
+
1(pallet truck)
+
1(reach truck)
Total=10

11
.

Titanium
oxide

25kg

2hr

300400

6(truck)
+
2(dock)
+
1(pallet truck)
+
1(reach truck)
Total=10

49

4.2 Problem Statement

Current system is labor intensive and was costing company time, money,
and most importantly, the safety of its workers.
Large amount of time is spent for loading and unloading operations.
Products are being damaged while handling.
Increase in idle time of workers led to unnecessary cost burden to company.
Movement of workers in the confined workplace area led to unnecessary
obstruction of material flow and machinery

4.3 The CTQ (critical to quality) diagram, depicting the need of

efficient material handling system:-

Figure 4.1 Critical To quality Diagram

50

4.4 ISHIKAWA (Fish Bone Diagram), for understanding the

general problems

Figure 4.2 General Problems

4.5 Pareto's chart to identify the major problems

Table No:-4.4
Problem

Workers Taking
More Than
Standard Time
Obstruction to
material flow

Day 1
(19/12/2014)
10am-5.00pm
Loading

Unloading

52

Day 2
(20/12/2014)
10am-5.00pm

Day 3
(22/12/2014)
12am-5.00pm

Total

loading

Unloading

loading

unloading

44

48

42

50

35

271

18

23

20

21

16

16

114

13

14

10

15

13

13

78

11

10

10

57

17

10

Pallet collapse
Wastage of time
due to nonavailability of
equipment
Forklift
obstruction due to
movement
Human Factors

51