5. 1.1Tour basedWork Sampling
• Location – Sarayu Hostel
• Date of sampling – 15th April 2022
• Time – 04:35 PM to 5:45 PM
• No. of workers – 53
• Type of sampling – Random
Category Nos.
VA 21
NVAN 12
NVA 20
Total 53
VA, 39.62%
NVAN,
22.64%
NVA,
37.74%
Percent Distribution ofVA, NVAN and NVA
6. VA
Finishing - applying Plaster
of Paris (PoP)
13
Finishing - Grinding 2
Carpentry 4
Electrical wiring 2
Total 21
NVAN
Scarping -waste cement 4
Brooming 3
Material shifting 5
Total 12
Carpentry
Scrapping and
Brooming
Material Shifting
Applying PoP
Grinding
7. NVA
Standing idle 6
Waiting for materials 4
Sleeping 1
Using mobile 2
Talking 5
Walking 2
Total 20
Waiting for
material
Walking
Sleeping
Standing idle
Talking
Using mobile
8. 62%
9%
19%
10%
Value Added Activities
Finishing - applying Plaster of
Paris (PoP)
Finishing - Grinding
Carpentary
Electrical wiring
33%
25%
42%
NonValue Added but Necessary
Activities
Scarping -waste cement
Brooming
Material shifting
30%
20%
5%
10%
25%
10%
NonValue Added Activities
Standing idle
Waiting for materials
Sleeping
Using mobile
Talking
Walking
9.
10. 1.2 Crew basedWork Sampling
• Location – OAT
• Date of sampling – 15th April 2022
• Time – 10:20 PM
• No. of workers in the crew– 10
• Type of sampling – Random
• 75 samples taken from video
Work categorization for Masons
VA - Spreading and leveling concrete
NVAN - Minor leveling of concrete at the edge
NVA - Idling
Work categorization for Helpers
VA -Transporting, pouring, and spreading
concrete
NVAN - Cleaning and handing over tools
NVA - Idling
15. Summary ofVA, NVAN & NVA activities
32%
25%
43%
Percent Distribution of overallVA,
NVAN & NVA
VA NVAN NVA
78%
7%
15%
Distribution ofVA, NVAN & NVA
activities for all Masons
VA NVAN NVA
13%
33%
54%
Distribution ofVA, NVAN & NVA
activities for all Helpers
VA NVAN NVA
16.
17. Observation Recommendation
Tour
based
WS
Standing idle and talking contributed 55% of NVA
activities as there was lack of supervisors.
Deployment of 2 supervisors.
Waiting for materials contributed 20% of NVA
activities.
To minimize waiting for materials,
preplanning of activities is required
by accessing daily and weekly
schedules.
Crew
based
WS
More workers were deployed that lead to 43% idle
time
Reduce the number of helpers.
Monitoring of productivity.
19. 2 Process Mapping
• Location – Sarayu Hostel
• Process– Carpentry work of wardrobe
doors and main doors of room
• Objective – optimize the flow
20. Process Chart – Current State
Location Symbol Activity
Location 1 Transfer of plywood fromTruck
Storage of plywood till the requirement at Ground
floor
Location 2
Transfer to the storage location of individual floor
storage room
Storage of plywood till the cutting operation
Location 3 Transportation to cutting, finishing workplace
Processing of plywood for fitting
Location 4 Transfer of finished plywood
Temporary storage till the rooms are ready for fitting
Location 5 Transfer of finished works for fitting location
Fitting and finishing operation
21. Process Chart – Future state
Location Symbol Activity
Location 1
(CentralWorkplace)
Transfer of plywood fromTruck
Storage of plywood til the requirement
Processing of plywood for fitting
Location 2 Transfer of finished plywood
TemporaryStorage of finished plywood
till the rooms are ready for fitting
Location 3
Transfer of finished works for fitting
location
Fitting and finishing operation
22. 1. Temporary storage
in
Ground floor
2. Manual shifting of plywood to individual floors
3.Temporary storage
in
Individual floors
23. 4. Processing of plywood for fitting 5.Temporary storage of finished plywood
25. Observation Recommendation
Process
mapping
The intermediate storage of plywood at
individual floor and operation location was
redundant
The single transfer of materials from central
work location to fitting location
The setting up of central work place at
courtyard wherein all carpentry work can be
streamlined
The workplace was distributed all over the
building
Inventory management issue as the plywood was
kept at so many locations
26. Comparison of Process Chart – Present vs Future state
Process A B Savings
Operation 2 2 0
Transporatation 5 3 2
Storage 3 2 1
10 7 3
28. Activity :- Concreting @ Open Air Auditorium
1 Cycle :- Completion of 1 section of concrete work
Cycle Time :- 7 min 28 sec (448 sec)
Manpower in as-in condition,
• No of masons :- 3
• No of helpers :- 7
Main Activities observed,
• Levelling
• Pouring
• Spreading
• Transporting
• Idling
• Waiting
Activity Details
Crew 1 – Mason #1
Crew 2 – Mason #2
Crew 3 – Mason #3
Crew 7 – Helper #4
Crew 8 – Helper #5
Crew 5 – Helper #2
Crew 10 – Helper #7
Crew 4 – Helper #
Crew 6 – Helper #3
Crew 9 – Helper #6
29. Crew based chart for as-is condition
Detection phase-
• The workers were idle most of the time (39% of total time) due to unclear
sequence of activities.
• The workers are not assigned with clear roles as evident from the CBC.
• The M4 is idle for most of the time.
• M9 & M10 were idle and waiting for most of the time.
Observation from As-Is Condition
30. • Workers were idle for almost 39% of the cycle time.
• From the table, it is observed that M4. M9 & M10 seem to be more idle, mostly waiting for the mixed
concrete.
Duration distribution of various activities in as-in condition
Observation from As-Is Condition
31. Crew based chart after 1st iteration
Improvement phase-
• The M4 was completely idle, hence he was removed.
• M9 & M10 whose major work was transporting was removed and assigned the same activity to M8.
• Clear roles has been assigned to Masons M6 & M7 in sequence to spread the Concrete.
• Masons M1, M2 & M5 starts levelling in a sequence after the spreading is done.
• The Pouring activity is completed with in seconds, so it was not considered in CBC.
After 1st iteration
33. Crew based chart after 2nd iteration Improvement phase-
• The works of Mason M1 was removed and the same activity was distributed to M2
& M5 in a sequence.
• The main activity of Mason M3 was spreading and the same activity was assigned to
M7 in continuous manner. in such a way that there is no idle time for M7.
After 2nd iteration
35. Crew based chart after 1st iteration Crew based chart after 2nd iteration
Crew based chart for as-in condition
COST SAVED- 48%
COST SAVED - 27%
Crew Based Charts - Summary
