Production Process Improvement to Reduce Working Time in Product Size Grading using Work Study Techniques

Abstract

This study aimed to improve the product size-grading process of an agricultural enterprise to enhance operational performance. The objectives were to reduce waste and improve productivity within the operational process. A duck egg farm was selected as the case study. Operational data were collected through direct observation of workers involved in the size-grading process. The Why–Why Analysis technique was applied to identify the root causes of operational problems at each stage of the process. In addition, flow process charts, left–right hand charts, and man–machine charts were employed to analyze work methods, evaluate operational efficiency, and determine standard working times. The results indicated that the existing process relied heavily on manual labor, resulting in delays during periods of high production volume and adversely affecting grading accuracy and delivery performance. The flow process chart identified 34 process steps, with an average processing time of 1,486.8 minutes and a total travel distance of 236.2 meters, indicating the presence of non-value-added activities and inefficient work sequences. Following process improvements through workspace reorganization and equipment rearrangement, unnecessary motions were eliminated, hand movements became more balanced, and hourly productivity increased by 18–20%. Furthermore, the application of the ECRS principle reduced the number of process steps from 34 to 32, shortened the average processing time by 25–30%, and minimized operational delays. Machine utilization increased from 70.7% to 90.6%, while worker utilization improved from 97.1% to 92.2%. These findings demonstrate more effective and balanced utilization of human and machine resources, contributing to enhanced overall production efficiency.