Optimization of labor allocation at a syringe production facility : work study

Abstract

At MD Company (Singapore), the syringe value stream faces escalating labor cost and high labor turnover. Two labor allocations were proposed previously to optimize current labor resources, with the aim of controlling the labor cost effectively without affecting the production. Proposal Two, which had demonstrated significant increase in productivity and reduced labor cost through computer simulations, entailed an addition of two workers each in the new dedicated inspector and material handler job designations. The associated new job scopes combine tasks which are currently assigned broadly to production technicians working on the syringe production floor. A work study approach was undertaken with the broad aim of reducing waste from the new job scopes, as well as to verify headcount used in the simulation of Proposal 2. Dedicating tasks to individuals presented opportunities to reduce repetition and to achieve collective savings via changes in methods. Within the work study, a method study provided a theoretical basis of how best to carry out the new job scopes, while a time study established time needed to perform a given set of tasks. Results found were consistent with that from simulation of Proposal 2. Further improvements were made in reducing inspection cycle time through streamlining of inspections. Identification and separation of tasks which are not performed constantly paved the way for one of the two material handlers to be hired on an overtime basis. Future iterative identification of waste and its removal could help current work converge to an optimal work standard.