Enhancing Productivity of Mixed-Model Assembly Line in Tikur Abbay Shoe S.Co
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Date
2018-10
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Addis Ababa University
Abstract
Tikur Abbay shoe S. Co is one of leather industry in Ethiopia, which produces a variety of shoe
model for local and export markets. The research is mainly focus on the export product, men
shoe (HARBER) model, production condition has different problem not good working
environment and less production efficiency this means the company not satisfies internal and
external customer interest such as quality, delivery time and work environment problem.
Footwear assembly tasks are very repetitive and provide the operators with little opportunity for
rest. Many operators perform only one operation with no job rotation. The repetitive nature of
the job caused work overload and that was made worse by other workers delivering unfinished
shoes to the operators.
The general objective to enhance productivity and increase competitiveness of company by
export product to meet international quality and workplace ergonomically comfortable, improve
work environment and safety requirement.
The methodologies for the study follows are discussion with target group, direct observation,
face-to-face interview and distribute questioner to collect ergonomic problem fact and observe
production section to record working environment problem this all use to collect the research
useful data. Data analysis is interpreted through a descriptive method by using MS–Excel 2016
software, were used to present data in pie chart, Minitab 16.2.4 software were used to prioritized
shoes model and MS-Visio were used to draw root causes analysis of work load and to illustrate
the processes layout.
The finding of the study shows that about 33.6 % of defected product is caused by operators due
to work overload in the production stations and due to existing layout problem 28 m distance
which is unnecessary movement and ergonomic problems.
Therefore, improving human ergonomics problem is used to reduce work overload and worker
health problem, improve work condition and improve chair and table design. If proposed layout
of production area implemented and ergonomics problem is solved the output of company
increased by 38 pieces of shoe per day and 33.6 % of defected products are solved and the
production efficiency is increased by 28.19 % which is 88.95%.
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Keywords
Assembly line, Mixed Model, Work overload, Working Environment, Ergonomics