NAME OF THE THESISMARIA SHAH (GROUP LEADER) 10IN80UZAIR AHMED QAZI (ASST.GROUP LEADER) 10IN94JAMEEL AHMED SHAIKH 10IN90 SAJID ALI SURIHO 10IN86 WAHEED AHMED KHUHRO 10IN69

Research Aim: The aim of this research is to optimize

a segment of material requirement planning process by implementing and analyzing time and motion study technique. The main results than achieve in the foam of reducing time and resources of the process.

Material Requirement Planning Material Requirements Planning (MRP) is a

computer-based production planning and inventory control system.

The major objectives of an MRP system are:

1. Ensure the availability of materials and components to the manufacturer. 2. Maintain the lowest possible level of inventory, 3. Plan manufacturing activities, delivery schedules, and purchasing activities.

Move Order Move orders are requests for the

movement of material within an organization.

They allow planners and facility managers to request the movement of material within a warehouse or facility for purposes like replenishment and material storage relocations.

Move orders are restricted to transactions within an organization.

Work Content The amount of work contained in a

given job. The amount of work contain in a given

process measured in “work-hours” or “machine-hours” (British Standards 3138, London, 1991).

Output= Time and Labor resources

Time Study Time study is a direct and continuous

observation of a task, using a timekeeping device to record the time taken to accomplish a task.

Technique Used: Stopwatch time study. Equipment: Timing device (Stopwatch)

and Time study observation sheet

Move Order Implementation Process

Generation of Move Order

Allocation of Reference No.

Transference of move order

manually

Listing of

material in

different

sections (FMD, Local, Import

& Consum

able)

Order picking

Dispatching

Checking

Time study observation sheet

Control Chart The control chart is a graph used to

study how a process changes over time. Data are plotted in time order.

1 2 3 4 5 60

1

2

3

4

5

65

1.31

4.46

2

1

0.656000000000001

4.2639

Control Chart of MRP-133 (Step-03)

Observations Lower LimitUpper Limit

No. of Observations

Obs

erva

tions

Pareto Analysis Pareto analysis is a formal technique

useful where many possible courses of action are competing for attention.

This technique helps to identify the top portion of causes that need to be addressed to resolve the majority of problems. 

This technique helps to identify the top 20% of causes that needs to be addressed to resolve the 80% of the problems.

05

101520253035404550

0%

20%

40%

60%

80%

100%

120%

Pareto-analysis of MRP-133Observations Acc.percentage

Tim

e (m

in)

Order PickingOrder picking is the process of pulling items

from inventory to fill a customer order. It is seen as the most labour intensive activity within a warehouse.

1. wave picking method: the order picker(s) move(s) to collect the products necessary for several orders.

2. piece picking or picker to part method3. zone picking method4. sorting systems method5. pick to box method

Cause & Effect Diagram

Existing Layout Of Main store

Calculation of Existing layout of Main Store

Total Area utilized at main warehouse = 5580.575 sq ft Offices area = 9.3*59 = 548.7 sq fttotal area=19800Total logical area of main warehouse = total area – offices

areaTotal logical area of main warehouse = (180*110) – 548.7 = 19800 – 548.7 = 19251.3 sq. ft.Percentage of area utilizes space in warehouse =5580.575/19251.3*100 = 28.89%

LAYOUT OF THE SUB-STORE #1

Calculation of Layout of Sub Store# 1 :

So the area of S.S#1 will be 5152 sq. ft.

Space occupy by the outside room mention in the figure S.S#1 is 273 ft

For total area of S.S #1 = Area of S.S#1- Area of outside room

occupied =5152-273 =4879 ft.

Suggested Layout Of Main Store

Calculation of Suggested Layout Of Main Store

Adding the Grand total utilized in Main warehouse & the total area of S.S#1

= 5580.575 +4879 ft. =10459.5 ft.Total logical area of main warehouse + the

total area of s.s#1 = 19251.3+4879

=24130.3Percentage of area utilizes space in warehouse =11284.575/24130.3*100 =43.34%

Existing Move Order Activities:

Suggested Move Order Activities

Elaborating Differences In Existing MRP And Suggested MRP System

Existing System

• Total No of steps = 10 • Total Time consumed = 95.6 • Total Workers Utilized = 16

Modified System

• Total No of steps = 05• Total Time consumed = 58.9• Total Workers Utilized = 13

Elaborating Differences In Existing MRP And Suggested MRP System

(A) Improvement in Steps = 10 – 5Improvement in Steps = 05

(B) Saved time = 95.6 - 58.9Saved time = 36.7 min

(C ) Improvement in utilized resource(Manpower) = 16 – 13

Improvement in utilized resource(Manpower) = 03