DEFACJO/101/0/2017

Tutorial Letter 101/0/2017

Design of Facilities and Jobs

DEFACJO

Year module

Department of Mechanical and Industrial

Engineering

IMPORTANT INFORMATION
Please register on myUnisa, activate your myLife e-mail addresses and
make sure that you have regular access to the myUnisa module
website, MODULE DEFACJO-2017-Y, as well as your group website.

Note: This is an online module and therefore it is available on myUnisa. However, in order to
support you in your learning process, you will also receive some study material in printed
format.

BARCODE
 CONTENTS

Page

1 INTRODUCTION ............................................................................................................................ 3
2 PURPOSE OF AND OUTCOMES FOR THE MODULE ............................................................... 3
2.1 Purpose .......................................................................................................................................... 3
2.2 Outcomes ....................................................................................................................................... 3
3 LECTURER(S) AND CONTACT DETAILS .................................................................................... 5
3.1 Lecturer(s) ...................................................................................................................................... 5
3.2 Department ..................................................................................................................................... 5
3.3 University ........................................................................................................................................ 6
4 MODULE-RELATED RESOURCES .............................................................................................. 6
4.1 Prescribed books ............................................................................................................................ 6
4.2 Recommended books ..................................................................................................................... 6
4.3 Electronic Reserves (e-Reserves) .................................................................................................. 6

5 STUDENT SUPPORT SERVICES FOR THE MODULE ................................................................ 7

6 MODULE-SPECIFIC STUDY PLAN............................................................................................... 7
7 MODULE PRACTICAL WORK AND WORK-INTEGRATED LEARNING..................................... 7
8 ASSESSMENT ............................................................................................................................... 7
8.1 Assessment plan ............................................................................................................................ 8
8.2 General assignment numbers......................................................................................................... 8
8.2.1 Unique assignment numbers .......................................................................................................... 8
8.2.2 Due dates for assignments ............................................................................................................. 8
8.3 Submission of assignments ............................................................................................................ 8
8.4 Assignments ................................................................................................................................. 10

9 OTHER ASSESSMENT METHODS............................................................................................. 10

10 EXAMINATION............................................................................................................................. 10
11 FREQUENTLY ASKED QUESTIONS .......................................................................................... 11
12 SOURCES CONSULTED............................................................................................................. 11
13 CONCLUSION.............................................................................................................................. 11
14 ADDENDUM ................................................................................................................................. 12

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1 INTRODUCTION

Dear Student

Welcome to the module, Design of Facilities and Jobs (Code DEFACJO), offered by
the Industrial Engineering section in the School of Engineering at UNISA.

This module is part of the qualification, Higher Certificate in Engineering: Industrial. This
is your first tutorial letter (TL); read it carefully before you start studying. It provides you
with an overview and specific information about this module. You should use it as a
guideline to your studies in this course.

This tutorial letter also provides you with general administrative information as well as
specific information about the subject. Read it carefully and keep it safe for future
reference. We trust that you will enjoy this course.

2 PURPOSE OF AND OUTCOMES FOR THE MODULE

2.1 Purpose

The purpose of this module is to acquaint the learner with the principles and practices of
the design of facilities and jobs.

2.2 Outcomes

After studying this supplement you should be able to:

UNDERSTAND THE PROCESS OF DESIGN OF FACILITIES AND JOBS

The process of designing a product for a customer

Explain the capacity planning process, and work out problems on capacity planning
Use decision tree analysis to solve decision problems
Understand the application of just in time production systems
Carry out facility location and layout planning

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 Use principles of job design and work measurement

UNDERSTAND WORKSTUDY

METHOD STUDY

Define and calculate productivity

Apply work study principles
Define objectives, scope, of method study
Outline method study procedure and apply various charts for documentation
Use the following charts in method study
Two-handed process chart
Diagrams indicating movement
Flow diagrams
String diagrams
Other methods for gathering information film
Multiple
Activity charts
Etc.

WORK MEASUREMENT

Definition and scope work measurement

Techniques of work measurement
Work measurement procedure.
Time study measuring elements
Performance rating
Relaxation allowance
Calculation of the standard time
Activity sampling
Activity sampling procedure.
Calculations done for activity sampling

Synthesis and standard data

Compiling Synthetic times

Analytical estimating
Analytical estimating procedures
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3 LECTURER AND CONTACT DETAILS

3.1 Lecturers

Name: Mr MN Sombane

Tel: (011) 471-2958

Email: sombamn@unisa.ac.za

Contact Times: Tuesdays to Thursdays 10h00 TO 13h00

NOTE: Availability does not mean that a student can show up at the lecturers office unannounced
but rather that the lecturer is available during the stipulated times for appointment booking
subject to the lecturers schedule!

Functions of the Lecturer:

Enquiries about technical content.

Set assignments.
Mark assignments.
Set examination papers.
Mark examination papers

3.2 Department

You may contact the Department of Mechanical and Industrial Engineering by post, e-
mail, telephone, or online through myUnisa.

Please refer to the booklet: My studies @ Unisa

Departmental Address:
Department of Mechanical and Industrial Engineering
Unisa (Florida
Campus) Private Bag
X6
Florida
1710
Phone: 011 471 2963
Use the general E-mail address: nkambule@unisa.ac.za

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 Find our department on the Internet at the online address: http://www.unisa.ac.za

Always state youre STUDENT NUMBER and your Module Code TSYSISS in all
correspondence and enquiries.

Whenever you contact the Department of Mechanical and Industrial Engineering,

ensure that the first thing you mention after greeting is your subject code! It does not
help to say you are a student in Industrial Engineering, lecturers deal with modules.

3.3 University

If you need to contact the University about matters not related to the content of this
module, please consult the publication My studies @ Unisa that you received with your study
material. This brochure contains information on how to contact the University (e.g. to whom you
can write for different queries, important telephone and fax numbers, addresses and details of the
times certain facilities are open).Always have your student number at hand when you contact the
University.

4 MODULE RELATED RESOURCES

4.1 Prescribed books

Title: Niebels Methods, Standards, and Work Design

Author: Freivalds A.
Edition: 13th or Later Edition

Publisher: McGraw-Hill

ISBN: 978-1-425-901066-8

4.2 Recommended books

Introduction to Work Study by ILO (International Labor Organisation)

Work Systems and the Methods, Measurement, and Management of Work by Groover
Operations Management by Heizer and Render
Any other reputed Work Study resource you can source

4.3 Electronic Reserves (e-Reserves)

There are no specific electronic reserves for this module other than content posted on
modules myUnisa page.

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5 STUDENT SUPPORT SERVICES FOR THE MODULE
5.1 Study Guide
Your Study Guide is the first and main source of tuition to be studied in totality! a
printed copy will be sent to you. T h e s t u d y g u i d e w i l l e l a b o r a t e o n c ertain
aspects of the text book but not all.

5.2 On line resources

Discussion forums are set up by your lecturer and available for discussions with your
peers https://my.unisa.ac.za

Some additional electronic resources are available from the Library site
(via www.unisa.ac.za).

DO NOT EMAIL ASSIGNMENTS TO LECTURERS UNLESS YOU HAVE MADE SPECIAL

ARRENGEMENTS. DO NOT FAX ASSIGNMENTS. DO NOT SEND ASSIGNMENT IN
FRAGMENTS, BUT SUBMIT THE COMPLETE ASSIGNMENT.

6 MODULE SPECIFIC STUDY PLAN

Use your assignment due dates to structure and pace your study plan.

7 MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING

There are no practical for this module

8 ASSESSMENT

8.1 Assessment plan

The overall assessment consists of two parts, assignments and examination.

The mark for this module is calculated as follows:
The year mark contributes 20% to the final mark
The examination mark contributes 80% to the final mark
The year mark is based on all the assignment marks obtained and their contribution towards
The final module mark is as shown in the table below:

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 CONTRIBUTION
ASSIGNMENT CONTRIBUTIONTOWARDS
TOWARDS YEAR
NUMBER FINAL SUBJECT MARK
MARK
1 (Compulsory) 50 % 10%
2 (Compulsory) 50 % 10%
TOTAL 100 % 20%

8.2 General assignment numbers

8.2.1 Unique assignment numbers

UNIQUE ASSIGNMENT NUMBERS

Assignment 1 746488
Assignment 2 805250

8.2.2 Due dates for assignments

The due dates for the submission of the assignments are:

THE CUT-OFF SUBMISSION DATES FOR THE ASSIGNMENTS ARE:

Assignment 1 2017-07-31

Assignment 2 2017-09-04

Note: The cut-off dates given here are the official, last dates on which a given
assignment may be submitted. Students must adhere to these dates only. All
other dates referring to cut-off submission dates for assignments, as may be
posted on myUnisa or elsewhere, refers to administrative dates as managed
by the Assignment Department and does NOT influence or change the above
dates.

8.3 Submission of assignments

Assignments are seen as part of the learning material for this module. As you do the
assignments, study the reading texts, consult other resources, discuss the work with fellow
students or do research, a n d e n s u r e t h a t you are actively engaged in learning.
Looking at the assessment criteria given for each assignment will help you to understand what
is required of you more clearly. In some cases, additional assessment might be available on the
myUnisa site for your module.

Failure to submit assignments on time may render you ineligible to sit for the exams at the
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end of the module.

PLEASE NOTE: Enquiries about assignments, (e.g., whether or not the University has
received your assignment or the date on which an assignment was returned to you) are to
be directed to assignments department. You might also find information on myUnisa. To go
to the myUnisa website, start at the main Unisa website, http://www.unisa.ac.za, and then
click on the login to myUnisa link under the myUnisa heading on the screen. . This
should take you to the myUnisa website. You can also go there directly by typing in
http://my.unisa.ac.za.

Please note: Although students may work together when preparing assignments, each
student must write and submit his or her own individual assignment. In other words, you
must submit your own ideas in your own words, sometimes interspersing relevant short
quotations that are properly referenced. It is unacceptable for students to submit
identical assignments on the basis that they worked together. That is copying (a form of
plagiarism) and none of these assignments will be marked. Furthermore, you may be
penalised or subjected to disciplinary proceedings by the University.

You will find your assignment and practical for this subject in Addendum 1 at the end of this
tutorial letter. The assignments are compulsory. Please submit the assignment and practical,
duly completed, to UNISA before the closing dates stated in this section.

Assignments should be addressed to:

The Registrar
PO Box 392
UNISA
0003

You may submit written assignments and assignments done on mark-reading sheets either by
post or electronically via myUnisa. Assignments may not be submitted by fax or e-mail unless in
special circumstances and this must be discussed with the lecturer prior to the submission.
For detailed information and requirements as far as assignments are concerned, see the
brochure myStudies@Unisa that you received with your study material.

To submit an assignment via myUnisa:

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 Go to myUnisa.
Log in with your student number and password.
Select the module.
Click on assignments in the left-hand menu.
Click on the assignment number you want to submit.

Follow the instructions on the screen.

You will receive the correct answers automatically for multiple-choice questions. For written
assignments, markers will comment constructively on your work. However, comprehensive
memorandums on compulsory assignments will be sent to all students registered for this
module on myUnisa.

IT IS VERY IMPORTANT TO CONSIDER THE FOOLOWING POINTS:

Failure to submit assignment 1 will result in denial of exam entrance for the student.
No late assignment submissions will be accepted.
No hand written assignments will be accepted, submit typed assignments only.
All electronic submissions must be in pdf file format.
Keep an electronic copy of your assignment for backup as assignments do occasionally get lost.
Not all assignment questions can be answered from your prescribed textbook content, some
questions will require that you perform independent research (a skill you are expected to master
as an engineering student) in order to be satisfactorily answered.
If assignments from different students are found to be duplicates then the mark from the first
marked assignment will be divided among the duplicated assignments you are encouraged to
work with each other but you must submit your own individual original work.
Each assignment answer must be referenced. It is not enough to only reference your
assignments at the bibliography page. The lecturer reserves the right to not mark an assignment
answer whose source is not referenced.
It is your responsibility to check whether Unisa has received your assignment by contacting the
call centre two (2) weeks after submission.
The booklet myStudies@Unisa explains how you may submit assignments electronically.

8.4 Assignments

Please see Addendum A at the end of this document for the assignment questions.

9 OTHER ASSESSMENT METHODS

There are no other assessment methods.

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10 EXAMINATION

A 3 hour examination will be scheduled for this module. Students can also be referred to the
myStudies@Unisa brochure for general examination guidelines and examination preparation
guidelines. Please note that students receive admission to the examinations on the submission
of their first assignment.

11 FREQUENTLY ASKED QUESTIONS

ARE THERE ANY ADDITIONAL SELF ASSESSMENTS I SHOULD CONSIDER OTHER

THAN THE ASSIGNMENTS?

You can look for plenty of practice questions in; your prescribed textbook, other non-prescribed
textbooks, the internet, and previous exam question papers.

12 SOURCES CONSULTED

Niebels Methods, Standards, and Work Design, 13 Edition.

th th
Operations Management, 10 & 11 Edition, Heizer & Render

13 CONCLUSION

After reading your tutorial letter make sure you purchase the prescribed book and get access to
library resources before attempting assignments.

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 DEFACJO/101
ADDENDUM A

ASSIGNMENT 1

QUESTION 1

1.1 Name any five contributors that you deem most influential to the field of Methods,
Standards, and Work Design (MSWD) and detail an in-depth substantiation (in bullet
point format) of their respective contributions and how those contributions affect the
practice of MSWD in modern day industry.
[25]
QUESTION 2

2.1 Identify a company of your choice and perform the following tasks:

2.1.1 Select one of their products and describe first in words, the entire operation
process for the selected product, thereafter, describe the process through the
use of a Operation Process Chart for the self-same product. (20)

2.1.2 Select one process from your drawn Operation Process Chart in 2.1.1, and
describe first in words, that entire process, thereafter, draw a Flow Process
Chart thereof. (20)

[40]

QUESTION 3

3.1 A car tyre manufacturer has a new line of nano-enhance next generation tyres
whose production is broken in to six steps as per below table. The demand for
these tyres is 4800 units per 40 hour week.

Performance Time

Task (in seconds) Predecessors

A 20 None
B 30 A
C 15 A
D 15 A
E 10 B,C
F 30 D,E

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 DEFACJO/101

Given the above information, perform the following tasks:

3.1.1 Draw a precedence diagram for this operation. (5)

3.1.2 Calculate the Takt Time for this operation. (3)

3.1.3 Determine the theoretical minimum number of workstations. (2)

3.1.4 Assign tasks to the workstations. (5)

3.1.5 Determine the total idle time present for each cycle. (2)

3.1.6 Calculate the overall efficiency of the assembly line with five workstations and
with six workstations, and comment on the implications of the results thereof. (6)

[23]

QUESTION 4

4.1 Use either the company already selected in question 2.1 or choose a different company
altogether and apply Operation Analysis techniques to two or more operation processes
of your choosing in order to improve these processes. Present a study report of your
Operation Analysis detailing the following points of interest:

4.1.1 Give a succinct description of each of the study areas you will be focusing on. (6)

4.1.2 Give a detailed quantified account of the study areas Key Performance Indicators
(KPIs: e.g. Std times, production rates, scrap rates, IOD status, direct activity costs,
etc.) before improvements. (6)

4.1.3 Present a report on your improvement suggestion in a table format where you outline;
1) the specific Operation Analysis technique/s used to analyse the study area, 2) your
suggested improvement, 3) the envisaged impact of your implemented suggestion in
terms of KPIs and lastly, 4) the expected monitory translation of the improved KPIs. (16)

4.1.4 Draw up an implementation cost projection of your suggested improvements and the
breakeven analysis thereof, clearly showing all your calculation steps. (10)

[38]

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 DEFACJO/101

QUESTION 5

5.1 An assembly line operator working at the Nissan/Renault Rosslyn plant has
been timed performing an activity comprising of three work elements with results
shown in the below table. Fatigue allowance is 12% and contingency allowance
is 6%.The following data was captured for the activity.

Task Performance Observed time minutes

element rating
1 2 3 4 5
A 110% 8 10 9 10 11
B 95% 29 30 28 38 31
C 100% 20 29 21 21 19

Tip: Be wary of outliers and adjust your calculations accordingly!!

5.1.1 Calculate average Cycle Time for each element. (2)

5.1.2 Determine the Normal Time for each element. (2)

5.1.3 Determine Work Content for the entire activity. (2)

5.1.4 Calculate the Standard Time for the activity. (2)

[8]

Total Marks = [134]

Full Marks = [134]

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 DEFACJO/101
ASSIGMENT 2

QUESTION 1

1.1 Design a takeaway coffee booth stand that will be able to accommodate a worker
of any gender and of any physical stature, including a wheelchair bound worker
who has full use of their upper torso bodily functions. The allocated floor space for
the coffee booth is 1.3 x 3.2 m2 with a height clearance of 2.4 metres. Your booth
design must include at a minimum all the rubric items given in the below table.

Coffee Booth Design Rubric % Contribution

1.1.1 A Sketch of the coffee booth design dimensioned to scale 15%
1.1.2 Demonstration of applied Manual Work Design principles 15%
Demonstration of applied Workplace, Equipment, and Tool Design
1.1.3 principles 15%
1.1.4 Demonstration of applied Work Environment Design principles 15%
1.1.5 Demonstration of applied Work and Systems Safety principles 8%
1.1.6 Calculations of estimating Capital Investment the coffee booth 10%
1.1.7 Calculations of estimated daily operational costs 10%
1.1.8 Calculations for costing a single standard cup of coffee 7%
1.1.9 Calculations for coffee cup pricing and expected profits thereof 5%

[60]

QUESTION 2

2.1 Visit a local coffee shop and develop for that shop time standards for making at
least three of their differently sized coffee cups (i.e. for three coffee sizes, small,
medium and large/XL/etc.). You are to design your own Time Study Form and
use it to record your times and perform your time studies for each one of the
three study instances.
[45]

QUESTION 3

3.1 In developing time standards for a certain operation, a time-study analyst

observed an operator for 45 minutes during which the operator completed 62
parts. The analyst rated the worker at 110%. The base wage for the operator is
R32 per hour and the firms policy is to assign a 12% total operator allowance for
fatigue and contingencies.

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 DEFACJO/101

Given the above information, calculate the following:

3.1.1 The Normal Time for the task. (3)

3.1.2 The Standard Time for the task. (3)
3.1.3 Suppose the operator produced 620 units during an eight hour shift. Calculate
wages earned by the operator. (6)

3.2 A worker working in a coffee booth at a relatively busy mall produced 86 standard
cups of coffees per shift. The company has a time standard of 2.4 minutes per
standard cup of coffee. Assuming the worker has a 30 minute lunch break, a 15
minute tea break per eight hour shift as well as 15% total operational allowances,
determine the below performance measures.

3.2.1 Calculate the standard hours earned by the worker. (3)

3.2.2 Calculate the workers efficiency for this shift. (4)

3.2.3 If the base rate is R9. per hour, calculate the workers earnings for the day. (3)

3.2.4 Calculate the standard labour cost per cup of coffee. (3)

3.2.5 Calculate the direct labour cost per cup of coffee using the workers efficiency for
this shift? (3)

3.2.6 Explain why there is a discrepancy or equivalence (depending on your specific

answers for questions 1.2.4 and 1.2.5) in the standard piece cost versus piece
cost based on worker efficiency. (4)

3.2.7 Discuss the advantages and disadvantages of paying a worker per number of
clocked hours versus paying them per standard hours earned. (4)

[38]

Total Marks = [143]

Full Marks = [143]

UNISA

2016

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