Productivity

Definition of productivity
 Productivity of material
At the design stage:
• Ensure least consumption of material,
• Purchase equipments and plants such that consumption of
material is economical.

At the operation stage:

• Use of correct process
• Right use of the process
• Operator training
• Proper handling and storage of products at all stages
• Proper packaging to reduce damage in transit

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 Factors tending to reduce productivity

Work content added due to the product

• The product or its components are designed such that it is
impossible to use most economical manufacturing processes.
• Excessive variety or lack of standardization.
• Incorrect quality standards.
• Excessive amount of material handling required.

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 Factors tending to reduce productivity

Work content added due to process

• Incorrect machine (and/or hand tool) used
• Process not operated properly
• Non-optimal layout with wasted movements.
• Working methods of operation causing wasted movements,
time and efforts.

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 Factors tending to reduce productivity
Ineffective time due to management
• Marketing policy which demands unnecessarily large number
of products.
• No standardization of components between as well as within
products.
• Failing to meet customer’s requirement from the beginning.
• No plan for flow of work.
• Improper supply of material, equipment.
• Improper maintenance of plant and machines.
• Insufficient safety measures.
• Improper working conditions resulting in interrupted work.

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 Factors tending to reduce productivity

Ineffective time within the control of worker

• Taking time off without good cause: by lateness, by idling at
work etc.
• Careless workmanship causing scrap or rework.
• Failing to observe safety standards.

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Management techniques to
reduce work content
 Nature of management
• Management is the organization and control of human activity
directed towards specific ends.
• Management techniques are systematic procedures of
investigation, planning and control which can be applied to
management problems.
• Systematic approach to the solution of the problems proceeds
step by step from known to the unknown, always on the basis
of ascertained facts.
• Since management deals with human beings, it can never be
completely scientific, and must partly be regarded as an art.

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 Reduce work content due to the
product
• Coupling of product design and process design phases (design
products such that most economical processes can be used).
• Pilot project/ prototyping to avoid mistakes at a advanced
stage (very common in chemical companies).
• Standardization of components.
• Setting correct quality standards
Stricter standards lead to increased manufacturing time, lenient
standards lead to greater variability.
• Knowing the customer – Management should conduct market
research and consumer surveys to know the customer better.

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 Reduce work content due to the
method
• Process planning – Identification of correct machines for the
process. In chemical industry, this is specified by the R&D
division or the license seller.
• Process research – Identification of best manufacturing
technique.
• Proper maintenance.
• Method study – Combine with process planning to give most
suitable tools for the operative. Includes factory layout,
working methods of the operative.
• Operator training – Improve working methods of the
operative.

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 Reduce ineffective time due to the
management
• Strategic decisions – Which markets to enter can affect
ineffective time to a great extent.
• Production planning – It is planning of proper programs of
work so that plant and workers are kept supplied without
having to wait.
• Proper programs should be applied only on the basis of sound
standards of performance.
• Work measurement – Setting up those standards.
• Material control – Workers and machines should not be idle
because of non-availability of material and tools.

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 Reduce ineffective time within control
of the worker
• Training.
• Make worker want to reduce ineffective time. (Create
conditions to make the worker get on with his work.
Hawthorne effect)
• Effective personnel policy and management’s attitude towards
the worker.
• Good relationship between management and worker.
• A sound wage structure, including incentive schemes
(typically based on time standards derived from work
measurement).

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