Download Gang Chart for Work Design: Gil-Mol Paper Production and more Assignments Engineering in PDF only on Docsity! IET 264-51 Fundamentals of Work Design Oct 7, 2003 Assignment # 6 Chapter # 6 Gil-Mol Associates – gang chart Objective: To demonstrate the ability to create a gang chart. Assignment: Create a gang chart showing the current method of operation as described below. Review the method for possible areas of improvement and develop a proposed method. Compare and contrast the two methods to support your recommendations and improvements. Show summaries of utilization. Use $18.00/hr for labor cost. Situation: The Gil-Mol plant produces paper in a continuous process. At the start of the line, a wood pulp and filler mixture flows over a continuous bronze screen, called a “Fourdrinier”, which is 12 feet wide by 75 feet long. Water is drawn off leaving criss-crossed wood fibers and filler material formed into a sheet the width of the screen. The damp sheet then travels between heavy press rolls and a woolen felt (blanket) which removes more moisture. It continues over steam-heated rolls. The sheet is kept in contact with the rolls by cotton asbestos dryer felts. An application of coat (starch, clay, and water) is applied at the coater by a modified rotogravure printing process. Roughly 15% of the weight of the paper is applied on each side at this point. The paper is then dried further over additional dryers. The paper passes over a series of steel rolls known as a calendar that forms a smooth, shiny finish on the sheet. From here it is carried to a slitter where the sheet is slit to required width before being wound on customer’s cores, to specification. This entire process is continuous and produces paper at approximately 500 feet per minute. Five operators are continuously employed on this section. While the paper is being processed, their function is primarily maintenance. However; about four times per 8 hour shift, it is necessary to reset the cutter blades on the slitter to meet the specific customer requirements. The five men are able to set up the blades in 15 minutes. A time study of the work elements revealed the following standards: Page 1 of 2 Element # Job Description Standard Time in Minutes Operator #1 1 Stop machine and remove over-run of paper 5.00 2 Place end of paper on new winder mandrel and start machine 2.00 Operator #2 1 Remove completed rolls from winder to overhead monorail 3.00 2 Position new winder mandrel 1.00 Operator #3 1 Assist Operator #2 with removing rolls to monorail 3.00 2 Assist Operator #2 with positioning new winder 1.00 Operator #4 1 Raise slitter bar and set blades 12.00 2 Assist Operator #1 by placing end of paper on new winder mandrel 2.00 Operator #5 1 Assist Operator #4 with raising slitter bar and setting blades 12.00 2 Assist Operator #1 by placing end of paper on new winder mandrel 2.00 Operator #1 is not able to start element 2 until Operators #4 & #5 finish setting the blades on the slitter mandrel. Operators #2 & #3 are unable to perform their first element until Operator #1 has completed one minute’s work on his first element and they can not complete their second element until Operator #1 has completed his first element. Likewise, Operators #4 & #5 are delayed in performing their first element until Operator #1 has completed the first minute’s work of his first element. The rolls of paper, as taken off the winder, average 36” in diameter and have a total length of approximately 2,500’ of paper. This assignment is to be done by each individual student. Neatness, grammar, and spelling count. Page 2 of 2
