Productivity is one of the major aspect in determining the profit or success in every business. There are so many products in our day to day life which cannot be manufactured without metals. The forging process is and will be into existence in order to cater the metal products requirement. This study was carried out in the forging industry which is one of the leading manufacturer of automobile components. The production is done in batches. All the processes and sub-processes were studied in detail to identify the potential areas to improve the productivity.
This paper focuses on improving the operator productivity in the cutting department. Various industrial engineering tools and techniques were used for analysing the manual activities in cutting department. Man-machine chart and ECRS technique gave an optimum solution to improve productivity and reduce the waste elements. IPO chart and DWM were prepared for exact understanding of the work in cutting department. We could reduce the manpower and thereby improve productivity which resulted in a cost saving benefit to company.