Umbilo Car Wash Production Line
Engineering Work Systems
Group 8
29 October 2024
Surname and Initials Student Number
1. Zungu NB 22302161
2. Somfongo L 22301736
3. Khumalo S 22301025
4. Thembani N 22301263
5. Thusi A 22303002
List of contributions to the report:
Task Member(s)
NB Zungu L Somfongo S Khumalo N A Thusi
22302161 22301736 22301025 Thembani 22303002
22301263
Introduction
Methodology
Observation
and process
analysis
Data Collection
Cycle time
calculation
Observations
and
measurements
References
abstract
1. Introduction
Umbilo Car Wash, located in Durban, serves as a significant center for vehicle
owners looking for reliable and efficient car cleaning services. Given the rise in
customer traffic, especially during peak hours such as weekends and holiday
seasons, the car wash faces difficulties in maintaining an effective flow of operations
while fulfilling high service quality standards. The aim is to analyze the car wash
process at Umbilo Car Wash, focusing on its operation, production line and its ability
to meet the company’s objective thus completing each car being washed within a
range of 25 - 30 minutes. To address these problems, this project explores the
optimization of Umbilo Car Wash's production line system to improve efficiency and
minimize cycle time per vehicle, allowing more cars to be cleaned in less time while
Figure 1: Umbilo car wash location
maintaining wash quality.
2. Methodology
It involves direct observations and time measurements techniques for each stage of
the car wash process, including an analysis of different vehicles and sizes. A
stopwatch was used to measure the time cycle of the process. Additionally, potential
limitations in worker behavior were analyzed. The flow process was well conducted.
This report aims to illustrate how the car wash operates as a production system, thus
identifying areas which require optimization.
The current method at Umbilo Car Wash is based on a semi-automatic assembly line
model, with vehicles passing through multiple stages: pre-rinse, soaping, scrubbing,
rinsing, drying, and final inspection. Each of these phases requires both physical
effort and automated equipment. However, when the car wash demand grows, this
existing procedure frequently results in bottlenecks, longer wait times, and
inefficiencies. The purpose of this project is to implement a systematic method to
optimize the workflow, which will focus on following areas.
The use of flow process charts, activity workers chart, tabulated observation time,
normal time and standard time, will be used to display recorded data
3. Results
Tasks were treated as a station in the production line, and each stage of the process
was timed to calculate the cycle time. This included pressure wash, soap application,
hand washing, drying, interior cleaning, and wheel polishing. During the process,
each production line consists of 4 workers, who are responsible for completing all the
tasks required to wash a vehicle. Including the following activities:
Pressure
Rinsing
washing
Soap Soap
Applicatio
Removal n
Figure 2: Loop car wash process Hand-
wasing
Flow Process Chart
Description: Umbilo Car Wash Production Line
Seq Activity Description Symbols Time Distance Analysis
.
1. The car is waiting to be 8.61 m
washed
D
1. Pressure wash 2.3 min Using water
only
2. The car is moved to the 3m
soap application station
3. Soap application Hand wash
of the
exterior
5. Pressure rinse 3.1 min
6. The car is moved to the 3m
drying station
6. Drying 14.7 min
7. The car is moved to be 3m
wheel polished
8. Wheel Polishing 4 min
9. Disinfection inspection 0.8 min
Process Decription
The vehicle enters the car wash, and a worker begins by spraying the
Pres car with high-pressure water to remove dirt and debris. This step
sure
was serves as the initial rinse.
h
After the initial rinse, soap is applied to the entire vehicle using a
Soa
p separate pipe or sprayer. This step prepares the car for thorough
appli cleaning.
catio
n
Han
Two workers then proceed to manually scrub the car’s exterior,
d ensuring that all surfaces are thoroughly cleaned with soap.
was
hing
Once the hand washing is completed, one worker uses the pressure
Soa
p
washer again to rinse off the soap from the entire car, leaving it clean
Rem and soap-free.
oval
A worker manually dries the car’s exterior and interior using towels or
air blowers. This step is critical, especially for larger vehicles, as it
Dryi
ng helps prevent watermarks from forming on the surface.
Time Study in minutes
Observed Normal time (Tn) Standard time (Tstd)
time Tobst x PR Tn(1 + Apfd)
(Tobst)
Pressure 1.18 1.18 x 67% = 0.79 0.79(1 + 15%) = 0.91
wash
Soap 0.88 0.88 x 67% = 0.59 0.59(1 + 15%) = 0.68
application
Hand 2.42 2.42 x 67% = 1.62 1.62(1 =15%) = 1.86
washing
Soap 3.8 3.8 x 67% = 2.55 2.55(1 + 15%) = 2.93
removal
Drying 16.52 16.52 x 67% = 11.07 11.07(1 + 15%) = 12.73
Wheel 4 4 x 67% = 2.68 2.68(1 + 15%) = 3.08
Polishing
Total cycle
time
Observed Normal time (Tn) Standard time (Tstd)
time Tobst x PR Tn(1 + Apfd)
(Tobst)
Pressure 0.83 0.83 x 67% = 0.56 0.56(1 + 15%) = 0.64
wash
Soap 0.75 0.75 x 67% = 0.50 0.50(1 + 15%) = 0.58
application
Hand 1.83 1.83 x 67% = 1.23 2.23(1 =15%) = 1.41
washing
Soap 2.5 2.5 x 67% = 1.68 1.68(1 + 15%) = 1.93
removal
Drying 15.1 15.1 x 67% = 10.12 10.12(1 + 15%) = 11.63
Wheel 4 4 x 67% = 2.68 2.68(1 + 15%) = 3.08
Polishing
Observed Normal time (Tn) Standard time (Tstd)
time Tobst x PR Tn(1 + Apfd)
(Tobst)
Pressure 1.62 1.62 x 67% = 1.08 1.08(1 + 15%) = 1.25
wash
Soap 1.83 1.83 x 67% = 1.23 1.23(1 + 15%) = 1.41
application
Hand 2.17 2.17 x 67% = 1.45 1.45(1 =15%) = 1.67
washing
Soap 2 2 x 67% = 1.34 1.34(1 + 15%) = 1.54
removal
Drying 18.02 18.02 x 67% = 12.07 12.07(1 + 15%) = 13.88
Wheel 4 4 x 67% = 2.68 2.68(1 + 15%) = 3.08
Polishing
Calculate Productivity and effeciency
Figure 3: This figure shows Fishbone diagram
Impact of the process on the environment
Water Use: Many carwashes recycle their water, which helps them save even
more.
Pollution: Professional car washes handle trash better than home washes, which
could pollute rivers and lakes with soap and dirt and grime.
Chemicals: While some vehicle washes utilize environmentally safe soaps, others
could employ harsh chemicals that harm the environment. (LI, TSE and FOK,
2016).
Impact of the process on the economy
Jobs: Residents get jobs from car washes. That means many carwashes create
job opportunities.
Local Business: By drawing clients who also shop nearby, they can support other
companies.
Taxes: Taxes paid by car washes go toward funding community services.
(Bocken et al., 2021).
Identification of Bottlenecks and Limitations
Community: Many car washes participate in neighborhood gatherings and
contribute to charity fund-raising.
Convenience: They give customers a quick and simple way to clean their
vehicles.
Environmental Awareness: Some encourage environmentally friendly behaviors,
educating people about conserving water and maintaining a clean environment.
Bottlenecks: Two major bottlenecks were identified:
A. Drying: The drying step, particularly for larger vehicles like the Avanza and
minibus taxi, took longer than expected, contributing to delays in meeting the
target time.
B. Interior Cleaning: Interior cleaning also took a significant amount of time,
especially for larger vehicles with more seating and space to clean.
Workers’ Behavior:
Socializing: Workers tend to socialize during the process, wearing earphones and
chatting which can slow down the workflow.
Breaks: Some workers occasionally take a smoke break lasting 2-3 minutes,
which impacts productivity.
Earphones: Workers wearing earphones may not always hear instructions or
notices from supervisors, leading to delays.
Improvements
Healthy means free from illness or Occupational injuries (South Africa, Department
of Labour 2004: 4). Implementing the 6S is the most suitable plan for improving the
Umbilo car wash productivity and efficiency by eliminating waste, reduce machine
breakdown and effective employee training on boarding and 6S training, resulting in
more cars washed at minimum labour time and high-quality service output. The 6S
are implemented below, serving as an engineering tool promoting professionalism
simultaneously prioritizing safety, ensuing that the supply is equalvent to the
demand, resulting in customer satisfaction.
Automated Wash Systems:
Implement completely automated vehicle wash systems to save labor expenses
and improve cleaning results consistency.
Use innovative methods to clean effectively and without damaging surfaces, such
as high-pressure rinsing or brushless systems.
Water Recycling Systems:
Investing in water recycling technologies can help cut water usage and minimize
its impact on the environment.
Use purification devices to guarantee that recycled water keeps a high level of
cleanliness.
Regular Maintenance:
Plan regular washing machine maintenance to avoid issues and guarantee top
performance.
Provide employees with training in proper usage and maintenance techniques to
improve the life of equipment.
Employee Training:
Staff members should receive thorough instruction on effective cleaning methods
and how to use equipment.
Safety protocols and quality control should also be emphasized. (Sampson and
Froehle, 2006).
Safety measures
Accident prevention, acknowledging and removing hazards in workplace is essential.
This can be done by placing safety awareness boards at every operation,
emphasizing on the importance of all subordinates to strictly always put on the
correct Personal Protective Equipment and proper signage at work, protecting them
from chemical and mechanical injuries, which include:
Closed shoes
Goggles
Facial musk
Gloves
Figure 3: This figure show flow chart
Flow Process Chart
Description: Umbilo Car Wash Production Line
Seq Activity Description Symbols Time Distance Analysis
.
1. The car is waiting to be 7 min
washed
D
1. Pressure wash 1.8 min Using water
only
2. The car is moved to the 3m
soap application station
3. Soap application 3 min Hand wash
of the
exterior
5. Pressure rinse 3 min
6. The car is moved to the 3m
drying station
6. Drying 14 min
7. The car is moved to be 3m
wheel polished
8. Wheel Polishing 3.5 min
9. Disinfection inspection 0.1 min
Time Study in minutes
Observed Normal time (Tn) Standard time (Tstd)
time Tobst x PR Tn(1 + Apfd)
(Tobst)
Pressure 1.18 1.18 x 100% = 1.18 1.18(1 + 15%) = 1.357
wash
Soap 0.88 0.88 x 100% = 0.88 0.88(1 + 15%) =1.012
application
Hand 2.42 2.42 x100% = 2.42 2.42(1 =15%) = 2.783
washing
Soap 3.8 3.8 x 100% = 3.8 3.8(1 + 15%) = 4.3815
removal
Drying 16.52 16.52 x 100% = 16.52 16.52(1 + 15%) = 18.99
Wheel 4 4 x 100% = 4 4(1 + 15%) = 4.6
Polishing
Total cycle
time
Observed Normal time (Tn) Standard time (Tstd)
time Tobst x PR Tn(1 + Apfd)
(Tobst)
Pressure 0.83 0.83 x 100% = 0.83 0..83(1 + 15%) = 0.95
wash
Soap 0.75 0.75 x 100% = 0.75 0.75(1 + 15%) = 0.86
application
Hand 1.83 1.83 x 100% = 1.83 1.83(1 =15%) = 2.10
washing
Soap 2.5 2.5 x 100% = 2.5 2.5(1 + 15%) = 2.875
removal
Drying 15.1 15.1 x 100% = 15.1 15.1(1 + 15%) = 17.36
Wheel 4 4 x 100% = 4 4(1 + 15%) = 4.6
Polishing
Observed Normal time (Tn) Standard time (Tstd)
time Tobst x PR Tn(1 + Apfd)
(Tobst)
Pressure 1.62 1.62 x 100% = 1.62 1.62(1 + 15%) = 1.863
wash
Soap 1.83 1.83 x 100% = 1.83 1.83(1 + 15%) = 2.10
application
Hand 2.17 2.17 x 100% = 2.17 2.17(1 =15%) = 2.49
washing
Soap 2 2 x 100% = 2 2(1 + 15%) = 2.3
removal
Drying 18.02 18.02 x 100% = 18.02 18.02(1 + 15%) = 20.72
Wheel 4 4 x 100% = 4 4(1 + 15%) = 4.6
Polishing
Conclusion
In conclusion this is the most suitable plan to improve the Umbilo car wash
production line for customers, and employees, ensuring that Umbilo car wash
increases and maintains its productivity. The analysis included, findings, some were
advantages for the car wash, some were disadvantaging the car wash. There are
recommendations on how to improve the layout, how traffic could be optimized and
how this saves the business time and money and then taking the business (Umbilo
car wash) to one step higher.
The report has clearly the Umbilo current production line and the methodology to
follow to produce exceptional results, the modern techniques, tools and Engineering
proficiency, Engineering methods and tools, demonstration of Engineering
professionalism, recommendations of the specified action plan of automated wash
systems, water recycling systems, regular maintenance, employee training, safety
measures, operating hours, budget and the timeline for the project to be successful,
attracting more customers, which then generate the Umbilo car wash economy.
Recommendations
To improve the efficiency and productivity of Umbilo Car Wash, (Industrial Students,
2024) kindly recommend the following changes to be made:
Applying Lean principles to assist in eliminating waste by reducing water
consumption in the car wash.
This will help in improving the workflow of the service in Durban, whereby
customers will receive quick assistance without waiting a long time in the
queue lane.
The acknowledgement of KAIZEN will help build the foundation of continuous
improvement within the local car wash, refining processes involved and
adding value to the service.
Using key performance indicators of the 6S principles will help in retaining a
positive image for Umbilo, thus attracting local and external customers
throughout the province of KwaZulu Natal, ensuring good accessibility
throughout social media platforms such as Twitter, Instagram and TikTok.
The importance of charting and diagramming will assist in tracking the GIS
system of the car wash, thus providing coordinates, directions and the
location of the car wash for better accessibility, especially to visitors in Durban
who may be lost in finding the location.
Implement an emergency service lane for people who are rushing to attend
pressing matters.
Include different payment systems such as Apple Pay since some customers
may not carry their physical cards. This will also improve customer
satisfaction.
A receipt for reviews and concerns should be considered, thus earning a good
relationship with the community of Durban and beyond as issues will be
attended beforehand.
