A TIME AND MOHON ANALYSIS OF CLEANING CPERATIONS IN MILK PLANTS Thesis {or Has Degree of M. S. MicmGAN STATE COLLEGE William E. Shiffermfifien ,195Q This is to certify that the thesis entitled "A TIME 19/00 4107-19” fiynuysis of (,Lgnyi/us- OPERATIONS uv Mal-K PLfiA/TS" presented by WILLIAM E. SHIFFEKMILLEK has been accepted towards fulfillment of the requirements for £— degree in- A 5"60‘- 70201. Erwin/6511416. Ummm Major professor Date M' [71/756 0-169 A TIME AND MOTION ANALYSIS OF CLEANING OPERATIONS IN MILK PLANTS BY William E. Shiffermiller W A Thesis Submitted to the School of Graduate Studies of Michigan State College of Agriculture and Applied Science In partial fulfillment of the requirements for the degree of MASTER OF SCIENCE Department of Agricultural Engineering 1950 THESIS ii ACKNOWLEDGEMEHTS The author wishes to express his apprecia- tion for the helpful suggestions and valuable assistance of Professor Arthur W. Farrell and Dr. Walter M. Carleton of the Department of Agricultural Engineering of Michigan State College. Acknowledgement is also due the Dairy In- dustries Supply Association for supplying the funds for the Fellowship under which this work was accomplished. The author also wishes to express his grati- tude to the management and employees of the dairies in which the data for this research project were collected. 244552 iii TABLE OF CONTENTS INTRODUCTION ---------------------------------- History of the Cleaning Operation in the Milk Plant ------------------------------ Attitude of Public Health Officials ------- Attitude of the Milk Industry ------------- Attitude of the Milk Plant Worker --------- Attitude of Equipment Manufacturers ------- Attitude of Cleaning Compound Manufacturers Explanation of Time and Motion Study ...... REVIEW OF THE LITERATURE ...................... Time and Motion Study Application in Allied Industries ----------------------- Specific Time and Motion Application in the Dairy Industry ------------------- Cases of Work Simplification in Dairy Cleaning -------------------------------- STATEKERT OF THE PROBLEM ...................... Importance of the Problem ................. Objectives -------------------------------- PROCEDURE ------------------------------------- RESULTS --------------------------------------- Type of Operation and Equipment - Dairy "A" Type of Operation and Equipment - Dairy "B" Type of Operation and Equipment - Dairy "C" Percentage of Total Plant Labor Involved in the Cleaning Operation ------------------ Breakdown of the Cleaning Operation Into Major Group Units ----------------------- Analysis of the Cleaning of Individual Pieces of Equipment --------------------- Accuracy of Comparison Between the Plants Studied and Application to all Milk Plants REC OMI‘IENDATI ONS ------------------------------- CONCLUSIONS ----------------------------------- LITERATURE CITED ------------------------------ APPENDICES Appendix "A" - ----------------------------- Appendix "B" ------------------------------ Appendix "C" ------------------------------ Page <0 CfiUHbt-bOJIOI-J ll 12 16 16 16 18 25 25 30 56 45 45 52 62 64 67 7O 20 38 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure l. 9. 10. 12. 15. 14. 15. 16. iv LIST OF FIGURES AND TABLES Time Study Observation Sheet ------- Dairy "A" 500 Gallon Milk Storage Tank and 100 Gallon Square Spray Vat ------------------------------ Dairy "A" Bottle Filler and Homogenizer ...................... Dairy "A" 200 Gallon Vats and Cabinet Milk Cooler -------------- Dairy "A" Separator-Clarifier, Cream Cooler, Milk Filter and Wall Open- ing Where Weigh Tank is Located -- Dairy "B" Clarifier, Homogenizer, and Preheater .................... Dairy "B" Bottle Filler ------------ Dairy "B" Wash Tank and Pipe Rack. Paper Bottle Machine was Installed but not Operated ................. Dairy "B" Milk Pasteurizing Vats --- Dairy "B" Weigh Tank ............... Dairy "B" 1000 Gallon Square Milk Storage Tanks .................... Dairy "B" 2000 Gallon Milk Storage Tank ----------------------------- Dairy "B" Cabinet Cooler, Separator, 200 Gallon Butter Milk Vat, and 100 Gallon Cream Vat ------------- Dairy "C" 1000 Gallon Milk Storage Tank and Positive Pump ----------- Dairy "C" 2500 Gallon Milk Storage Tank and Centrifugal Pump -------- Dairy "C" Bottle Filler ............ Page 24 28 28 29 29 52 55 55 54 54 55 55 59 59 4O Figure Figure Figure Figure Figure Table Table Table Table Table Table 17. 19. 20. 21. Page Dairy "C" Homogenizer, and Small Parts Rack ----------------------- 40 Dairy "C" Short Time Pasteurizer, 500 Gallon Vats, and Small Wash Tank ----------------------------- 41 Dairy "C" Separator, Preheater, and Positive Pump .................... 41 Dairy "C" 500 Gallon Vertical Coil Vat, and 500 Gallon Butter Milk Vat ------------------------------ 42 Dairy "C" 500 Gallon Cheese Milk Pasteurizing Vats and Surface Cooler --------------------------- 42 Percent of Total Labor Cost Repre- sented by Cleaning Labor --------- 44 Time in Minutes Involved in Major Cleaning Operations - Dairy "A" -- 45 Time in Minutes Involved in Major Cleaning Operations - Dairy "B" -- 46 Time in Minutes Involved in Major Cleaning Operations - Dairy "C" -- 47 Percentage of Total Cleaning Labor Represented by Major Group Units - 49 Time Involved in Preparing washing Solutions, and Getting and Re- turning the Hose for Rinsing ----- 50 Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table A-So A-G o A-7 o A-B. A-9. A-lO. A-ll. A-12. A-15. A-léo A-15. A-l6 c A-17. A-lB 0 vi APPENDICES TABLES Appendix A Dairy "A" 200 Gallon Round Pasteurizing Vat —————————————— Dairy "A" weigh Tank ............ Dairy "A" Small Cream Surface Cooler ........................ Dairy "A" Multiple Section Cabinet Cooler ---------------- Dairy "A" Milk Filter ----------- Dairy "A" 100 Gallon Spray Vat -- Dairy "A" 500 Gallon Milk Storage Tank .......................... Dairy "A" Bottle Filler --------- Dairy "A" Acid Washing of 200 Gallon Vats Once Per Week ----- Dairy "A" Homogenizer ----------- Dairy "A" Separator ------------- Dairy "A" Clarifier ............. Dairy "A" Centrifugal Milk Pump - Dairy "A" 60 Gallon Round Butter Milk Vat —————————————————————— Dairy "A" 200 Gallon Cheese Vat — Dairy "A" Hot Water Sterilization of Equipment .................. Dairy "A" Assembly and Disassembly of Sanitary Pipe and Fittings - Dairy "A" Washing of Sanitary Pipe and Fittings .................. Page ll 15 14 15 16 l6 17 18 Table A—lQ. Table A-20. Table A-22. Table B-2. Table B-5. Table B-4. Table B-5. Table 8-6. Table B-7. Table B-8. Ta‘Ole 8-9 0 Table B-lO. Table B-ll. Table 8-12. Table 3-13 0 vii Dairy "A" Preparing Buckets of Chlorine Solution --------------- Dairy "A" Preparing Buckets of Washing Solution ---------------- Dairy "A" Filling and Emptying Wash Tank ....................... Dairy "A" Miscellaneous Pipe Washing Operations -------------- Appendix B Dairy "B" Weigh Tank —————————————— Dairy "B" Multiple Section Cabinet Cream Cooler -------------------- Dairy "B" 1000 Gallon Square Milk Storage Tanks ................... Dairy "B" 100 Gallon Round Cream Pasteurizing Vat ———————————————— Dairy "B" 2000 Gallon Upright Milk Storage Tank .................... Dairy "B" 200 Gallon Rectangular Pasteurizing Vats ............... Dairy "B" 200 Gallon Round Butter Milk Vat ------------------------ Dairy "B" Clarifier ............... Dairy "B" Separator --------------- Dairy "B" multiple Section Cabinet Milk Cooler --------------------- Dairy "B" Bottle Filler ----------- Dairy "8" Homogenizer ------------- Dairy "B" Centrifugal Milk Pump --- Page 18 18 19 19 2O 21 22 22 25 24 24 25 27 28 29 51 52 Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table B-l4 o B-15. 8-160 8-17. 3-18. B'lg . 0-10 0-2. 0-5. C-4. C-5. C-6. C-7. C-8. 0'90 C-lO. C-ll. Dairy "B" Positive Displacement Pump ------------------------------ Dairy "B" Tubular Preheater --------- Dairy "B" Making up Buckets of Cleaning Solution ----------------- Dairy "B" Filling wash Tanks -------- Dairy "B" Sterilizing Equipment ----- Dairy and "B" Washing Sanitary Pipe Fittings ---------------------- Dairy "B" Assembly and Disassembly of Sanitary Pipe and Fittings ----- Appendix C Dairy "C" Weigh Tank ---------------- Dairy "C" HomogeniZer --------------- Dairy "C" 2500 Gallon Storage Tank -- Dairy "C" 300 Gallon Round Pasteurizing Vat .................. Dairy "C" 500 Gallon Square Coil Vat Dairy "C" Positive Displacement Pump Dairy "C" Tubular Preheater -------- - Dairy "C" Bottle Filler Dairy "C" 500 Gallon Round Pasteurizing Vat —————————————————— Dairy "C" 1000 Gallon Upright Milk Storage Tank ...................... Dairy "C" Vertical Coil Round Pasteurizing Vat .................. Page 55 54 54 55 55 56 57 58 59 4O 40 41 42 44 45 47 47 48 Table C-12. Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table C-15. 0.14. 0’15 0 0-16. C-17. 0-18. 0-19. 0-20. C-2l. C-50. 0-51. 0-520 ix Dairy "C" 1000 Gallon Cottage Cheese Vat ----------------------- Dairy "C" 800 Gallon Cottage Cheese Vat Dairy "C" Surface Cooler ----------- Dairy "C" 40 Gallon Surge Tank for H.T.S.T. Pasteurizer Dairy "C" multiple Section Cabinet Cooler Dairy "0" Clarifier ................ Dairy "C" Separator ---------------- Dairy "C" Raw Milk Plate Cooler -—-- Dairy "C" Centrifugal Milk Pump ---— Dairy "C" High Temperature Short Time Pasteurizer Dairy "C" Preparing Buckets of Cleaning Solution ---------------- Dairy "C" Sterilizing Equipment ---- Dairy "0" Filling Small Wash Tank -- Filling Large Wash Tank -- 2" Valves ................ Dairy "C" Dairy "C" Dairy "C" 1%" Valves ............... Dairy "C" Assembly and Disassembly of 2" Pipe at Short Time Pasteurizing --------------------- Dairy "C" Washing 2" Pipe and Fittings at Short Time Pasteurizer Dairy "C" Wash 1%" Sanitary Pipe and Fittings --------------------- "C" Assembly and Disassembly Dair " Sanitary Pipe and Fittings --- l 12 Dairy "C" 2" Pipe Washed on Power Driven BruSh ..................... Page 49 5O 5O 51 52 55 55 56 57 58 59 59 6O 6O 6O 61 61 62 65 64 INTRODUCTION Histogy of the Cleaning Operation in the Milk Plant Milk while being natures most nearly perfect food has the disadvantage of being a good media for the growth of bacteria. Some of these bacteria cause only spoilage of the product, but others are disease producing organisms capable of causing serious milk borne epidemics. The use of milk as a food dates from the earliesl're- corded history, but the sanitary handling of milk is of comparative recent origin. The rise of the great urban centers of the world and particularly the urban growth of the United States after 1860 made the distribution of milk a complex problem. The outbreak of several milk borne epidemics shortly before 1900 gave a great impetus to sanitary control of milk supplies. One of the earliest recorded efforts was by Dr. Henry Coit of Newark, New Jersey, who in 1894 formed the Essex County Medical Milk Commission.which was the forerunner of the American Association of Medical Milk Commissions (l). The progress since that time has been rapid until today the quality control of milk sup- plies has reached a very high level. The number of milk borne epidemics has been reduced to almost none and the keeping quality of this periShable food has been greatly increased. The methods used to clean.the equipment in.the early milk plants varied from.conscientious attempts by the -2- better operators to do the best job possible with the limi- ted cleaning methods and.materials available, to outright filthy practices by the poorer operators. Most of the improvement in plant sanitation.has come about since 1920. The steady improvement of cleaning mat- erials and detergents has made it possible to do a much better job of cleaning. Also the introduction of stainless steel in equipment construction made cleaning much.easier. In general, the method employed in cleaning milk plant equipment today is: 1. After use, flush lines and equipment with water. 2. Disassemble all lines and equipment. 5. wash all milk contact surfaces using various solu- tions of commercial washing chemical compounds and various brushes, sponges, etc. 4. Rinse all lines and equipment with clean water. 5. Assemble equipment. 6. Sterilize by the use of hot water, steam, or chemi- cal sterilizers. Attitude of Public Health Officials The public health official can well point with pride to his record in improving plant sanitation practices in milk plants. Today the milk plant is looked upon with envy f by other branches of the food industry. The attitude of the regulatory official as to the actual method of plant equipment cleaning varies somewhat from ,y -5- area to area, but most milk ordinances state a fairly definite.method of plant equipment clean up. Due to limited personnel, it is impossible in actual practice for the health.official to inspect the cleaning methods used in the milk plant very often. He must de- pend on periodic inspections and bacteriological analysis of the product to control sanitation practice. In the past, sanitation programs have been plagued by political appointment of unqualified personnel without technical training. While this has been reduced very much in recent years, it is still all too prevalent. The right thinking health official knows that a re— sponsible milk plant operator is not going to jeopardize his investment by unsanitary practices. But the official must make his rules to cover the most unscrupulous operator. The health official should be trained scientifically and be able to accept scientific data concerning plant equipment cleaning methods. Attitude of the Milk Industry The attitude of management toward the cleaning opera- tions has varied from extreme interest in good plant sanitation and complete cooperation with health officials, to a few cases of slovenly practices and outright resistance to board of health regulations. : In general, management has not taken a very great in- terest in the methods of cleaning and have tended to accept , this expense as a necessary evil. Very few plants break their labor costs down far enough to include cleaning labor as a separate item, and those that do, accomplish it in a rather hit and miss manner. This is true of the large corporations as well as small plants. The recent man power shortages of the war and post war periods has caused an upsurge in cleaning method investi- gation. Investigations are now under way or contemplated that may revolutionize the whole cleaning operation. Attitude of the Milk Plant Worker The cleaning operation in the milk plant is one of very great importance, yet in the past, the poorest type of workmen were usually given the job. Most dairy workmen do not consider the clean up job a very desirable one. Typical comments are: "It is a woman's work", "I get too wet", "I want to operate the equipment". There are some grounds for complaint from a health standpoint. The clean up man is constantly exposed to wet, damp conditions which can give rise to colds, rheumatism, etc. Attitude of Equipment Manufacturers The equipment manufacturer must satisfy both the regu- latory official and the milk plant customer. ‘Unlike many other lines of machinery, the dairy equipment engineer must first consider the sanitary aspects instead of the mechanical or other aspects. For many reasons, some pieces of equipment require -5- large amounts of labor to disassemble, clean, and reas- semble. The design of equipment is usually the result of a compromise between the factors of public health reg- ulation and cost. The equipment companies have constantly improved their equipment and milk plant equipment is generally considered the best in the food industry. The equipment engineer could undoubtedly design equipment that would be easier to clean if he did not have to compromise on so many other factors. Attitude of Cleaning_Compound Manufacturers The cleaning compound manufacturers have constantly improved cleaning compounds. Every year they spend large amounts of money on research in trying to develop better cleaning compounds. much of their work has been on the compounds themselves rather than the actual method used in the plants, although they have contributed much in the latter field. In general, their attitude has been one of service to the industry rather than just salesmen of cleaning compounds. They also must give considerable attention to regulatory officials wishes. Explanation of Time and Motion Study Time and motion study is the analysis of the methods, of the materials, and of the tools and equipment used, or -5- to be used in the performance of a piece of work. This analysis is carried on with the purpose of: 1. Finding the most economical way of doing the work. 2. Standardizing the methods, materials, tools and equipment. 5. Accurately determining the time required by a qualified person working at a normal pace to do the task. 4. Assisting in training the worker in the new method.(2) In simpler terms, it is work simplification and is one of the tools used in the rapidly expanding field of methods engineering. In the past there has been a tendency to separate time study from motion study, but in recent years this tendency has been reversed and they are now considered together as they supplement each other. It is generally agreed that time study was originated by Frederick W. Taylor at the Midvale Steel Company in 1881. (5) The originators of motion study as we know it today were Frank B. Gilbreth and his wife Lillian M. Gilbreth. (4) The work of this great man and wife team is one of the most interesting in the field of science. Their life and work were the basis for the current best selling book, "Cheaper by the Dozen", and the motion picture of the same name. Mr. and Mrs. Gilbreth broke down opera- tions performed by man into fundamental motions of the two hands which they called Therbligs. By the use of these tools they sought to simplify operations in many fields. -7- In the general use of time and.motion study, the oper- ation is broken down into its simplest elements or steps. The steps are then put on a devise known as a process chart which is a graphical representation of each step needed to complete the operation. A flow diagram is then made which traces the path of the operator, material, or object through the plant. This is usually followed by an activity chart which is a breakdown of the operation plot- ted against a time scale. After all this is completed the data are analyzed in an effort to find a better method. Each step is subjected to rigid questioning to find if it is necessary, if it can be combined with other steps, or be replaced by a better step. When the operation has been improved, it is then After the operator has become The taught to the operator. proficient in the new method, a time study is made. operation is broken down into elements or steps and a stop watch reading is taken of each step. Enough readings are taken to assure a representative sample, usually around ten for each element. The performance is then rated, which is that part of a time study in which the person taking the study rates the operator with his own idea of a normal performance. The normal performance is usually taken as 100 per cent. The rating given the operator is then multiplied by the average time of each step. This time will then equate all operators both fast and slow. All of the individual -8- times of each step are then added up to give the total time for the whole operation. To this is added an arbi- trary amount to take care of allowances for rest, per- sonal needs, or unusual working conditions. The result is the standard time for the operation. This time is then used as a basis for establishing piece work rates, setting a fair days work, predicting man power requirements, and predetermining cost of finished product. The mass production industries have made the most use of time and motion study. Most of these industries have methods engineering departments who search constantly for better methods using time and motion study as a tool. Most of the operations in these industries are of the repetitive type which is a short sequence of operations repeated at frequent intervals. This type of operation lends itself very well to time and motion analysis, and most time and motion work in the past has been on these operations. In recent years time and motion study has been expanded to include some nonrepetitive operations such as maintenance work, janitor clean up, and work operations occuring at infrequent intervals. One of the most interesting chapters in the growth of the great automobile industry is the use of time and motion studies in their never ending search for better methods. -9- REVIEW OF THE LITERATURE The use of time and motion study in milk plant opera- tion is so new that very little reference to it can be found in the literature. Reference to specific applica- tions to the cleaning operation cannot be found. Therefore most of the references cited have been taken from other industries that have more or less simi- lar operations. The milk industry has always tried to practice some work simplification, although it was never given exactly this methods engineering nomenclature. Considerable amounts of literature on the cleaning opera- tion in milk plants are available, but most of this is on the compounds rather than the methods. Time and Motion Study_Applications in.Allied Industries That time and motion analysis can be applied to non- I repetitive operations was demonstrated by Sadoff (29) who made time and motion studies of all the clean up and ! maintenance operations at the large Swift and Company meat packing plant in Chicago. Six senior time study men de- voted three full years to this study. They were able to simplify the operations and establish standard times for each operation. Gobb (15) also established standard times for truckers and sweepers and put these men on an incentive pay plan which reduced the man power required from 19 to 11 men. -10- Emmons (ll) applied time and.motion analysis to the jan- itors in a factory building, and was able to establish a schedule of operations that resulted in large savings. In his work with.time and motion applications to job order shops, Tidball (32) proved the fallacy in the state- ment that it was impossible to have standard times for special order shops. The continuous flow processes of the chemical industries have much.in common with milk plant operation. Von Pechmann (34) and Rossmoore and Aries (26) applied time and motion analysis to these industries with great success. They re- port savings in time up to 54% on some operations. In the liquor distilleries, large amounts of time are spent in bottling and clean up operations much like milk plant operations. Vlissinger (35) applied time and motion studies to these operations and reports savings as high as 53%. All operations in the food industry have much in com- mon. The use of time and motion studies in food plants other than dairy plants has become quite common in recent years. Engel (l2) reports some very interesting savings made in an English walnut food factory. Nadler (20) ap- plied time and motion study to canning plant operations with a great deal of success. He lists some of the re- sults of these studies: 1. Improved schedules. 2. Predetermination of job requirements. 5. Checks on worker efficiency. 4. Determination of best methods. Mundel (19) has devoted a large amount of time to ap- plications of time and motion study to farm operations such as doing farm.chores. These operations in the past have taken a large amount of the farmers time. In some cases Mundel was able to reduce the time required by 50%. Another interesting time and motion application by Mundel was on the hand peeling of tomatoes in a canning factory. By the use of micromotion camera studies, he was able to effect large savings on this operation (18). That time and motion study has many uses other than rate setting was brought out by Stearns (28) when he ex- plained the plant managers use of time and motion study by controlling schedules, man power requirements, and method of operation. Teranes (51) made a study of the walking required in a factory packing department. By the use of time and motion analysis he was able to reduce the walking required per man in an 8-hour day from.12,000 feet to 1800 feet, with a resulting saving in labor of over 30%. Specific Time and Motion‘Applications in the Dairy Industry Probably the most extensive use of time and motion study in the dairy industry has been made by the H. P. Hood and Sons Company. This dairy firm has established a full time methods engineering and work simplification -12.. department. This department has been in operation 8 years, and during this time, they have been able by the use of time and motion analysis to reduce their operation time considerably (10). Dunlop (9) explains his method of training personnel in work simplification by the use of company schools. At present, this company is making a work simplification study of the cleaning operation in their plants. Felling (24) reports the use of time and motion analy- sis applied to wrapping cheese in an Australian cheese factory. He was able to save 2500 dollars yearly by an improved method. Morrow (17) applied time and motion study to the retail delivery of milk with good results. The use of time and motion study in.a British.milk bot- tling plant is discussed by Proctor (23) in a paper presen- ted at the 1949 Worlds Dairy Congress. Cases of Work Simplification in Daigngleaning Perry and co—workers (22) have developed several clean- ing aids which show considerable promise in reducing clean- ing costs. He lists the following aids: l. The Hot water Generator. - This machine eliminates the suction tee and delivers water at a tempera- ture of 115 degrees F. to special hose stations. These hose stations are strategically located about the plant. The water supply is controlled by shut off valves located at the end of the hose. 2. 3. -15- Sanitary Pipe Cleaner. - This machine by the use of solution fed revolving brushes, and a novel rinsing arrangement enables a sanitary pipe to be cleaned inside and out, and rinsed in a con- tinuous arm motion. Sanitary Fitting Cleaner. - This machine utilizes a tank equipped with solution fed revolving brushes, both inside and outside. A continuous stream of water from.a tap enables quick rinsing. Separator Disc Cleaner. - This machine uses solu- tion fed revolving brushes that cleans the inside and outside of the disc at the same time. Solution Fed Hand Brushes. - These are brushes in which the solution is pumped through the handle into the brushes while cleaning. Central Cleaning Solution Tank - This utilizes a central tank in which all general cleaning solu- tions are mixed and then piped to various outlets in the plant. Spray Sterilizing Unit. - This machine forces the sterilizing solution by air pressure through a hose and jet nozzle. It is used for spraying vats, storage tanks, etc. A recent development in the cleaning of cold milk stor- age tanks is the use of pump fed revolving jets. This machine consists of a solution tank, pump, pipe and jets. The jets which revolve in a horizontal and vertical plane -14... are placed in the center of the tank, and the cleaning solution is circulated through the jets until the tank is clean. Good results were reported by the plant operator and these results were checked by board of health officials. This method was tried on.hot milk tanks with less success but more experimental work is contemplated on this phase (50). Samuelson (27) found the use of the steam jet utilizing the Venturi principle with a cleaning solution was effective and economical in cleaning equipment exteriors, conveyors, floors, and bottle capping machines. Myrick (16) states that from 20 to 25 per cent of the total plant labor cost is involved in the cleaning opera- tion. This is in agreement with Robinson's estimate of 30 per cent (25). myrick also suggests that brushes are an important factor in labor saving in.the cleaning operation. He recommends that the brush should be designed especially for each cleaning Operation, with emphasis placed on the size, shape, and kind of bristles. Fowler (14) found that the cleaning operation was the most neglected job in the dairy, given for the most part to the poorest worker. He suggests that the cleaning operation should be a carefully planned operation with each piece of equipment cleaned in a standard manner. The function of plant design in the cleaning operation is brought out by Burnett in his explanation of the opera- tion of the new Producers Creamery Company plant at Lebanon, -15- Missouri. This plant has been designed for sanitation with equipment layout and cleaning operations planned in detail. This plant uses a great deal of glass pipe which is cleaned in place by circulatory methods (5). For a number of years the dairy plants in Europe have been using circulatory methods for cleaning dairy equip- ment without disassembly. In general, the sanitary stan- dards in Europe are lower than in the United States, but it may be to our advantage to make a thorough investiga- tion of this great labor saving method. Fisker (l5) and Postumus (21) in papers presented at the 1949 Werlds Dairy Congress explain systems used to clean by circulatory methods a milk pasteurizing plant com- pletely assembled. The general method is as follows: 1. Plush system with cold water. 2. Circulate with alkali cleaning solution. 5. Flush.with cold water. 4. Circulate with acid cleaning solution. 5. Flush with water. 6. Circulate chlorine solution and leave solution in system until next operation. -15- STATEMENT OF THE PROBLEM A Time and Motion Analysis of the Cleaning Operations in Milk Plants. Importance of the Problem The equipment in the milk plant consists of some 14 to 20 pieces of machinery. All of this equipment is made of stainless steel, tinned copper, or some alloy suitable for milk handling. This equipment is connected.by sani- tary milk pipe in lengths varying from 10 feet down to 5 inches. In these lines are tees, ells, and valves. The amount of pipe varies from about 100 linear feet in small plants to as high as 10,000 linear feet in large plants. Every piece of equipment and all the sanitary lines are completely disassembled, washed, reassembled and then sterilized every day, 565 days per year. This is a very time consuming and expensive operation as well as a dis- agreeable task from.the workers standpoint. Objectives To determine the elemental motions involved in the cleaning operations in three commercial milk plants,and to find the average time required for a normal worker to perform.these elemental motions. To study the resulting motions and elemental times for the purpose of: 1. Eliminating unnecessary motions. 2. 3. 4. 5. -17- Simplify necessary motions. Determine the individual parts of pieces of machinery that require the most time to clean. Determine the percentage of total labor cost represented by the cleaning operations. Make comparisons between the three dairies when practical. Break down the operations into major group units and analyze these units. All of the suggested simplifications to be based on known practices, and equipment available at the present time. -13- PROCEDURE Three commercial dairies were selected according to representative size. Dairy "A“ received 20,000 pounds of milk daily, dairy “B" 40,000 pounds, dairy "C" 100,000 pounds. A great deal of credit must be given the manage- ment of these companies for granting permission to make such.a study so unusual to the dairy industry. The first thoughts of a dairy worker on having a stop watch check his work is that the manager is checking on.him and is dissatisfied with.his production. It was necessary to use a great amount of diplomacy and sell the men on the purposes of the study. By proceeding on this basis, the entire study was completed without incident and in a spirit of mutual good will. In the mass production in- dustries, this problem.wou1d not present itself as their i workers are familiar with the use and functions of time and motion study. Dairy "B" was a union plant, while dairies "A" and "C" were non-union. This type of study falls into the nonrepetitive class, and it is one of the hardest of this class to which to apply time and.motion analysis. The ordinary time and motion study is made on short cycle operations of a few elements or steps repeated many times per day. The clean- ing operation in a milk plant is performed only once daily. The various cleaning operations are performed at any time in the 24-hour day, and the number of elements -19- or steps can run as high as 100 on some pieces of equip- ment. In an ordinary time and motion application, a motion and work simplification study is made first. Then the worker is trained in the better method after which a time study is made of the new method for rate setting purposes. In.this study it was impossible to instruct the worker, nor was it desired, as the motions and time desired were as exist today in representative commercial milk plants. The procedure followed was to make repeated Observa- tions of the cleaning Operation of each piece of equipment. Each Operation was broken down into elements or steps that were convenient to time. When it was reasonably certain that each step of a particular operation was followed.by the worker without change, a time study of the operation was made. The watch used was a decimal minute watch with one sweep of the hand divided into one hundred parts of one hundredth of a minute each. All time recorded was in unit minutes and hundredths of a minute. The method of timing used was the "snap back method". This method is open to some criticism.in that some small amount of time is lost in the snapping of the hand back to zero at the end of each element, even though.the watch automatically starts again. Most of the criticism.of this system occurs when it is used for rate setting. In -20- this study, rate setting was not involved and due to the uninstructed worker not always following the elements in numerical order, this method was much easier to apply. Carroll states (6) "While observing a long series Of very fast elements, the continuous method is invaluable. For practically all other studies, the snap back method is much preferred. The snap back method includes a small error in each reading. This is inconsequential in comp parison with the probable errors in human judgment in- cluded when rating the performance." The elements of each Operation was recorded on the regular time study sheets used by the Industrial Engine- ering Section Of the Mechanical Engineering Department at Michigan State College. These sheets were not exactly suited to this type of study, but they were already printed and it seemed advisable to take advantage of this. In most cases ten elemental time values were taken for each step. This required a great amount of time, both in the Observation of the worker as to his motions, and the recording of the time for ten complete cycles. The ten elemental times were then averaged arithmetically and the actual time for each element found. The most important problem of the study was then en- countered in the question of how to rate the performance, and apply allowances. This will be the most difficult part for the dairy layman to understand. In all industrial -21... applications Of time study, it is desired to find the time required for an average worker to perform a given task. For this reason, the performance is rated as to the effort of the particular worker. Workers vary a great deal in their speed of performance, this range us- ually being from one third of normal performance to twice normal performance (7). In this study it was also desirable to arrive at the time required for the average worker to perform the task. All the Operators were rated on a basis of 100% for an average operation. Another interesting aspect of the rating of this study is the question of the cleanliness of the equipment after the performance. Certainly, the time required to perform a cleaning operation is a function of the cleanli- ness of the equipment after cleaning. In the rating of the worker as to speed and efficiency, the writer leaned heavily on his more than a decade of practical experience as a dairy worker and plant superintendent. In this study, it was assumed that the equipment was cleaned satisfactorily after the performance of the task. In cases where there was reason to doubt this, the entire cycle time was discarded. Also, during the entire time of this study, the products of these dairies were under rigid board of health bacteriological analysis, and all Of the products were within legal limits. This position -22.. seemed tanable, because of the fact that it was desired to find the time required in the cleaning operation as it exists today in commercial plants. The rating Of the performance makes it possible to arrive at elemental and cycle times that, with.eome de- gree of accuracy, would be applicable to all milk plants. Allowances are then combined with the rating and ap- plied to each actual element time. The concept of allow- ances is one that may come as a surprise to some dairy managers. Many of these managers like to believe that they get close to sixty minutes work per hour out Of each plant worker, but such is far from the actual case. Allow- ances must be made for personal needs, such.as going to the toilet, getting a drink, etc. Additional allowances must be made for fatigue and avoidable and unavoidable delays. The value of these allowances depends very much on the type of work involved. In some types of work such as blast furnace work in steel mills, this may run as high as 50%, while in light work, under good conditions, it could be as low as 5%. Most shop Operations fit in a class for which 20% is normal allowance (8). The figures that were used in this study were 5% for personal needs, 10% for fatigue allowances, and 5% for de- lay allowance, making a total allowance of 20%. This seemed to be a reasonable allowance for this type of work —23_ which.is not of the worst type, but nevertheless is not of the best, because of hot, wet conditions. This would be in line with the over-all shop average, and from the writer's own experience this is about as it exists in com- mercial plants. Most of the pieces of equipment was relatively easy to break down into timeable elements although some of the equipment required a large number of elements which were completed at different times in.the day. The most dif- ficult operation to break down was the disassembly, clean- ing and reassembly of the sanitary pipe. This required a great deal of thought in order to keep from.having merely a total time, which would not explain very well where the time was involved. The system decided upon was to divide the pipe into representative lengths of 6" to 2', 2' to 4', 4' to 7', and 7' to 10'. By taking enough time trials of each length division, it was possible to arrive at a fairly accurate figure. The disassembly and assembly were broken down into elements. The carrying of the pipe to and from the wash tanks was based on actual trips made without re- gard to pipe length. After all the equipment in all three milk plants was timed, it was then recorded in the final form and analyzed. 2000 DAIRY "B1! &ALLON UPRIGHT - —a t H E—o J V1 01:25.“ - rm 1. 17"“ alkafiéiuu DALK 10 013811 :LélHlOle. 01.7.30 057 e99 .471 0&6 0:58 .L‘l on“? 01:23 053 _ .557 120; .404 2. walk 20 ft., turn on water in hose, return to vat .40 .58 .49 .45 .45 .56 .59 .45 .48 .44 with hose. . _ .435 " .510 5. Rinse Tank. 2.40 5.10 2.65 2.59 2.56 2.48 2.5c 2 48 2.59 2.46 2.522 " 5.026 4. Walk 50 ft., get bucket of cleaning solution and .85 .95 .87 .75 1.05 .98 .91 .84 .79 .88 return to tank. .882 N 1.05 5. Climb into tank with bucket and brush. .60 .75 .65 .581 .07 .69 .71 .68 .59 .65 .655, " .785 6. Josh Tank. 5.40 4.10 5.01 5.91 5.46 4.10 5.87 5.45 5.81 4.01 , _ _ p 5.712 " 4.454 7. Climb out of tank. .50 .55 .51 .291 .58 1 .51 .55 .40 .58 . 4 _ .541 ” .409 8. ‘fiash manhole cover. 1.50 1.29 1.55 1.45 1.51 1.19 1.25 1.59 1.56 1.28 . 1.510 " 1.572 9. Rinse Tank. 1.20 1.55 1.55 1.251 1.18 1.17 1.24 x 1.54 1.56 . 1.266 " 1.519 10. ‘Ealk 20 ft., return hose, turn off water, return .37 .59 .45 .36 .55 .44 .57 .41 .45 .52 to tank. .587 " .464 110 Close 11151131013. 051 047 .63 045' .57 .51 056 .63 X .53 .556 " .645 _ i - 1 -_ _ 1 cl .7 -_ _____11. i__ - - .11 a--_i_-ci--.._--l_ca.n_«.__i_ic”___ii__l 1 1 - ._ n_i-i-i_ - - - ;__.l _____,- __ ,, 1-4,--i __ -_. 4 - -1. L _-_ __.-__~___________+._____ ‘ a 1 1 3 ” —‘””“TT"'T 7 ” ”“”"“""'"’7‘“‘m" '"”“”—””“”ETI?IT‘5 1 1 _ . 1‘ r: T)» ~___ _ ii a. ‘ _- +______ 1 rfomamtlng 100% 1 14.840 1 ’ ‘ Allowances 29%“ 1 1 _- - 1 q a “ ‘ “"9 V. 1 1. mmwwumaamw W1 1 REAfJflN 1 2 ,1’11i11’ ‘Aix‘i‘ 111111112 1 .«TA'VDA‘M‘ 11(1‘1535» ""1 11' 1V 1'13 [TIP OPFRAHMv'sVAME T‘Uff Ikerb '1vm1 RAH “H1‘ RAM 5 ‘3 M 1,. Wow 1‘T1.‘\1 1’11" «111+» Figure l — Time Study Observation Sheet RESULTS The description of the motions involved, and the time required for each step in the cleaning operations can be found in the appendices. Appendix "A" applies to Dairy "A", Appendix "B" to Dairy "B", and Appendix "C" to Dairy "C". A complete time study observation sheet as an ex- ample is given in Figure 1. Type of Qperation and Equipment - Dairy"A" This dairy is typical of small fluid milk plants. The products handled include bottled milk and cream, cho- colate milk, butter milk, and cottage cheese. The milk is received in 10 gallon cans from the producer pick up trucks and it is processed in the regular manner. From the filler, the cases are handled by case trucks to the refrigerator, and are loaded on the route trucks in the same manner. Receiving Equipment - The receiving equipment consists of a two compartment weigh tank suspended over a surge tank. The equipment is placed in a space out in the wall, with dumping on one side of the wall and the milk pumped away on the other side. Iilk Filter - The filter is of the plate type, with the filter cloth held between two plates. Separator and Clarifier - Both the separator and the Clarifier use the same frame and driving mechanism. The -26... interchange of bowl parts makes it possible to change from separating to clarifying. Each.has a capacity of 5500 pounds per hour. Pasteurizing Equipment - This equipment consists of two 200 gallon round glass lined vats, and one 200 gal- lon stainless steel vat. Each of these vats have an enamel outside lining. In addition, a small 100 gallon square spray vat is used for special products. The but- ter milk vat is a 60 gallon round glass lined vat with a vertical coil. Milk Cooling Equipment - The pasteurized milk is cooled over a multiple section surface cooler of the cabinet type. This cooler is of an older type and the brine and water headers must be removed for cleaning. The cooler is composed of 5 sections. The cream is cooled over a small single section surface cooler. Homogenizer - The homogenizer is of the single stage type with a capacity of 500 gallons per hour. Bottle Filler - The bottle filler is a 10 valve fil- ler with 4 capping heads of the rotary type. Milk Storage Equipment - This equipment consists of one 500 gallon horizontal cylinder type tank with a sur- face cooling section inside. Milk Pumps - Two centrifugal milk pumps and one posi- tive displacement pump are used. Sanitary Pipe and Fittings - The pipe and fittings -27- are of the 1%" size, with a few 1" pieces. Cleaning Equipment - The cleaning equipment consists of one wash tank 11' x l' x l' with pipe rack attached, and assorted brushes and sponges. -28... Figure 2 - Dairy "A" 500 Gallon Milk Storage Tank and 100 Gallon Square Spray Vat Figure 5 - Dairy "A" Bottle Filler and Homogenizer -29- Figure 4 - Dairy "A" 200 Gallon Vats and Cabinet Milk Cooler Figure 5 - Dairy "A" Separator-Clarifier, Cream Cooler, Milk Filter, and Wall Opening Where Weigh Tank is Located Type Of Operation and Equipment - Dairy "B" This is a medium size dairy with a typical operation. The products handled include bottled milk and cream, cho- colate milk, and butter milk. This dairy did not manu- facture its own cottage cheese. The milk is received in 10 gallon milk cans from pro- ducer pick up trucks. The cans are brought into the plant and returned to the truck by power driven chain conveyers. A paper bottle machine was installed but not in Operation at the time this study was made. Receiving Equipment - The weigh tank is of the sus- pended one compartment type with a surge tank below. Milk Storage Equipment - The milk storage equipment consists of two 1000 gallon square storage tanks with surface cooling coils inside, and one upright 2000 gallon cold wall storage tank. Clarifier - The clarifier has a capacity of 10,000 pounds per hour. Separator - The separator is not of the air tight type and has a capacity of 5500 pounds per hour. Homogenizer - The homogenizer has a capacity of 500 gallons per hour. Preheater - The preheater is of the tubular type con- sisting of three large tubes each containing 12 milk tubes. Pasteurizing Equipment - The pasteurizing equipment consists of five 200 gallon rectangular spray vats, one -51— 200 gallon round vat for butter milk, and one 100 gallon round vat for cream. I Bottle Filler - The filler is of the vacuum type with 16 filling valves and six capping heads. Milk Pumps - The milk pumped by 5 centrifugal pumps and 1 positive displacement type pump. Milk Cooling Equipment - The milk cooling equipment consists of 2 multiple section cabinet type coolers, l with 6 sections 5' x 4', and the other with 5 sections 5' x 5'. Sanitary Pipe and Fittings - The pipe and fittings are all 1%". Cleaning Equipment - The cleaning equipment consists of two 11' x l' x 1' wash tanks, one 4' x 2' x 2' wash tank, and one power driven brush for disc cleaning, and assorted brushes and sponges. -32.. “Err“? 1: r;- ,. xh,‘ Figure 6 - Dairy "B" Clarifier, Homogenizer, and Preheater Figure 7 - Dairy "B" Bottle Filler .453- Figure 8 - Dairy "B" Wash Tank and Pipe Rack. Paper Bottle Machine was Installed but not Operated Figure 9 - Dairy "B" Milk Pasteurizing Vats -34- Figure ll - Dairy "B" 1000 Gallon Square Milk Storage Tanks -35- Figure 12 - Dairy "B" 2000 Gallon Milk Storage Tank Figure 15 a Dairy "B" Cabinet Cooler, Separator, 200 Gallon Butter Milk Vat, and 100 Gallon Cream Vat -36.. Type of Qperation and Equipment - Dairy"cn This dairy is a large diversified fluid milk opera- tion. The products handled include bottled milk and cream, chocolate milk, butter milk and cottage cheese. In addition, this dairy operates a roller milk drier and a vacuum pan, and make some ice cream mix. In the analy- sis of this dairy, only the regular bottled operation and cottage cheese were considered. The plant also manufactures some butter. The milk is received in 10 gallon cans from producer pick up trucks and is moved in and out of the dairy by roller and chain conveyors. The full milk cases are moved to and from the bottle filler by power driven chain conveyers. Receiving Equipment - The weigh tank is a single com- partment type suspended over a surge tank. Milk Storage Equipment — This equipment consists of two 2500 gallon horizontal cylinder type tanks, and one 1000 gallon upright tank. Pasteurizing Equipment - The milk is pasteurized in a high temperature short time system with a capacity of 12,000 pounds per hour. The milk for cottage cheese is pasteurized in two 500 gallon round vats. The butter milk is made in a 500 gallon round vat. The chocolate milk and special milk is made in two 500 gallon round vats. The cream is pasteurized in two 500 gallon square -37.. vertical coil vats, and one 500 gallon round vertical coil vat. Separator - The separator is of the air tight type with a capacity of 10,000 pounds per hour. Clarifier - The clarifier has a capacity of 20,000 pounds per hour. Homogenizer - The homogenizer is of the single stage type with a capacity of 12,000 pounds per hour. Milk Cooling Equipment - The pasteurized products are cooled in the short time press. Two multiple section cabinet coolers are used for cooling cream and bulk milk. All of the incoming milk is cooled in a plate type cooler with a capacity of 20,000 pounds per hour. This cooler is of the narrow plate type. The cheese milk is cooled on a single section surface cooler. Bottle Filler - The bottle filler is a 24 valve, 8 capping head type. Cottage Cheese Equipment - This equipment consists of two spray type vats of 1000 gallon, and 800 gallon capacity. Milk Pumps - The pumps used were 5 positive displace- ment pumps, and 5 centrifugal pumps. Sanitary Pipe and Fittings - The pipe and fittings used were 1%" and 2". Cleaning Equipment - This equipment consisted of one 11' x l' x l' wash tank equipped with power driven pipe ~58- brush, and two 4' x 2' x 2' small wash tanks plus assorted brushes and sponges. -59.. Figure 14 - Dairy "C" 1000 Gallon Milk Storage Tank and Positive Pump 0 . O - - - - v - - m“ - ._ - Figure 15 - Dairy "C" 2500 Gallon Milk Storage Tank and Centrifugal Pump -40... ...—222 .222 .22 ..2...: 2.2.2.. 2.:..: 2.2.222 - n—I —..|:- - Dairy "C" Bottle Filler Figure 15 Rack Figure 17 - Dairy "C" Homogenizer, and Small Parts -41- Figure 18 - Dairy "C" Short Time Pasteurizer, 300 Gallon Vats, and Small Wash Tank Figure 19 - Dairy "C" Separator, Preheater, and Positive Pump -42.. Figure 20 - Dairy "C" 300 Gallon Vertical Coil Vat, and 500 Gallon Butter Milk Vat Figure 21 - Dairy "C" 500 Gallon Cheese Milk Pasteurizing Vats and Surface Cooler -43- Percentage of Total Plant Labor Involved in the Cleaning @eration The amount of labor involved in the cleaning opera- tion in dairy plants has long been a point of discussion among dairy plant_operators. The figures given for this labor by various individuals have varied widely. A fig- ure often given is 50%. One of the reasons for the wide variance in this figure is the variation in the different methods of calculating total plant labor. If the opera- tions of washing cans and bottles Were to be considered as part of the cleaning labor, then the figure would ap- proach 50% or even higher. In the case of a small dairy performing these Operations by hand, this labor should be charged to cleaning operations. Another cause of variance is the question of what constitutes total plant labor. If the labor of engineer— ing and maintenance personnel, laboratory workers, plant superintendent, and route check out and check in men is charged to plant labor, the percent of labor represented by cleaning will be less. In this study, the total plant labor was considered to be all the labor involved in receiving the milk, pro- cessing, washing and filling the bottles, and placing in the storage room. The labor involved in loading out the route trucks was not considered, nor was the time involved in actual -44- checking in of the routes, but the unloading and stack— ing of the empty cases was considered. No engineering or maintenance labor was used. The plant superinten- dent's time was omitted but all working foremen and supervisors' time was included. The laboratory labor not directly concerned with plant processing was omitted. Only the daily routine cleaning operations were taken into account. Infrequent operations such as washing win- dows and walls were omitted. Table 1. Percent of Total Labor Cost Represented by Cleaning Labor. Daily *Percefit of Total Labor Total Daily Cleaning Cost Represented by Man Hours Man Hours Cleaning_Labor Dairy "A" ' 49 9.26 16.69% Dairy "B" 85 16.60 20.01% Dairy "6" 140 24.66 17.61% These figures would vary a small amount according to the method of calculating plant labor. But the labor in- cluded in this analysis is generally considered as the operational plant labor by most plant operators. -45- Breakdown of the Cleaning Operation Into Major Group Units The following tables give a break down of the total daily cleaning time divided into major operations of as- sembly and disassembly, cleaning milk contact surfaces, cleaning equipment exteriors, and rinsing with water be- fore and after cleaning. Table 2. Time in minutes Involved in major Cleaning Operations - Dairy "A". Assembly 'Wasth£DE and Wash Contact Nomenclature Disassembly Rinse Exteriors Surfaces 5 - 200 Gallon 5.414 4.629 5.756 25.157 Pasteurizing Vats Weigh Tank 2.280 8.150 4.580 6.552 Cream Surface 5.257 2.721 .745 2.865 Cooler Cabinet Cooler 8.512 5.470 1.410 8.564 Milk Filter 4.454 .948 ----- 1.425 100 Gallon Square .727 1.780 2.420 2.557 Spray Vat 500 Gallon Milk 1.790 5.550 ----- 7.166 Storage Tank Bottle Filler 5.557 5.290 2.551 4.490 Acid Washing of ---------- 1.400 7.570 Vats Once Per We 6 k -45- Vat Assembly —_WE§ETMIIE and Wash Contact Nomenclature Disassembly Rinse Exteriors Surfaces Homogenizer 26.505 2.286 1.412 14.890 Separator 18.866 4.259 2.212 22.948 Clarifier 10.487 5.000 ----- 10.885 2 - Centrifugal 5.554 .600 ----- 1.922 Pumps 60 Gallon Vertical ----- 4.870 1.000 12.540 Coil Vat 200 Gallon Cheese ----- 8.420 ----- 14.770 Vat Hot Water --------------- 2.640 Sterilization Sanitary Pipe 125.272 55.540 ----- 50.016 and Fittings Total 210.255 89.275 25.066 176.091 Table 5. Time in Minutes Involved in Major Cleaning Operations - Dairy "B". Assembly *Wash MiIE and Wash Contact Nomenclature Disassembly Rinse Exteriors Surfaces Weigh Tank 1.408 9.200 5.574 16.276 5 Section Cabinet 2.090 6.948 2.645 11.205 Cooler 2 - 1000 Gallon ----- 6.120 ----- 12.508 Square Storage Tanks 100 Gallon Round ----- 5.256 5.261 7.820 -47- Assembly WaSh HiIE and Wash Contact _Nomenc1ature Disassembly Rinse Exteriors Surfaces 2000 Gallon Up- 1.047 4.545 ----- 5.646 right Storage Tank 5 - 200 Gallon ----- 15.145 6.750 84.715 Rectangular Vats 200 Gallon Round .528 6.447 12.291 8.850 Butter Milk Vat Clarifier 19.890 8.500 2.751 14.056 Separator 10.681 8.614 2.215 17.576 6 Section Cabinet 1.568 11.578 4.562 17.571 Cooler Bottle Filler 20.585 8.150 15.604 16.567 Homogenizer 26.455 5.987 ----- 11.827 4 - Centrifugal 6.440 5.464 1.028 6.504 Pumps Positive Displace- 7.974 .891 .449 5.414 ment Pump Preheater 9.956 2.019 ----- 6.716 Sterilizing Equip- --------------- 18-696 ment Sanitary Pipe 521.098 5.050 ----- 65.245 and Fittings Total 428.851 105.904 56.910 526.950 Table 4. Time in Minutes Involved in Major Cleaning Operations - Dairy "0". Assembly - :fiaéh Milk and Wash Contact Nomenclature Disassembly Rinse Exteriors Surfaces 1.555 5.544 4.845 10.502 Weigh Tank ~48- Assembiy WaSE'MiIk and Wash Contact Nomenclature Disassembly Rinse Exteriors Surfaces Homogenizer .857 1.547 .554 ----- 2 - 2500 Gallon 4.150 11.552 ----- 22.568 Storage Tanks 2 - 500 Gallon 5.590 6.056 8.564 16.018 Round Pasteuriz- ing Vats 2 - 500 Gallon .890 9.574 7.412 29.056 Square Vertical Coil Vats 5 - Positive Dis- 46.857 1.944 2.172 16.107 placement Pumps Preheater 5.625 .496 ----- 8.429 Bottle Filler 21.584 12.959 11.651 17.861 5 — 500 Gallon 4.266 11.475 9.480 15.678 Round Pasteuriz- ing Vats 500 Gallon Round ----- 5.494 5.100 18.275 Vertical Coil Vat 1000 Gallon Cheese ----- 8.897 2.254 12.014 Vat 800 Gallon Cheese ----- 5.701 2.520 10.159 Vat Surface Cooler ----- 1.560 ----- 9.489 40 Gallon HOTOSOT. ----- 0914 10870 10306 Surge Tank 2 - Cabinet Coolers20.156 15.950 5.160 25.478 Clarifier 15.712 8.610 1.069 17.577 Separator 25.540 6.858 4.285 58.285 Plate Milk Cooler 15.598 1.160 ----- 51.046 -49- Assembly wash Milk and Wash Contact Nomenclature Disassembly Rinse Exteriors Surfaces Pumps Short Time Pasteu- 17.716 21.574 2.460 28.890 rizer less San- itary Pipe and Fittings Sterilizing Equip- --------------- 10.082 ment Sanitary Pipe 462.828 15.180 47.028 106.661 and Fittings Total 649.462 147.565 117.088 446.716 Table 5. Percentage of Total Cleaning Labor Represented by Major Group Units. Assembly and Disassembly Rinse Dairy "A" 57.9% 15.9% Dairy "B" 42.8% 10.5% Dairy "c" 45.8% 9.9% ‘Wash‘Milk Wash Contact Exteriors Surfaces I ’z’ 4 O 1545’ 51 O 7:") I 5.74 52.6% [‘3’ r” 7.94 50.24 The type of breakdown shown in Table 5 reveals some very interesting information on what happens within the cleaning operation. The fact that around 40% of the cleaning time is infolved in the assembly and disassembly of equipment and lines, shows very forcibly that no matter how efficient the actual washing operation is, large -50- amounts of time will be necessary for assembly and dis- assembly. Of course, this time can be reduced some by good motion economy, but there will be an irreducible minimum.as long as the equipment is disassembled. The actual washing of the surfaces that come in con- tact with the milk require about 50% of the total clean- ing time. It is in this group that good cleaning methods will show substantial savings. The washing of the equipment exteriors requires from 4 to 8% of the total cleaning time. In some pieces of equipment almost as much time is spent in washing the outside surfaces as is spent in.washing the milk contact surfaces. The rinsing of the equipment before and after washing represents from 10 to 15% of the total cleaning time. This is exclusive of the time involved in getting and re- turning the hose, and turning the water valves on and off. Table 6. Time Involved in Preparing Washing Solutions, and Getting and Returning the Hose for Rinsing. Time in Min- .Time in Min- utes to Pre- Percentage utes to Get Percentage pare Washing of Clean- and Return of Clean- __ Solutions ing_Labor Hose ing_Labor Dairy "A" 45.495 8.1% 10.916 1.98% Dairy "B" 59.657 5.9% 22.550 2.20% Dairy "0" 77.412 5.2% 41.975 2.80% The time involved in preparing cleaning solutions represents from 5 to 8% of the total cleaning labor. This time is made up of walking and getting washing pow- der, filling buckets and tanks with water, and mixing the solutions. The time required to get and return the hose, and turn the water and steam valves represents about 2.5% of the total cleaning time. This time would be much greater in many cases if the workers did not leave the hose running. It was observed that if the hose was re- turned and turned off at the end of each use, the time involved would be twice as great or about 5% of the total time involved. The time involved in this operation is of importance far in excess of man hours involved because it is this operation that causes the wet, sloppy condi- tions found in most dairies. In general, in the cleaning of any piece of equipment, the steps necessary to complete the operations are as follows: 1. Disassemble equipment. 2. Walk to hose station, turn on water and return to equipment. 5. Rinse milk remnants from equipment. 4. Return hose to station and turn off water. 5. Valk and pick up cleaning powder or cleaning sol— ution, brush or sponge, and return to equipment. 6. 7. 8. 9. 10. ll. -52- Wash milk contact surfaces. Wash equipment exterior. Walk to hose station, turn on water, and return to equipment. Rinse equipment. Return hose, turn off water, return to equipment. Assemble equipment. Analysis of the Cleaning of Individual Pieces of Equipment Sanitary Pipe and Fittings - The cleaning of sanitary pipe and fittings represents the largest amount of clean- ing time of any of the types of equipment. Percentage of Total Cleaning Represented by Sanitary Pipe and Fittings Dairy "A" 54.5% Dairy "B" 59.2% Dairy "0" 42.6% From.60 to 80% of this time is involved in the disas- sembly of the pipe and fittings, the carrying of the pipe and fittings to the wash tank, carrying the pipe and fit- tings back to the assembly position, and reassembly of the pipe and fittings. -55- Percentage 6f TetalPipe and—Fittings Cleaning Time Represented by Carrying Pipe and Fittings to and From the Wash Tank Dairy "A" 8.9% Dairy "8" 15.8% Dairy "0" 14.9% With the exception of Dairy "A", extreme inefficien- cies existed in this operation. In Dairy "A", the pipe was taken down in large sections and carried to the wash tank and after washing, was reassembled in large sections at the wash tank and carried into position. Also, the distances traveled were relatively short. In the case of the other two dairies, the pipe for the most part was carried sections at a time back and forth to the wash tank over relatively long distances. The hexagon nut pipe and fitting connections are a source of considerable assembly and disassembly time. The steps in this operation are as follows: 1. Loosen hex nut with wrench. 2. Unscrew hex nut by hand. 5. Place paper gasket. 4. Screw hex nut hand tight. 5. Tighten hex nut with wrench. This operation is practically impossible to simplify in its present form. -54- In the actual washing of the pipe and fittings, Dairy "A" used the following system: 1. 2. 3. 5. 7. As far method Fill wash tank with clear water. Place pipe in water to soak. Drain tank and fill with water and place washing powder in tank. Wash pipe by a two man operation; with one man picking up the pipe and holding, while the other man runs a brush through the pipe. The pipe is then placed on a pipe rack. The tank is then drained and refilled with water and a chlorine solution added. The pipe is then taken from the rack and placed in the solution. The tank is then drained and the pipe assembled. as the actual washing of the pipe is concerned, this is fairly fast even though two men are involved. Because of the soaking, the pipe is not washed on the out- side, but the time involved in.the filling and draining of the tank is a very inefficient operation. Dairy "B" also allowed the pipe to soak. The pipe and fittings were washed as a one man operation, and after washing, the pipe and fittings were placed at the end of the tank. Then followed a very time consuming operation 0f placing the pipe and fittings on a pipe rack in a defin- ite position. The pipe was then rinsed.with a hose. -55- Dairy "0" WQShed.their pipe and fittings in two small tanks and on one power driven, solution fed brush. The pipe and fittings were not allowed to soak and, in all cases, the pipe was washed on the outside with a metal sponge. It is interesting to note that the time required to wash the outside of the pipe is greater than the time to wash the inside. In the case of the fittings, they were not washed on the outside. After washing, the pipe was rinsed with a hose. Separator and Clarifier - Because of the large nmm- ber of the parts in this type of equipment, the assembly and disassembly time is great. This varied from 50 to 50% of the total washing time. The time involved in rinsing varied from 10 to 20% of the total time. The rinsing time is brought about by the large amount of milk slime that adheres to the parts and must be removed before washing. The time involved in washing the ex- teriors of this type of equipment is not large. The time required to wash the milk contact surfaces averages about 40%. or this time, the washing of the discs re- quires a large part of this time. The assembly and disassembly of this equipment was accomplished in about the same manner in all three plants. But, in the case of Dairy "0“, the parts were car- ried almost one at a time, a long distance to the waSh tank. The other two dairies used a parts rack. Dairy "B“ used a power driven, solution fed brush to wash the discs while Dairies "A" and "C" washed them.by hand brush. Because of the different sizes of the discs, it was imp possible to get an accurate comparison of the relative merits of the two methods. Homogenizer - These machines are composed of many parts, some of them of very small size. The assembly and disassembly time of this type of equipment is great. The method of washing this piece of equipment followed by plants "A" and "B" was to completely disassemble the home- genizer, wash all parts with a brush, rinse and reassemble. Dairy “C" followed a radically different method which was as follows: 1. Circulate rinse homogenizer after use. 2. Connect small solution vessel to system. 5. Place cleaning powder in solution vessel and circulate solution for 25 minutes. 4. Break connection and circulate rinse for 6 minutes. This system of cleaning has been followed for over 7 years, with only periodic disassembly for checking cleanliness and replacing gaskets. This method of cleaning results in a saving of over 40 minutes per day. Plate Heat Exchangers - Dairy "C" was the only plant using this type of equipment. This plant used a Short time high.temperature system for pasteurizing the milk, -57- and a plate type cooler for cooling incoming raw milk. The system used to clean the cooler was to unloosen the press and wash each plate with a brush and rinse all the plates at one time with a hose. The method used to clean the short time unit was to circulate an acid and then an alkaline solution for 20 minutes each through the plates. The press was then loosened and each plate brushed.with a brush and washing solution, and each plate was rinsed individually. Only the actual time involved in the cleaning of this equipment was used as during the 40 min- utes of circulating time, the operator was doing other work. In both of these Operations, the disassembly and as- sembly time is great. The moving of each plate after washing would have to be classed as disassembly operations. In the case of the short time system, 14 minutes were re- quireito get the circulating solutions ready. Since only cold milk was run through the cooler, it was not necessary to circulate this system. In the calculations on the short time system the dis- assembly, washing, and assembly of the pipe connecting the system were not charged against the short time, but were included in the regular pipe washing operation. Milk Pumps - In the cleaning of positive displacement Pumps, from.50 to’65fl of the total pump cleaning time is involved in assembly and disassembly. These pumps are -58.. made up of many parts, several of which require a wrench for disassembly. As long as these pumps must be disas- sembled, there is not much chance for much motion ec- onomy. Even in the case of centrifugal pumps, the time involved in assembly and disassembly is as great or greater than the washing time. Cabinet Coolers - An excellent example of the effect of design on the total cleaning time is given by the cabinet cooler of Dairy "A" and two more of this same type at Dairy "C". These are multiple section coolers but instead of having the sections connected to the brine and water inlets by a swivel joint, they are bolted to- gether. This makes it necessary to Spend large amounts of time in removing and replacing the headers. The as- sembly and disassembly percentage of the total cleaning time for the cabinet is from 50 to 56%, while in the case of the swivel type it is only around 6%. The method used in cleaning this type of equipment is to open the cabi- net and then rinse the milk remnants free. A large amount of time was spent in the rinsing of the sections in this type of equipment both before and after washing. This rinsing represented 20 to 50% of the total cabinet wash- ing time. The sections and the troughs were washed in the regular brush and bucket manner. Bottle Fillers - The percentage of the total filler cleaning labor represented by the major group units is as follows: Assembly wash Milk and Wash Contact Disassembly Rinse Exterior Surfaces Dairy "A" 25.9% 22.1% 15.8% 50.2% Dairy "B" 52.4% 12.9% 24.8% 26.4% Dairy "0" 50.1% 18.1% 16.2% 25.0% This type of equipment is also composed of a large num- ber of parts. The type of filler in Dairy "A" was a small simple model, but the fillers in the other two plants were large complex models. A large amount of time is involved in the washing of the exterior of the filler, particularly in the washing of the capping headers. In Dairy "B" two complete sets of complex capping headers were used, which required a large amount of time to wash. The disassembly, washing, and reassembly of the fil- ling valves also involve a large amount of time. A large amount of the rinsing time was taken to rinse the exterior, such as the star wheels, guides, etc. Pasteurizing Vats - The type of vats used in the plants were of various types, and used for many different purposes. One of the most interesting observations on the cleaning of vats with stainless steel outside liners was the large amount of time spent in washing the outside -50- of the equipment. In two cases, more time was spent in washing the outside surfaces of the vats than was spent in washing the interior. This was not true of painted and enameled outside surfaces, as practically no time was spent in the washing of these surfaces. Another interesting observation was the large amount of time required to wash the coil in vertical coil vats. In all cases more time was spent in washing the coil than was spent on the interior of the vat. The standard procedure in washing the larger vats was to get in the vat with bucket and brush. The smaller vats were washed from the outside. The type of product used and the length of heating time in any one day govern the time required for cleaning. Storage Tanks - The washing of storage tanks of the manhole type is a particularly distasteful job from the worker's standpoint. He is forced to crawl through the manhole and wash the interior with a brush and bucket of solution. The surfaces of the tank are very slick and he is in constant danger of falling down. The number of storage tanks of this type in the whole dairy industry that are washed satisfactorily day after day is limited. The plant superintendents themselves find it distasteful even to crawl in the vats to inspect them. From a motion economy standpoint, the cold wall type of tank is much to be desired over the type that contains -51- cooling coils. The time required to rinse these tanks represents from 27 to 30% of the total tank cleaning time. This is brought about by the worker's desire to do as much work with the hose as possible and reduce the amount of time spent in the tank. In dairies "B" and "C" no attempt was made to steril- ize the tanks after washing. Dairy "A" sterilized the tank by spraying a chlorine solution on the inside sur- faces with a hand spray. This is a very desirable and efficient way to accomplish this. Preheaters - Dairies "E" and "C" used preheaters of the multiple internal tube type. Dairy "A" did not use a preheater. The percentage of total preheater cleaning time represented by major units: Assembly ’WaSh Milk and Wash Contact Disassembly Rinse Exteriors Surfaces Dairy "B" 46.0% 9.5% ---- 31.1% Dairy "c" 26.6% 5.6% ---- 61.9% The method followed by Dairy "B" was to circulate a washing solution through the tubes before cleaning. Dairy "C" did not circulate this solution. In both cases, the tubes were cleaned by running a brush through the tubes. -52- The circulating system increased the percentage of assembly and disassembly operation due to the assembly of the circulating system, and reduced the percentage of washing the milk contact surfaces. From a standpoint of cleanliness of equipment, the circulating system is much to be preferred. Weigh Tanks — The percentage of the total weigh tank cleaning time represented by the major group units is as follows: Assembly Wash Milk and Wash Contact Disassembly Rinse Exteriors Surfaces Dairy "A" 10.9% 58.5% 20.0% 50.0% Dairy "B" 4.1% 27.2% 15.8% 47.9% Dairy "0" 6.8% 15.6% 21.2% 45.5% The weigh tank used in Dairy "A" was of the two com- partment type. The tank was located in a wall opening which.required considerable walking back and forth in the assembly, disassembly, and rinsing operations. Accuracy of Comparison Between the Plants Studied and Ap- Blication to all Milk Plants During this study the writer carried on correspondence with many plant operators relative to cleaning methods. Also many additional plants were visited and cleaning methods observed. The practical experience of the writer -53- as a dairy plant worker and superintendent was used to a great extent in the analyzing of the results. All of the elemental time values given in the appen- dices have been rated as to performance in order to level out fast and slow workers and allowances added to take care of personal needs, fatigue allowance, and avoidable and unavoidable delays. The fact that the performance was rated as to effort only, and the method not considered, the time required to clean a particular piece of equipment of the same size and type varied between the three dairies studied, and could be expected to vary in all dairies. As was previously mentioned, the cleanliness of the equipment would have a great effect on the cleaning time. But in all cases, it was assumed that the equipment was cleaned satisfactorily. A good worker putting out great effort would be rated high regardless of his method. A slow worker, armed with a good method, may complete the same operation faster; thus leading to some discrepancies in the rating of the performance. The main purpose of the study was to observe the cleaning operation in three commercial plants as it ex- ists today. From the writer's own experience, the opera- tions appeared to be typical of the average dairy. But the question of whether a sampling of three dairies would -65- be a representative sampling could be justifiably raised. As far as the effect of the performance rating and allowances are concerned, they would only effect the fig- ures given for the percentage of total plant labor repre- sented by cleaning. All other figures percentage-wise would not be effected by this. In all cases the actual average time is given in the appendices for all elements. -54- RECOMMENDATIONS l. The use of a hot water generator that delivers water at washing temperature to small hoses located at strategic points about the plant. The hoses are equip- ped with a press type shut off valve at the nozzle end. This should save from 3 to 5% of the cleaning labor. In addition, it saves large amounts of water as well as helping to eliminate wet, sloppy conditions. 2. The use of a central cleaning solution tank in which the cleaning solutions can be made up to correct strength and then piped to strategic plant locations. In the three dairies studied 5 to 8% of the cleaning time was involved in preparing cleaning solutions in buckets. In addition, the solution can be kept at the same strength and much waste is eliminated. 3. If local regulatory officials will permit the installation of glass pipe lines which can be cleaned in ‘place, or the in place cleaning of existing stainless steel lines, it would be highly desirable. The time in- volved in the cleaning of sanitary pipe is the largest single item.of cleaning expense. The amount of labor savings possible here would depend on.the amount of pipe handled in this manner. 4. The following method of cleaning sanitary pipe and fittings is recommended: -55- a. Use a pipe rack that is on wheels to eliminate walking back and forth to the wash tank. b. Place the pipe and fittings on this rack in a definite order and then wheel it to the wash tank. c. Use a power driven pipe brush with revolving brushes on the inside and outside. This will enable the pipe to be washed on the outside at the same time it is being washed on the inside. The brushes are solution fed. The wash tank should be equipped with a rinse pipe which will enable the pipe to be rinsed on the inside and outside at the tank. The pipe should then be placed back on the rack in the same place. d. Use a small fittings wash tank composed of two power driven solution fed brushes which will wash the fittings on the inside and out- side at the same time. A small stream.of water from a pipe in the rinse side will en- able quick rinsing. The fitting is then put back on the rack in a definite position. 6. The pipe rack is then pushed along the as- sembly route, assembling each piece in order. 5. Serious consideration should be given to the use of steam jet cleaning, using the Venturi principle for -55- the cleaning of equipment exteriors. A fairly large amount of cleaning time is involved in this operation and since the equipment exterior does not effect the product quality, some savings are possible here. With this kind of a system, the exteriors of the equipment would all be cleaned at the same time. 6. Pump fed jets have recently been used in the cleaning of cold milk storage tanks of the manhole type. The use of this system eliminates the necessity of the man getting in the tank and, according to reports, the machine cleans very satisfactorily. 7. The use of parts racks on wheels for all pieces of equipment composed of a large number of parts such as the homogenizer, separator, and clarifier. 8. The use of solution fed revolving brushes for the cleaning of separator and clarifier discs. 9. The cleaning operation should be a carefully planned operation with a fairly definite method for each operation. A new man placed on the clean up job should be carefully supervised.until he knows the operation. 10. The plant layout should be planned in a functional manner to reduce walking time in the cleaning operation. -67.. CONCLUSIONS 1. The use of time and motion study as a means of analyzing cleaning operations brings out some hidden in- formation that would be difficult to observe by any other method. 2. The percentage of total plant labor represented by the cleaning operations in the three dairies was: Dairy "A" 18.89% Dairy "B" 20.01% Dairy "0" 17.61% 3. The percentage of total cleaning labor represented by major group units was: Assembly WashIMilk and wash Contact Disassembly Rinse Exteriors Surface Dairy "A" 57.9% 15.9% 4.1% 51.7% Dairy "B" 42.8% 10.5% 5.7% 52.6% Dairy "0" 45.8% 9.9% 7.9% 50.2% 4. No matter how efficient the actual cleaning op- eration is, large amounts of time will still be necessary for assembly and disassembly. 5. Some motion economy can be incorporated into the assembly and disassembly operation, but as long as the equipment is disassembled, it will require changes in de- sign to effect large savings. -68- 6. Considerable amounts of time are spent by the clean up worker in just holding the hose and rinsing e qu ipme nt . 7. In some pieces of equipment as much time is spent in washing the outside of the equipment as is spent in washing the milk contact surfaces. 8. Percentage of total cleaning labor represented by preparing washing solutions: Dairy "A" 8.1% Dairy "B" 5.9% Dairy "0" 5.2% 9. Percentage of total cleaning labor represented by getting and returning hose: Dairy "A“ 1.98% Dairy "B" 2.20% Dairy "0" 2.80% 10. The importance of the above operation is far in excess of the labor involved because of the wet, sloppy conditions caused by this operation. Also, if the water was not left running by the operator in many cases, the percentage value for this operation would be about twice as great. 11. The disassembly, washing, and reassembly of sani- tary pipe and fittings requires the following percentages of total cleaning labor: Dairy "A" 34.5% -59- Dairy "B" 59.2% Dairy "0" 42.6% 12. Of the above time, 60 to 80% is involved in as- sembly and disassembly, and carrying the pipe and fittings to and from the wash tank. 15. A number of cleaning aids are now available that, from a motion economy standpoint, show some promise. 14. The design of equipment to reduce assembly and disassembly time is greatly needed. 15. One very promising solution to the dairy clean- ing problem, if and when it becomes possible, is the cleaning by circulating methods with the equipment so designed and constructed that it may be permanently assembled. l. -70- LITERATURE CITED Adams, H. S. Milk and Food Sanitation Practice. p. 1. The Commonwealth Fund. New York, 1947. Barnes, Ralph M. Motion and Time Study. 5rd Edi- tion, p. l. John.Wiley and Sons. New York, 1949. Barnes, Ralph M. Motion and Time Study. 5rd Edi- tion, p. 7. John.Wiley and Sons. New York, 1949. Barnes, Ralph M. Motion and Time Study. 3rd Edi- tion, p. 12-15. John Viley and Sons. New York, 1949. Burnett, Claran. Designed For Sanitation. National Butter and Cheese Journal. 40:52-35. October, 1949. Carroll, Phil. Jr. Time Study For Cost Control. 2nd Edition, p. 70. McGraw-Hill Book Co. New York and London, 1943. Carroll, Phil. Jr. Time Study For Cost Control. 2nd Edition, p. 82. McGraw-Hill Book Co. New York and London, 1945. Carroll, Phil. Jr. Time Study For Cost Control. 2nd Edition, p. 100. McGraw-Hill Book Co. New ‘York and London, 1943. Dunlap, Harold G. How to Make Work Simplification Work. Food Industries. 21:1548-49. November, 1949. 10. 11. 12. 15. 14. 15. 16. 17. 18. 19. 20. -71- Dunlap, Harold G. Work Simplification Pays Off. Food Industries. 21:1556-59. October, 1949. Emmons, James W. Janitors On Schedule. Factory Management. 95:66. April, 1957. Engel, Robert C. Basic Plant Operations Improved. Food Industries. 12:52-55. November, 1940. Fisker, A. N. Chemical Cleaning of the Pasteur- ization Plant. Proceedings XIIth International Dairy Congress. 3:519-20. 1949. Fowler, K. L. Substantial Savings by Planned Equip- ment Cleaning Programs. Milk Plant Monthly. 39:54-55. January, 1950. Gobb, A. F. Truckers and Sweepers on Bonus. Factory Management. 95:47-48. March, 1957. Myrick, Norman. Let‘s Look at Brushes. American Milk Review. 5:54-36. December, 1948. Marrow, Alexander. Time Studies Show How to Reduce Distribution Costs. Food Industries. 19:794-95. June, 1947. Mundel, M. E. Work Simplification Applied to Peel- ing Tomatoes. Factory Management. 102:89-91. May, 1944. Mundel, M. E. Farm Work Simplification. Mechanical Engineering. 65:565-66. August, 1945. Nadler, Gerald. Time and Motion Study in Canning Plants. Food Industries. 22:256-237. February, 1950. 21. 22. 25. 24. 25. 26. 27. 28. 29. 50. -72- Postumus, 0. Cleaning Dairy Equipment and the Control of the Efficiency of the Cleaning Pro— cesses in Holland. Proceedings XIIth International Dairy Congress. 5:288-50. 1949. Perry, John R. Some New Ideas for Cleaning Dairy Plant Equipment. Journal of Milk and Food Technology. 11:88-95. March, 1948. Proctor, F. Labor Saving Methods in British Milk Bottling Dairies. Proceedings XIIth International Dairy Congress. 5:145. 1949. Pelling, E. 0. Changed Layout Saves 52,500. Factory Management. 98:64-65. February, 1940. Robinson, E. A. Engineered Sanitation. National Butter and Cheese Journal. 40:26-29. April, 1949. Rossmore, H. and Aries, R. S. Time and Motion Study in the Chemical Process Industries. Chemical and Engineering News. 25:5142-5144. October, 1947. Samuelson, Joseph. Steam Detergent Cleaning. American Milk Review. 5:14-15. June, 1948. Stearns, R. A. Managerial Use of Time Study. Iron Age. 155:71 April 19, 1945. Sadoff, B. I. Standard Times for Maintenance. Factory Management. 102:145-150. December, 1944. Editorial. Tank Cleaner. American Milk Review. 7:62. January, 1950. 51. 52. 54. -75- Teranes, S. R. Less Walking More Working. Factory Management. 95:44-45. March, 1957. Tidball, L. D. Time and Motion Study for Job Order Shops. Rubber Age. 59:88-91. May, 1956. Vlissinger, A. V. Easier to Do Jobs Get Done Faster. Factory Management. 99:66-68. June, 1941. Van Pechmann, W. Operating Standards in Chemical Industry. Chemical Engineering News. 117:1621. October 10, 1945. APPENDICES -1- Appendix.A Table A-1. Dairy "A" 200 Gallon Round Pasteurizing Vat Actual Aver- Allowed Element age Time in Time in Number Element Description. NMnutes Rating Minutes 1. Walk :50 ft. and get brushes .587 150% .580 and cleaning solution and return to vat. 2. Raise vat cover. .045 " .067 5. Take out thermometer stem. .10 " .150 4. Remove milk outlet valve. .188 " .282 5. Climb in vat with.hose. .25 " .575 6. Wash.inside vat with.eteel 2.28 " 5.420 sponge using continuous motion and rinsing. 7. Wash.inside vat cover with. .847 " 1.270 brush.and cleaning solution. 8. Wash inside vat with brush. 1.09 " 1.650 and cleaning solution.using continuous motion. ' 9. Climb out of vat. .071 L .106 10. Rinse inside of vat. .474 n .711 11. Close cover. .058 n .057 12. Wash thermometer bulb. .154 n .201 15. wash top of cover. .706 " 1.050 14. Wash outside of vat. .575 n .862 15. Wash.outlet valve. .918 u 1.577 16. Rinse outside of vat. .555 n .852 17. Replace outlet valve. .426 _;§§2 Total Cycle Time 15.609 Performance Rating 150% Allowances Iggp Total % Table A-2. Dairy "A" weigh Tank Actual Aver- giiowid Element 386 Time in e n Eflmber Element Description Minutes Rating Minutes 1. Remove right strainer come .156 150% 0204 partment. 2. Remove left strainer come .152 n 0198 partment. " 5. Walk 15 ft. througgkdoor to .221 0551 other side of t . n 4. Remove weigh tank cover. .éig " :ggz 5. Pull out surge tank - 0 n 575 6. ‘Walk 7 ft. to hose and.turn .25 . on water and return to tank. -2- Appendix A Table A-2. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 7. Rinse strainers and one half .910 150% 1.565 of tank. 8. Walk 15 ft. through door to .232 " .548 other side of tank. 9. Rinse other side of tank and .925 " 1.584 surge tank. 10. Walk 10 ft. get bucket of .504 " .456 cleaning solution and brushes and return to tank. 11. Wash inside and outside of surgel.560 " 2.540 tank with brush using con- tinuous motion. 12. wash weigh.tank cover. .848 " 1.270 15. Wash right dump compartment. .959 " 1.400 14. Wash left dump compartment. .866 " 1.299 15. Wash outside of dump tank. 1.060 " 1.590 16. Walk 15 ft. through door to .255 " .552 other side of tank. 17. Wash right strainer. .757 " 1.150 18. Wash left strainer. .795 " 1.180 19. Wash outside of dump end of 1.060 " 1.590 tank. 20. Rinse strainers with.hose. .798 " 1.190 21. Walk 15 ft. with hose to .242 " .565 other side of tank. 22. Rinse surge tank and cover .804 " 1.200 and dump compartment. " 25. Place surge tank. .122 n .183 24. Place weigh tank cover. .214 n .521 25. Walk 15 ft. through door. .222 u .555 26. Replace right strainer. .155 u .252 27. Replace left strainer. .161 ~241 Total Cycle Time EI-450 Performance Rating 150% Allowances 20% Total 50% Table A-5. Dairy "A" Small Cream Surface Cooler Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes RatingMinutes 1. Remove shields. .602 150% .333 2. Remove top distribution 215 . trough. -5- Appendix A Table A-5. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 5. Remove bottom distribution .205 150% .507 trough. 4. Rinse cooler. .810 " 1.211 5. Wash.left shield with brush .495 " .742 and solution. 6. Wash right shield. .489 " .747 7. W381]. top trough. .515 n 0472 8. Wash bottom trough. .506 " .459 9. Wash right side of cooler. .595 " .592 10. Wash left side of cooler. .599 " .598 11. Rinse with hose. 1.01 " 1.510 12. Replace top trough. .217 " .525 15. Replace bottom trough. .214 " .521 14. Replace shields. .708 " 1.062 Total Cycle Time 9.240 Performance Rating 150% Allowances 200 Total 36 Table A-4. Dairy "A" Multiple Section Cabinet Cooler Actual Aver- Allowed Element age Time in Time in Ngmber Element Description Minutes Rating Minutes 1. Walk 50 ft. and get bucket .688 100% .688 of cleaning solution and return to cooler. " 2. Unscrew holding screw and .454 .454 pull right shield back. 5. Unscrew holding screw End .602 " .602 pull left shield bac . 4. Remove top trough and cover. .450 a 1.320 5. Remove brine and water 1.62 . headers. 6. Walk 10 ft. turn on watei in .504 " .304 hose and return to coo er. n 7. Rinse with hose. 1.25 " 1.335 8. Wash.inside of right shield. .405 n .510 9. Wash.right side of first .510 ° cooling section. a 10. Push against shield. Jig: " g: 11. Wash.left side of first .5 . cooling section. " 12. ‘Wash right side of second .514 -514 cooling section. -4- Appendix A Table A-4. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 15. Push section against shield. .110 100% .110 14. Wash.left side of second .501 " .501 ' section. 15. Wash.right side of center .519 " .519 section. 16. Wash.inside of left shield. .591 " .591 17. Wash left side of fourth .555 " .555 . cooling section. 18. Push.section.against shield. .108 " .108 19. Wash.right side of section. .515 " .515 20. Wash.left side of fifth .522 " .522 section. ' 21. Push.section against shield. .112 ” .112 22. Wash.right side of section. .525 " .525 25. Wash.right side of center .559 " .559 section. n 24. WaSh top trough. 1065 n 1065 25. Wash cover. .242 u .242 26. Wash shield plates. .555 " .555 27. Wash.bottom.trough. 1.48 n 1.48 28. Wash outside of cooler. 1.41 n 1.41 29. Rinse cooler. 2.22 n 2-22 50. Push two right sections in .158 .158 place. " 176 51. Push two left sections in .176 . place. 52. Replace headers. 3-24 : 5-2$1 55. Replace top trough. .571 n 0552 54. Replace cover. .152 n .558 55. Push.right shield into place .558 . and fasten. 56. Push.left shield into place .571 " .571 and fasten. 2279—0-15 Total Cycle Time Performance Rating 80% Allowances 20g / T015 al 166/0 -5- Appendix A Table A-5. Dairy "A" Milk Filter Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Unscrew screws holding .495 150% .742 plates. 2. Raise top plate. .082 " .125 5. Remove used filter cloth. .105 " .154 4. Remove support screen. .225 " .557 5. Rinse With hose. .514 n 0471 6. Wash.plates with'brush and .645 " .964 solution using continuous motion. 7. Wash.support screen. .506 " .459 8. Rinse with hose. .518 " .477 9. Walk 50 ft. and get new filter .451 " .676 cloth.and return to filter. 10. Place filter cloth. .089 " .155 11. Replace support screen. .218 " .527 12. Lower top plate. .088 " .152 15. Tighten holding screws. 1.22 " 1.850 Total Cycle Time 6.825 Performance Rating 150% Allowances 206 Total % Table A-6. Dairy "A" 100 Gallon Spray Vat Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes RatingMinutes 1. Walk 50 ft. get brushes and .422 120% .506 bucket and cleaning solu- tion and return to vat. n 2. Walk 50 ft. turn on water and .505 .606 return with.hose to vat. 5. With.hose in one hand and .786 " .945 steel sponge in other, scour and rinse inside vat. " 206 4. Dump bucket of solution in vat. .172 n .954 5. Wash inside of vat with brush .795 . and solution, using con- tinuous motion. 6. Pull plug valve and wash with .195 " .234 7. Disassemble pump. 1::%9 " 1.710 8. wash.pump with brush and solution. -5- Appendix A Table A-6. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 9. Wash outside of vat with 2.02 120% 2.420 brush. 10. Rinse inside and outside 1.49 " 1.780 with.hose. 11. Assemble valve. .188 " .225 12._ Assemble pump. 1.45 " 1.710 Total Cycle Time 11.796 Performance Rating 100% Allowances 20% Total 120% Table A-7. Dairy "A" 500 Gallon Milk Storage Tank Actual Aver— Allowed Element age Time in Time in Number Element Description Minutes RatinggMinutes 1. Open manhole. .255 110% .280 2. Walk 40 ft. get bucket of .645 " .707 . cleaning solution and brushes and return to vat. 5. walk 10 ft. and turn on water .229 " .251 in hose and return to vat. 4. Rinse vat. 5.01 " 5.310 5. Climb through manhole. .229 " .251 6. Wash inside of vat with brush 5.58 " 5.710 and solution, usingtion- tinuous brushing mo on. 7. Climb out of tank. .170 3 .187 8. Wash.manhole port cover. _ .755 u .806 9. Wash plug valve. .767 n .845 10. Rinse inside tank with.hose. 1.86 n 2.040 11. Walk 60 ft. and get chlorine 1.91 2.100 hand spray and return to vat. 12. Spray inside vat with chlorine 1.48 2 1.228 15. Close manhole. 1038 n .585 14. Return chlorine spray: walk -552 __:___. 60 ft' 18.200 Total Cycle Time Performance Rating 90% Allowances I§§§ [O -7- Appendix A Table A-8. Dairy "A" Bottle Filler Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Remove bowl cover. .126 100% .126 2. Raise bowl. .105 " .105 5. Remove holding clips from .287 " .287 valve filling assemblies. 4. Place valve assemblies in .526 " .526 bucket. 5. Walk 50 ft. and get brushes .644 " .644 and solution, return to filler. 6. Walk 50 ft. and turn on water .555 " .555 in hose and return with hose. 7. Rinse bowl and outside filler. 1.91 " 1.91 8. Wash inside and outside bowl 2.59 " 2.59 with brush and solution. 9. Wash capping headers. 1.96 " 1.96 10. Wash filling valves with .650 " .650 brush.and solution without removing from bucket. 11. ‘Wash bowl cover. 1.47 " 1.47 12. Rinse filler. 1.58 " 1.58 15. Replace filling valves in 2.57 " 2.57 bowl. 14. Replace cover. .145 " .145 15. Wash.fi11er frame work. .591 " .__5211 14.867 Total Cycle Time Performance Rating 80% Allowances 20% Total 105% Table A-9. Dairy "A" Acid.Washing of 200 Gallon Vats Once Per Week Actual Aver- Allowed Element age Time in Time in Emeer Element Description Minutes Rating_Minutes 1. Walk 60 ft. and get acid and 1.352 150% 2.045 return to vat with brushes. n 492 2. Turn on water and fill bucket. .528 n .153 3. Place acid in bucket. .102 n .141 4. Climb into vat. .094 " 5:150 Spread layer of acid solution 2.106 on walls of vat with brush, using continuous motion. -3- Appendix A Table A-9. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 6. Climb out of vat. .088 150% .152 n 7. Spread layer of acid on out- .852 1.248 side of vat. 8. Spread layer of acid on .094 " .141 thermometer stem. 9. Spread layer of acid on out- .764 " 1.146 let valve. 10. Wait for acid to act. 2.858 " 4.287 11. Climb into vat with hose. .124 " .186 12. Wash with hose and brush. 5.290 " 4.955 using continuous motion. 15. Get out of vat. .108 " .162 14. Wash outside of vat with 2.178 " 5.267 brush, l5. Wash.va1ve. 1.014 " 1.521 Total Cycle Time 25.004 Performance Rating 150% Allowances 20 Total 5 % Table A-lO. Homogenizer Dairy "A" Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes RatinggMinutes 1. Push.parts platform in place. .547 120% .656 2. Remove plunger rod guard. .178 n .215 5. Loosen packing gland tie .510 .612 rods. . 4. Remove gauge. .268 x '321 5. Remove pressure regulating -777 ‘932 assembl . 6. Loosen suition inlet and suc- .407 " .488 tion manifold port cover nuts. u l 950 7. Remove tie rods and plunger 1.61 . ort covers. 8. Logsen plunger rods. .405 s 1 323 9. Remove plunger rod, packing ~890 ' gland, and packing box. n 948 10. Repeat above. '790 u '949 11. Re eat above. '791 ° P " 525 12. Remove discharge valves. .271 n .586 15. Remove suction valves. ~522 " ‘340 14. Remove gaskets. .284 . -9- Appendix A Table A-lO. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 15. Remove suction inlet port. .489 120% .586 16. Remove manifold port cover. .497 " .596 17. Remove gauge well. .420 " .504 18. Loosen discharge valve .588 " .455 cover nuts. 19. Remove discharge valve .408 " .489 covers. 20. Remove gaskets from.packing 1.47 ” 1.760 gland. 21. Remove milk outlet assembly. .407 " .488 22. Walk 20 ft. turn on water in .454 " .520 hose and return. 25. Rinse all parts and block. .975 " 1.170 24. Walk 20 ft. and get bucket of .502 " .602 cleaning solution and brushes. 25. ‘Wash plunger rod. .295 " .554 26. Repeat above. .507 " .568 27. Repeat above. .506 " .567 28. Wash two tie rods. .501 " .561 29. Repeat above. .506 3 .567 50. Repeat above. .522 n .586 51. Wash.packing box. .272 n .526 52. Repeat above. .292 n .550 55. Repeat above. .294 n .552 54. wash packing gland. .514 u .576 55. Repeat above. .519 n .582 56. Repeat above. .529 n .594 57. wash discharge valve cover. .201 n .241 58. Repeat above. .209 fl 0250 59. Repeat above. .199 n 0238 40. ‘Wash side suction inlet port. .204 a .244 41. Wash manifold port cover. .195 n .231 42. Wash suction valve. .185 n 0243 45. Repeat above. 0203 n 0257 44. Repeat above. -198 n '244 45. Wash discharge valve. .204 n 0244 45. Repeat above. ~204 " ~249 47. Repeat above. ~208 " '514 48. Wash gauge stem. 0429 n '411 49. Wash milk outlet assembly. .545 " .556 50. Wash pressure regulating valve '464 ' bod . n 51. Wash gauge well. ~512 ,, ~22: 52. Wash hex nuts. A «'5'75 a 9973 55. Wash outside of block. .811 fl -5 5 0 54. Wash block port holes. .467 . -10- Appendix A Table A-10. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 55. Wash.p1unger rod port cover. .502 120% .562 56. Repeat above. .501 " .552 57. Repeat above. .506 " .557 58. Wash.outside homogenizer .566 " .459 frame. 59. wash.1ower plunger. .144 " .172 60. Wash valve adapter. .166 " .199 61. Wash breaker ring. .199 " .258 62. Wash.upper valve seat. .171 " .205 65. Wash lower valve seat. .164 " .196 64. Wash double ended valve plug. .177 " .212 65. Wash.packing gland. .104 " .124 66. Walk 20 ft. and get bucket .489 " .586 of chlorine and return. 67. Rinse parts in solution. .515 " .615 68. Rinse block with solution. .418 2 .501 69. Place packing gland gaskets. .211 n .255 70. Place gaskets in block. .615 n .758 71. Assemble plunger rods, pack- .650 .756 1 box and gland. 72. Repgit above. .655 2 .759 75. Repeat above. .650 u .756 74. Assemble plunger port covers .506 .607 and tie rods. n g 27 75. Repeat above. .525 " ~52 76. Repeat above. 9522 u .192 77. Place gauge well. .152 n .587 78. Place discharge valve covers. .525 n . 05 79. Place milk outlet assembly. .505 n .373 80. Assemble and place pressure .728 . control valve. " 81. Place discharge valves. .198 n .33: 82. Place suction valves. .263 n .276 85. Place gauge. 025 u '597 84. Place suction inlet nuts and .498 . manifold port. a 85. Place discharge valve cover .684 .320 nuts. " so. Tighten all nuts with wrench. 2.222 " fizégg 87. Replace guard. 0 -————- 45.149 Total Cycle Time Performance Rating 1032; Allowances 120% Total Appendix A Table A-ll. Dairy "A" Separator Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_linutes 1. Walk 60 ft. and return with 1.02 150% 1.550 parts platform. 2. Remove control valve head. .526 " .489 5. Remove valve body. .196 " .294 4. Remove valve seat disc. .052 " .078 5. Remove coupling ring. .225 " .554 6. Remove coupling nut. .188 " .282 7. Remove cream control base. .104 " .156 8. Remove cream seal. .052 " .078 9. Remove check valve. .060 " .090 10. Remove milk outlet assembly. .114 " .171 11. Remove mdlk outlet seal. .057 " .085 12. Remove frame cover. .251 “ .576 15. Remove bowl coupling ring. .595 " .592 14. Remove bowl t0p and top disc. .119 " .178 15. Remove disc carrier and discs. .224 " .556 16. Remove bowl locking nut. .218 " .527 17. Remove bottom.bowl shell. .272 2 .408 18. Remove milk inlet connections. .651 n .976 19. Walk 10 ft. and turn on.water .297 .445 in hose and return with at r. 20 Riggzepgtgepar o 2.829 " 4.259 ' ' n 21. Wash outside of separator with 1.475 2.212 brush and hose. " 22. Move parts p1atform.to wash .462 .695 tank. " 123 25. Turn on water in washand.rinse .082 . tanks. 24. Put wash powder in tank. .212 3 .513 25. Place all parts in wash tank. 1.542 n 2.169 26. wash.va1ve body and place in .115 . rinse tank. 27. Wash valve stem and place in .124 " .186 rinse tank. 28. Wash valve seat disc and Place 0092 u ’158 in.rinse tank. a 29. Wash coupling ring and place ~156 '249 and place in rinse tank. n 243 50. Wash cream control Egse and .162 0 lace in rinse ta . n 51. Wagh cream seal and place in '122 '183 rinse tank. 057 n .085 32. Wash check valve and place in ' rinse tank. 089 u .133 35. Wash coupling ring and Place ° in.rinse tank. Appendix A Table A-ll. (Continued) Actual Aver- Allowed Element age Time in. Time in Number Element Description Minutes Ratinnginutes 54. Wash milk outlet assembly .229 150% .545 and place in rinse tank. 55. 'Wash outlet seal and place .157 " .255 in.rinse tank. 56. Wash.reinforcing cup and place .085 " .124 in rinse tank. ' 57. Wash elbow and place in rinse .114 " .171 tank. 58. wash.sea1 ring and reducer and .101 " .151 place in rinse tank. 59. Wash reinforcing cup and place .104 " .156 in rinse tank. 40. ‘Wash.inlet seal and place in .102 " .155 rinse tank. 41. Wash.holder and place in.rinse .096 " .144 tank. 42. Wash.howl coupling ring and .585 " .574 place in rinse tank. 45. Wash bowl top and place in 1.072 " 1.608 rinse tank. 44. Wash top disc and place in .554 " .501 rinse tank. n 45. Wash disc carrier and place .819 1.228 in rinse tank. " 46. Wash bowl locking nut and .114 .171 place in rinse tank. a 47. Wash bowl rubber and place in .204 .506 rinse tank. " 48. ‘Wash bowl shell and place in .855 1.249 rinse tank. 49. Wash disc and place in 5.994 " 8-991 rinse -- average time for 1 disc is .111 -- total discs 54. 50. Remove parts from rinse and 1.554 " 29010 lace on platform. 51. Pugh parts platform to .494 " ~741 se arator. n 52. Placg bowl shell. .271 " oggg 55. Place bowl locking nut. «385 n .186 54. Place disc carrier. .125 " 4'125 55. Place disc -- average time 2'750 ' for 1 disc is .051 -- total discs 54. n 56. Place top disc. éég ,. fig: 57. Place bowl top. ° 47 n 520 58. Place bowl coupling ring. .5 ° -13.. Appendix A Table A-ll. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 59. Place frame cover. .248 150% .572 60. Place milk outlet assembly. .255 " .579 61. Place milk outlet seal. .116 " .174 62.- Place check valve. .191 " .286 65. Place cream seal. .055 ” .082 64. Place cream control base. .149 " .225 65. Place coupling nut. .081 " .121 66. Place coupling ring. .187 " .280 67. Place valve seat disc. .059 " .088 58. Place valve body. .125 " .189 69. Place control valve head. .250 " .545 70. Assemble milk inlet assembly. 1.025 " 1.557 71. Place milk inlet assembly. .544 " .516 Total Cycle Time 48.711 Performance Rating 150% Allowances 20c Total Table A-12. Dairy "A" Clarifier Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes RatiDEMiHUPQS 1. Walk 50 ft. and return with 1.100 150% 1.550 parts platform. a 2. Remove milk outlet coupling .246 .569 ring. 5. Remove milk outlet connection. .109 s .165 4. Remove frame cover. .252 " 0548 5. Remove bowl coupling ring. .597 n .595 6. Remove bowl top. 9113 n '177 7. Remove bowl rubber. ~119 n '178 8. Remove disc carrier and discs. .210 n .515 9. Remove bowl locking nut. .210 n '515 10. Remove bowl shell. o284 u '425 11. Push parts p1atform.to wash .486 .729 tank. 12. Place parts in wash tank. .955 3 1.232 15. wash milk outlet coupling t nk .196 ' ring and place in r nse a - 14. Wash milk outlet connection .214 " .521 and place in rinse tank. -14- Appendix A Table A-12. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 15. Wash bowl rubber and place .144 150% .171 in rinse tank. 16. Wash bowl coupling ring and .557 " .505 place in rinse tank. 17. Wash bowl top and place in .875 " 1.509 rinse tank. 18. Wash bowl shell and place in .728 " 1.092 rinse tank. 19. Wash disc and place in 5.960 " 5.940 rinse -- average time for 1 disc is .099 -- total discs 40. 20. Remove parts from rinse. .854 " 1.251 21. Push parts platform to .498 " .747 separator. 22. Place bowl shell. .507 " .460 25. Place bowl locking nut. .577 " .565 24. Place disc carrier. .119 " .178 25. Place disc -- average time 2.240 " 5.560 for 1 diSc is .056 -- total discs 40. 26. Place bowl top. .515 2 .769 27. Place bowl coupling ring. .551 ' .496 28. Place frame cover. .254 " .551 29. Place milk outlet connections. .218 3 .527 50. Place milk outlet coupling ring. .215 ___§§§g Total Cycle Time 24.590 Performance Rating 150% Allowances 20 Total % Table A-l5. Dairy "A" Centrifugal Milk Pump Actual Aver- gllowid Element age Time in ‘ me n Number Element Description Minutes Rating Minutes 1. ‘Unscrew holding screws. oggg 1§0% :13: 2. Disassemble pump. 9 16 n 324 5. Wash milk inlet and outlet .2 ‘ assembly. n . 4. Wash impeller. :33: ,, .122 5. Wash spring. -15- Appendix A Table A-15. (Continued) Actual Aver-s Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 6. Wash.back plate. .218 150% .524 7. Rinse purrip. 0200 N 0500 8. Place back plate gasket. .107 " .160 9. Place back plate. .168 " .252 10. Place spring. .061 " .091 11. Place impeller. .054 " .081 12. Place milk inlet and outlet .150 " .225 assembly. 15. Tighten holding screws. .212 " .518 Total Cycle Time 2.950 Performance Rating 150% Allowances 20% Total 150% Table A-14. Dairy "A" 60 Gallon Round Butter Milk Vat Actual Aver- Allowed Element age Time in Time in Npmber Element Description Minutes Rating Minutes 1. Walk 20 ft. turn on hose .544 140% .480 and return to vat. 2. Walk 50 ft. get bucket of .416 " .582 cleaning solutions and return to vat. 5. Rinse vat. 1-37 2 2°51 4. Wash inside of vat. 5.45 n 4.85 5. Wash cooling coil. 5.85 n 5.56 6. Wash underside of vat cover. .757 u 1.05 7. Wash outside of vat. .719 a 1-00 8. Wash outlet valve. .790 " é°ég 9. Rinse vat. 1-63 ,, -492 10. Walk 20 ft. turn off hose, .552 __;___ and return to vat. 19.76 Total Cycle Time Performance Rating 120% Allowances 20% T0531 140% -15- Appendix A Table A-15. Dairy "A" 200 Gallon Cheese Vat Actual Aver— Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 15 ft. turn on hose .277 150% .415 and return to vat. 2. Rinse vat. 2.01 " 5.01 5. Fill 1/5 full with water. 1.48 " 2.22 4. Walk 15 ft. get dipper of .276 " .414 powder and return to vat. 5. Wash vat with steel sponge. 6.16 " 9.24 6. Wash strainer. 1.20 " 1.80 7. Wash cheese knives. 1.01 " 1.51 8. Rinse vat. 1.65 " 2.47 9. Rinse cheese curd from floor. 1.96 " 2.94 10. Walk 15 ft. turn off hose, .275 " __;gig and return to vat. Total Cycle Time 24.45 Performance Rating 150% Allowances 20% Total 155% Table A-16. Dairy "A" Hot Water Sterilization of Equipment Actual Aver- Allowance Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 25 ft. to 200 gallon .255 100% .255 vat. 2. Turn on.hose and place in vat. .094 a .82: 5. Turn steam on vat. .066 " .048 4. Start vat agitator .048 n .176 5. Walk 10 ft. to surface cooler .176 . and turn on steam. 6. Walk 10 ft. and open vat outlet .194 " .194 valve. " 7. Start pump . 0092 n '33: 8. Walk 10 ft. to homogenlzer. .126 n .268 9. Start homogenizer and raise .268 . pressure. " . 4 10. Walk 25 ft. to vat. 'Ség " .353 11. Turn off pump. .058 ,. .058 12. Turn off steam on vat. 0052 " .052 15. Stop agitator. 0 n 094 094 . 14. Open vat outlet valve. . -17.. Appendix A Table A-16. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 15. Walk 10 ft. to homogenizer. .115 100% .115 16. Stop homogenizer. .080 " .080 17. Walk 25 ft. to surface cooler. .268 " .268 18. Turn off steamt .116 " .116 19. Drain bottom trough. .148 " .148 20. Walk 25 ft. to filler. .254 " .254 21. Drain filler. .186 " .186 Total Cycle Time 2.976 Performance Rating 80% Allowances 20 Total % Table A-17. Dairy "A" Assembly and Disassembly of Sanitary Pipe and Fittings. Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Ratipg Minutes 1. Loosen pipe hex nuts with .068 150% .102 wrench. 2. Unscrew hex nuts by hand. .155 " .199 5. Walk 50 ft. and get gaskets .559 " .508 and return to vat. " 4. Pick up pipe. .070 n .105 5. Place gasket. .079 n .118 6. Pick up mating pipe and place. .090 " .155 7. Screw hex nut by hand. .141 " .211 8. Tighten.hex nut with wrench. .088 " .152 9. Walk to upper deck and get .587 .580 pipe section and return to wash vat - distance 50 ft. " 595 10. Carry pipe section to upper .597 . deck and return gofzash vat - distance 5 . 11. Walk 20 ft. to pipe section .257 " .585 on lower floorhandtcarry section to was va . n 12. Carry section 20 ft. from .286 .429 vat to assembly position on lower floor. 15. Walk around assembled pipe to 1.10 loosen and tighten - dis- tance 140 ft. " 1.65 Performance Rating 150% Allowances 20% Total -18- Appendix A Table Ae18. Dairy "A" Washing of Sanitary Pipe and Fittings This is a two man.operation, with one man.picking up the pipe and holding while the other man.runs pipe brush through pipe. The pipe is then placed on pipe rack. Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Ratinnginutes l. Wash.pipe sections from. .057 150% .085 6" to 2' in length. 2. Wash pipe sections from. .085 " .127 2' to 4' in length. 5. Wash pipe sections from .150 " .195 4' to 7' in.1ength. 4. Wash pipe sections from .198 " .297 7' to 10' in length. 5. Wash ells. .051 " .076 6. Wash tees. .061 " .091 Performance Rating 150% Allowances 20% Total 750% Table A-l9. Dairy "A" Preparing Buckets of Chlorine Solution Actual Aver- Allowed Element age time in Time in Number Element Description Minutes RatingpMinutes 1. Turn on water in hose and .552 150% .498 fill bucket. " 2. Walk 5 ft. to chlorine jug. .065 n .094 5. Pour chlorine in water. .125 [pigg Total Cycle Time 0775 Performance Rating 150% Allowances 20c 50% Table A-20. Dairy "A" Preparing Buckets of Washing Solution Actual Aver- $ii0wid Element 886 Time in e n Number Element Description Minutes Ratinnginutes w 1. Walk 10 ft. to get dipper .260 150p .590 of wash powder and return to hose. -19 .- Appendix A Table A-20. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 2. Turn on hose and fill .540 150% .510 bucket. 5. Put powder in bucket. .151 “ .196 Total Cycle Time 1.096 Performance Rating 150% Allowances 20% Total 155% Table A-21. Dairy "A" Filling and Emptying Wash Tank Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 5 ft. to hose. .055 150% .094 2. Turn on water. .051 " .076 5. Return with.hose to vat. .078 " .117 4. Fill vat with water. 1.52 3 2.280 5. Return hose. .070 " .105 6. Turn.off water. .075 n .109 7. Pull vat plug. .047 .070 8. Drain tank. 1.85 " 2.740 Total Cycle Time 5.590 Performance Rating 150% Allowances 20% Total 150% Table A-22. Dairy "A" Miscellaneous Pipe Washing Operations Actual Aver- gllowid Element age Time in me n Ngmber Element Description Minutes Rating Minutes 1. Walk 10 ft. and get dipper .242 150% .565 of wash powder and return to tank. ll 2. Reach under tank and get .502 .455 chlorine jug and pour into vat. u 5. Take pipe from rack and place 1.21 10810 in vat. Performance Rating 150% Allowances _22g Total 150p Allowed Time in Rating_Minutes Appendix B Table B-1. Dairy "B“ Weigh Tank Actual Aver- Element age Time in Number Element Description Minutes 1. Remove weigh.tank cover. .111 2. Remove surge tank cover. .170 5. Walk 10 ft. turn.on.hose and .270 return to tank. 4. Rinse weigh.tank and surge 1.900 tank. 5. Remove dump grid. .091 6. Remove dump screen. .226 7. Rinse dump screen. .775 8. Walk 15 ft. get dipper of .557 powder and return to tank, place powder in.tank. 9. Wash dump grid. .845 10. ‘Wash dump screen. 5.55 11. wash.weigh tank cover. 1.265 12. Wash outside scale framework. 1.570 15. wash.weigh.tank. 4.440 14. Wash inside surge tank. 1.44 15. Wash outside surge tank. 1.226 16. ‘Wash.splash guard. .549 17. ‘Wash.surge tank cover. 1.655 18. Rinse all parts. 5.177 19. Walk 10 ft. turn off hose .286 and return to tank. 20. Replace weigh tank cover. .188 21. Replace screen. .115 22. Replace dump grid. .151 25. Replace surge tank cover. .162 24. Replace splash guard. .178 Total Cycle Time Performance Rating 110% Allowances 20p Total 130% 150% n 3333383388: 3323 33:3 - ” .144 .221 .551 2.470 .118 .295 1.004 .464 1.095 4.520 1.644 1.781 5.772 1.870 1.595 .455 2.122 6.750 .571 .244 .149 .209 .210 .251 55.859 Appendix B Table B-2. Dairy "B" multiple Section Cabinet Cream Cooler Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. ‘Qpen cabinet. .275 100% .275 2. Walk 15 ft. turn on water, .509 " .309 return with hose to cooler. 5. Rinse cooler. 2.710 " 2.710 4. Walk 15 ft. return hose, turn .511 " .511 off water, return to cooler. 5. Walk 50 ft. get bucket of .864 " .864 cleaning solution, return to cooler. 6. Climb up on wash rack with .254 " .254 bucket of solution and brushes. 7. Remove top distribution trough. .525 " .525 8. Wash inside left shield. 1.250 " 1.250 9. 'Wash left side of first .751 " .751 cooling section. 10. Pull back section. .108 " .108 11. Wash right side of first .762 " .762 section. " 12. Wash left side of center .755 .755 section. " 15. Pull back section. .107 u .107 14. Wash.right side center section. .755 n .755 15. wash.left side third section. .760 u .760 16. Pull back section. .116 w .116 17. Wash right side third section. .754 n .754 18. Wash inside right shield. 1.245 a 1.243 19. wash bottom.trough. 1.210 " 1-213 20. Wash top trough. 1.450 n 1- 238 21. Climb down from rack. .208 n 0 04 22. Walk 15 ft. turnontwaterl,L .504 .5 return with hose o 000 er. a 25. Rinse cooler. 4.258 " $.32? 24. Replace top distribution 1.047 - trough. " 25. Close cabinet. bi t 2°32: W 2:32: 26. Wash.outside cooler ca ne . 1.279 n 1.279 27. Rinse outside cabinet. 28. Walk 15 ft. return hose, turn off water, return to cooler. .551 " .551 Total Cycle Time 25.519 Performance Rating 80% Allowances 20% Total [I555 -22.. Appendix B Table B-5. Dairy "B" 1000 Gallon Square Milk Storage Tanks Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes 1. Walk 15 ft. turn water on, .586 100% .586 return to tank with hose. 2. Rinse tank. 1.580 " 1.580 5. Walk 15 ft. return.hose, turn .526 " .526 off water, return to tank. 4. Walk 50 ft. get bucket of .844 " .844 cleaning solution and re- turn to tank. 5. Climb into tank. .289 " .289 6. Wash inside tank. 4.540 " 4.540 7. Climb out of tank. .115 " .115 8. Wash cover. 1.210 " 1.210 9. Walk 15 ft. turn water on, .565 " .565 return.to tank with hose. 10. Rinse tank. 1.680 " 1.680 11. Walk 15 ft. turn off water, .546 " .546 return to tank. 12. Close cover. .564 " __;§§4 Total Cycle Time 11.846 Performance Rating 80% Allowances 20% Total 100% Table B-4. Dairy "B" 100 Gallon.Round Cream.Pasteurizing Vat Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 10 ft. turn water on, .255 190% 4505 return to vat with hose. 2. Rinse vat. 1°580 3 1'33: 5. Walk 10 ft. return hose, Eurn .244 . off water return to va . 4. Walk 40 rt.'get bucket of .747 " ~895 cleaning solution and re- turn to vat. n 5. wash outside vat cover. 1-223 " 1'473 1 490 1.788 6. Wash outside vat. '150 ,. 1 580 7. Wash underside of vat cover. 1 567 " 6:440 8. Wash inside vat. 5'243 n .291 9. Walk 10 ft. turn on water. ' return to vat with hose. Appendix B Table B-4. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 10. Rinse vat. 1.117 120% 1.540 11. Walk 10 ft. return.hose, turn .267 " .267 off water, return to vat. Total Cycle Time 16.416 Performance Rating 100% Allowances 20 Total % Table B-5. Dairy "B" 2000 Gallon Upright Milk Storage Tank Actual Aver- Allowed Element age Time in. Time in Number Element Description Minutes Rating Minutes 1. Qpen.manhole. .557 120% .404 2. Walk 20 ft. turn.0n.water, .425 .510 return to vat with hose. " 5. Rinse tank. 2.522 't 5.026 4. Walk 50 ft. get bucket of .882 1.058 cleaning solution and re- turn to tank. " 5. Climb into tank with bucket .655 .785 and brush. 5. wash tank. 3.712 1: 4-454 7. Climb out of tank. .541 a 1.532 8. Wash.manhole cover. 1.510 '. . 9. Rinse tank. 1.266 n 1.2%: 10. Walk 20 ft. turn off water, .587 . return to vat. n 11. Close manhole. ~555 ...:222 14.840 Total Cycle Time Performance Rating 138% Allowances Total 2 % Appendix B Table 3'5- Dairy "B" 200 Gallon.Rectangular Pasteurizing Vats Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 10 ft. turn water on .255 110% .291 in.hose, return with hose to vat. 2. Rinse vat, leaving hose run- 1.102 " 1.212 ning in vat. 5. Walk 15 ft. get dipper of .522 " .554 cleaning powder, return and place powder in vat. 4. Walk 15 ft. get bucket of .540 " .574 cleaning solution and re- turn to vat. 5. Wash indicating thermometer. .588 " .426 6. Wash stem of recording ther- .542 " .596 mometer. 7. Wash top of vat covers. 1.250 " 1.550 8. wash underside of vat covers. .819 " .901 9. Wash.inside vat, letting 12.586 " 15.620 cleaning solution.run out slowly. " 10. Wash outlet valve. .828 .910 11. Rinse vat. 1.652 " 1.817 12. 'Walk 10 ft. to return hose, .514 " .545 shut off water and return to vat. " 15. Close cover. .122 __;l§é Total Cycle Time 22.550 Performance Rating 28% Allowances a Total not Table 3-7, Dairy "B" 200 Gallon Round Butter Milk Vat Actual Aver- gilowid Element age Time in me n Ngmber Element Description Minutes Rating Minutes 2 1. Walk 10 ft. turn on wateg, .264 140p .569 return.with hose to va . n 4 0 2. Rinse vat. l'ggg n 2:430 5. Walk 10 ft. return.hose: Eurn ' off water return to va . n 4. Walk 40 ft.’get bucket of .725 1-016 cleaning solution, return to vat. -25- Appendix B Table B-7. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 5. Wash.outside vat cover. 2.858 140% 4.001 6. Wash outside vat. 5.925 " 8.295 7. Wash underside vat cover. 2.840 " 5.970 8. Wash inside vat. 5.475 " 4.860 9. Disassemble outlet valve. .121 " .169 10. wash outlet valve. 1.115 " 1.558 11. Walk 10 ft. turn on.water, .284 " .597 return.with hose to vat. 12. Rinse vat. 2.827 " 5.957 15. Walk 10 ft. return hose, .277 " .587 turn off water, return to vat. " 14. Assemble outlet valve. .257 .559 Total CyCIe Time 52.200 Performance Rating 120% Allowances 20% Total 2 Table B-8. Dairy "B" Clarifier Actual Aver- Allowid Element a89 Time in Time n Number Element Description Minutes Rating Minutes 1. Remove coupling nut. .252 190% '32: 2. Remove outlet connicgion. .549 . and supporting P a 9' n 5. Remove frame cover bolts .454 .454 and raise frame cover. n 4. Remove coupling ring. ’87? n '22? 5. Walk 10 ft. turn on water. .26 . return.with hose to clarifier. " 6. Force bowl up with water .241 .241 pressure. n .842 7. Remove coupling ring. .125 n .123 8. Remove bowl top. . ' ,, 456 d 456 o 9. Remove disc carrier and lscs. .541 a .541 10. Remove bowl lock nut. .661 ,, .661 11. Remove bowl shell. 1’125 " 1 125 12. Place discs on disc rack. 6 440 n 6.440 15. Rinse all parts. ' 1' 455 455 o 14. Carry disc rack 40 ft. to - waSh tank. -25- Appendix B Table B-8.(Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 15. Wash disc on revolving brush. 7.560 100% 7.560 Average time for 1 disc is .12 - total discs 65. 16. Walk 40 ft. carry discs back .427 " .427 to clarifier. 17. Talk 50 ft. get bucket of .525 " .525 cleaning solution, return to clarifier. 18. Wash disc carrier. .658 " .658 19. Wash bowl shell. 1.211 " 1.211 20. Wash bowl rubber. .127 " .127 21. Wash bowl top. .755 " .755 22. Wash coupling ring. .415 " .415 25. Wash outlet connection. .411 " .411 24. Wash supporting plate. .451 " .451 25. Mash coupling ring. .541 " .541 26. Wash milk inlet assembly. 1.700 :: 1.700 27. Wash clarifier. 2.751 " 2.751 28. Rinse all parts. 2.060 " 2.060 29. Place parts on rack. 1.577 H 1.577 50. Place bowl shell. .559 u .559 51. Place bowl locking nut. 1.115 n 1.115 52. Place disc carrier. .245 n .245 55. Remove discs from disc rack. .640 n .640 54. Place discs on disc carrier. 5.670 5.670 Average time for l ggsc is .087 - total discs . . 55. Place bowl rubber. .186 3 .222 56. Place bowl top. .245 n l 062 57. Place coupling ring. 1-052 " .526 58. Lower frame cover and lock. .526 n .161 59. Place supporting plate and .161 . outlet connection. " 568 40. Place cou li nut. ~568 ’ 41. Assemble indnglace milk inlet 1.258 " 1.258 connection. , 42. Walk 10 ft. return hose, turn .254 ' .254 off water, return to clarifier. 46.557 Total Cycle Time Performance Rating 80? Allowances _§98 Total 100% -27... Appendix B Table B-9. Dairy "B" Separator Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Remove milk and cream.spouts. .271 120% .525 2. Remove coupling ring. .847 " 1.016 5. Remove bowl top. .258 " .509 4. Remove top disc. .197 " .256 5. Remove disc carrier and discs. .518 " .581 6. Remove bowl rubber. .550 ” .596 7. Remove bowl shell. .549 " .418 8. Walk 10 ft. turn on water, .261 " .515 return with hose to separator. 9. Rinse all parts. 4.714 " 5.650 10. Walk 10 ft. return hose, turn .266 " .519 off water, return to separator. 11. Walk 40 ft. get bucket of .492 " .590 cleaning solution, return to separator. 12. Wash outside separator frame. 1.846 3 2.215 15. Wash.howl shell. 2.990 n 5.580 14. Wash bowl top. .781 u .957 15. Wash spout assembly. 2.096 n 2.510 15. Wash top disc. .856 " 1-005 17. Wash disc carrier. .749 '. .898 18. Wash bowl rubber. .249 " .298 19. Walk 50 ft. carry discs to .488 .585 wash tank. 20. Wash.discs on power brush. 6.010 " 7.210 Average time for 1 disc is 008 "’ tOtal discs 75. u 555 21. Walk 50 ft. carry discs back .465 . to se arator. 22. Walk 10pft. turn on w::§?fi,re- .261 " .513 turn to separator w 085. n 25. Rinse all parts. 2.470 n gags; 24. Walk 10 ft. return hose, turn .261 . . off water, return to separator. " 25. Place bowl shell. "222 ,, .515 26. Place disc carrier. 0 0 n 4.500 27. Place discs. Average time for 5'75 1 disc is .05 - total (11308 75. 124 u .148 28. Place top disc. .267 n .520 29. Place bowl rubber. .208 n .249 50. Place bowl top. ' -28— Appendix B Table B-9. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 51. Place coupling ring. 1.205 120% 1.446 52. Place milk and cream spouts. .258 " .509 Total Cycle Time 40.954 Performance Rating 100% Allowances 20. Total % Table B-10. Dairy "B" Multiple Section Cabinet Milk Cooler Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Open cabinet. .255 1i0% .280 2. Walk 10 ft. turn on water, .245 .269 return to cooler with hose. " 5. Rinse cooler. 1.976 n 2.175 4. Walk 10 ft. return.hose, turn .270 .297 off water, return to cooler. " 5. Walk 40 ft. get bucket of .755 .850 cleaning solution, return . to cooler. ' 6. Remove top trough. .125 L 1.722 7. Wash top trough. 1.520 t. 1.617 8. 'Wash inside left shield. 1.470 " l 015 9. Wash left side of first .925 . section. n 10. Pull back section. .13 a 1.555 11. 'Wash right side of first .9 - section. " 12. ‘Wash.left side of second .947 1-O41 section. " .132 15. Pull back section. .915 n 1 004 14. Wash right side of second . section. n .986 15. Wash left side of third .897 section. 127 n .159 16. Pull back section. .958 n 1 031 17. Wash right side of third . 860121011. 3. 1.009 18. Wash left side of fourth .918 section. .120 n .152 19. Pull back section. Appendix B Table B-10. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 20. Wash right side of fourth .899 110% .988 section. 21. Wash.1eft side of fifth .940 " 1.054 section. . 22. Pull back section. .115 " .124 25. Wash right side of fifth .940 " 1.054 section. 24. Wash left side of sixth .951 " 1.024 section. 25. Wash.right side of sixth .940 " 1.054 SBCtiOno 26. Wash bottom.trough. 1.170 " 1.280 27. Wash outside cabinet. 4.148 " 4.562 28. Walk 10 ft. turn on water, .265 " .291 return to cooler with hose. 29. Rinse cooler. 8.550 x 9.405 50. Walk 10 ft. return hose, turn .265 .289 off water, return to cooler. " 51. Replace top trough and close .867 .955 cabinet. Total Cycle Time 57.055 Performance Rating 90% Allowances 20% Total 0% Table B-ll. Dairy "B" Bottle Filler Actual Aver- gilowid Element age Time in me n Number Element Description Minutes Ratinnginutes 1. Remove shield. .114 190% .é%g 2. Walk 50 ft. get 2 buckets of .555 . cleaning solution, return to filler. " 5. Remove vacuum assembly. 1.273 " loigg 4. Remove rubber vacuum seal. .134 n :104 5. Remove filler cover. .847 n .847 6. Disassemble level control . float assembly. 1.586 " 1.586 7. Remove filling rubbers and drip plates and place in bucket. -30.. Appendix B Table B-11. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Descrippion Minutes Rating Minutes 8. Remove filling valves and 5.670 100% 5.670 place in bucket. 9. Walk 10 ft. turn on water, .268 " .268 return to filler with.hose. 10. Rinse filler. .867 " .867 11. Walk 10 ft return.hose, turn .255 " .255 off water, return to filler. 12. Crank bowl down. .528 " .528 15. wash inside bowl. 2.160 " 2.160 14. Wash bowl filling ports. 1.247 3 1.247 15. Wash outside bowl. 1.750 " 1.750 16. ‘Wash lifter plates. .744 ' .744 17. Wash filler frame work. 4.550 L 4.550 18. Wash star wheels. 2.228 " 2.228 19. Wash 15 capping headers. 9.026 " 9.026 20. Wash filling valves - 15 5.425 5.425 valves. " 21. Wash filling rubbers and 1.054 1.054 drip plates. 22. Wash.leve1 control float .612 " .612 assembly. ‘ 25. Wash vacuum assembly. .915 n .913 24. Wash rubber vacuum seal. .550 " 2.§§0 25. Wash bowl cover. 2.150 n .267 26. Walk 10 ft. turn on wafiefi, .267 - return to filler wit ose. n 27. Rinse filler. 7.285 n 7.323 28. Walk 10 ft. return.hosefipnrn .266 . off water, return to er. " 29. Roll up bowl. '577 n 4.14% 50. Place filling valves in filler 4.140 . b 0W]. 0 N 51. Place drip plates and filling 2-808 2'808 rubbers. n .485 52. Roll down bowl. '22: n .245 55. Place filler cover. -749 n .749 54. Place rubber vacuum sealo 1°592 t: 1.392 55. Assemble level control . assembly and Pla°6° " 2.450 56. Assemble vacuum assembly 2°450 and place. 62.820 Total Cycle Time Performance Rating 80% Allowances 20@ Total 100% 'Table B-12. Appendix B Dairy "B" Homogenizer Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 15 ft. turn on water, .555 150% .552 return with hose to homogenizer. 2. Circulate rinse homogenizer. 1.580 " 2.070 5. Walk 15 ft. return hose, .548 " .522 turn hose off, return to homogenizer. . 4. Walk 50 ft. get bucket of .569 " .855 cleaning solution, return to homogenizer. 5. Remove all hex nuts. 1.820 " 2.750 6. Remove gage. .154 " .201 7. Remove pressure control .591 " .586 assembly. 8. Remove manifold. .445 " .664 9. Remove strainer. .155 " .252 10. Remove port covers. .525 3 .487 11. Remove plunger rods. 2.268 5 5.402 12. Remove packing glands. 1.164 " 1.746 15. Remove suction and discharge .527 . .790 valves. 14. Wash block. 2.155 x 5.250 15. Wash gage stem. .158 " ~207 16. Wash pressure control 2.280 5-420 assembly. - 17. Wash manifold. .446 3 ~569 18. Wash manifold strainer. .265 ‘. .332 19. Wash 5 plunger rods. .515 " 2.376 20. Wash.5 packing glands. 1.584 " 10054 21. Wash suction and discharge .705 - Valves 0 ‘ 22. 'Walk 15 ft. turn on water. .555 n '529 return with hose to homo enizer. n 25. Rinse Ell parts. 1-278 n 1.3%; 24. Walk 15 ft. return hose, turn .555 . off water, return to homogenizer. Performance Rating 150% Allowances 205 Total 150% -32- Appendix B Table B-l2. (Continued) Assembly by Other Man Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 25. Place suction and discharge 1.125 100% 1.125 valves. 26. Place 5 packing glands. 5.558 " 5.558 27. Place 5 plunger rods. 1.708 " 1.708 28. Place port covers. .894 " .894 29. Assemble pressure control .886 " .886 assembly and place. 50. Place gauge. .125 " .125 51. Place manifold and manifold 5.270 " 5.270 strainer. 52. Place all hex nuts and tighten. 4.251 " 4.251 Total Cycle Time 45.212 Performance Rating 80% Allowances 20% Total 166’. Table B-l5. Dairy "B" Centrifugal Milk Pump Actual Aver— Allowed Element age Time in Time in Eumber Element Description Minutes Rating Minutes 1. Disassemble pump. .486 190% .486 2. Walk 15 ft. turn on water, .559 .559 return to pump with.hose. 5. Rinse pump. .515 3 .515 4. Walk 20 ft. get bucket of .457 .457 cleaning solution, return to pump. " 5. Wash back plate. .548 " °ggg 6. Wash milk inlet and outlet .528 . housing. " '7. Wash impeller. .253 n :33 8. Wash pump frame. °§§1 ,' '351- 9. Rinse pump. - 28 n .528 10. Walk 15 ft. return.hose, turn .5 . off water, return to pump. " .11. Walk 50 ft.get pump gasket, .545 .545 return.to pump. " l 124 12. Assemble pump. 1'124 5.526 Total Cycle Time Performance Rating 80% Allowances 20% Total 166% Table B-l4. -55- Appendix B Dairy "B" Positive Displacement Pump Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Remove wing nuts. .558 100% .558 2. Remove cover. .164 " .164 5. Remove rotor shaft nuts. .964 " .964 4. Remove rotors. .176 " .176 5. Remove pump body. .274 " .274 6. Walk 10 ft.turn on water, .257 " .257 return with hose to pump. 7. Rinse pump. .261 " .261 8. Walk 40 ft. get bucket of .758 " .758 cleaning solution, return to pump. " 9. Remove rotary seal nuts. 1.585 1.585 10. Wash rotary seal springs. .188 x .188 11. Wash rotors. .657 n .657 12. Wash.rotary seal rubbers .565 .565 and washers. n 15. Wash.rotary seal nuts. .874 n .874 14. Wash pump body. .765 u .765 15. Wash pump cover. .565 n .565 16. Wash pump frame work. .449 " .449 17. Rinse pump parts. .650 " .650 18. Walk 10 ft. return hose, turn .251 .251 off water, return to pump. " 19. Walk 50 ft. get pump gaskets, .551 .551 return to pump. 20. Place rotary seal nuts. 1.697 2 1.2g; 21. Place pump body. .259 u .258 22. Place rotary seal washers. .258 u .279 25. Place rotary seal springs. .279 " 1.640 24. Place rotors. 1-640 n '515 25. Place gasket. .515 " ~129 26. Place pump cover. ~129 " ’750 27. Place wing nuts. .750 ..a... 15.557 Total Cycle Time Performance Rating 80% Allowances 20; Total 0N -54- Appendix B Table B-15. Dairy "B" Tubular Preheater Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Assemble pipe for circula- 5.250 100% 5.250 tory cleaning, using pre- heater circulating system. 2. Walk 40 ft. get bucket of .725 " .725 cleaning solution, return to preheater. 5. Pour bucket of solution into 1.112 " 1.112 circulating system. 4. After 20 minutes, stop pump, 2.990 " 2.990 loosen end port covers and drain solution. 5. Open end ports. .704 " .704 6. Remove gaskets with knife. 5.012 " 5.012 7. Push long handled brush 4.716 " 4.716 through 56 tubes. 8. Walk 15 ft. turn on water, .527 " .527 return with hose to pre- he 8.1362? 0 9. Rinse preheater. 2.019 " 2.019 10. Walk 15 ft. return hose, turn .558 " .558 off water, return to pre- heater. 11. Walk 10 ft. get gaskets, .258 " .258 return to preheater. " 12. Place gaskets and close port 2.160 2.160 covers. .______ Total Cycle Time 21.569 Performance Rating 80% Allowances 200 a m Table B-l6. Dairy "B" Making up Buckets of Cleaning Solution Actual Aver- gllowid Elemen age Time in .me n Egmbert Element Description Minutes Rating Minutes 1. Walk 10 ft.pick up bucket, .541 100% .541 dipper of wash powder and return to hose. " 2. Turn on hose and fill bucket. .422 " :igg 3- Dump powder in bucket and mix. .185 _____ .946 Total Cycle Time Performance Rating 80% Allowances 20° Total % -55- Appendix B Table B-17. Dairy "B" Filling Wash Tanks Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 20 ft. turn on water, .412 100% .412 return.with hose to tank. 2. Fill wash tank. 5.960 " 5.960 5. Walk 20 ft. return hose, .455 " .455 turn off water, return to tank. 4. Walk 50 ft. get bucket of .574 ” .574 cleaning solution, return and pour solution in tank. Total Cycle Time 7.581 Performance Rating 80% Allowances 20% 150% Table B-18. Dairy "B" Sterilizing Equipment Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 5 ft. turn on hose, .165 150% .244 return to weigh tank. " 2. Fill weigh tank. 2.856 n 4.280 5. 'Walk 5 ft. return hose, turn .152 . .228 off water, return to tank. " 4. Walk 10 ft. get chlorine, .505 .454 return to tank, place chlorine in tank. 5. Turn on pump, walk 70 ft. to .695 " 1.042 homogenizer and start homogenizer. 6. Walk 15 ft. to pasteurizing .105 " .154 Vats. ' 7. Splash chlorine solution on 5.496 " 8.240 inside of vats. " 8. Drain entire system. 5.520 -£;2§9 19.622 Total Cycle Time Performance Rating 130% Allowances 20; Total 5 P -36.. Appendix B Table B-19. Dairy "B" Washing Sanitary Pipe and Fittings Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes Pipe Lengths 6" to 2' 1. Pick up pipe and run brush .115 100% .115 through pipe. 2. Walk to end of vat and place .091 " .091 pipe. Pipe Lengths 2' to 4' 1. Pick up pipe and run brush. .172 " .172 through pipe. 2. Walk to end of vat and place .105 " .105 pipe. Pipe Lengths 4' to 7' 1. Pick up pipe and run brush. .257 " .257 through pipe. " 2. 'Walk to end of vat and place .152 .152 pipe. Pipe Lengths 7' to 10' 1. Pick up pipe and run brush .540 " .540 through pipe. u 2. Walk to end of vat and place .156 .156 pipe. 1. Place all pipe on pipe rack 15.280 " 15.280 in a definite position. 2. Place all fittings and valves 7.710 " 7.710 on pipe rack in a definite position. 1. Pick up ell, runr brush through: 0158 n '158 place ell at end of tank. " 155 2. Pick up tee, run brush through, .135 - place tee at end of vat. Washing Valveg fl 1. Disassemble valve. '21? n '23; 2 .401 ° . Wash valve. 296 .. .295 5. Assemble valve. ° Performance Rating 38? Allowances 5 Total 155% Table B-20. -37- Appendix Pipe and Fittings Element Number Element Description B Dairy "B" Assembly and Disassembly of Sanitary l. 2. 5. 4. 5. 6. 7. 8. 9. 10. Loosen pipe hex nuts with wrench. Unscrew hex nuts by hand. Pick up pipe. Place gasket. Pick up mating pipe and place. Screw hex nut by hand. Tighten hex nut with wrench. Carry sections of pipe to wash tank - 60 trips - total ft. walked 1500. Carry sections of pipe from pipe rack to assembly location - 65 trips - total ft. walked 1420. Walk 500 ft. around assem- bled pipe to tighten and loosen hex nuts. Performance Rating 80% Allowances 20% Total 100% Actual Aver- Allowed age Time in Time in Minutes Rating Minutes .105 100% .103 .185 " .185 .108 " .108 .112 " .112 .125 " .125 .229 " .229 .121 " .121 15.046 " 15.046 16.521 " 16.521 2,250 " 2.250 -58- Allowed Time in Ratinnginutes Appendix C Table 0-1. Dairy "C" Weigh Tank Actual Aver- Element age Time in Number Element Description Minutes 1. Remove right cover. .120 2. Remove left cover. .117 5. Remove one section of dump .065 guard. 4. Remove other section of dump .065 guard. 5. Remove strainer. .206 6. Walk 5 ft. turn on hose and .252 return. 7. Rinse weigh tank. 1.415 8. Place hose in tank. .106 9. Walk 60 ft. get wash powder .916 and return. 10. Place powder in weigh tank. .105 11. Wash inside and outside of 5.507 weigh tank. 12. Walk 5 ft. turn off water .207 and return. 15. Wash right cover. .955 14. Wash left cover. .954 15. Wash strainer. 2.704 16. Wash one section of dump .417 guard. 17. Wash other section of dump .424 guard. 18. Wash sample port covers. .228 19. Wash can washer drain. 1-249 20. Wash dump rack. ~450 21. Wash scale frame. ~549 22. Walk 5 ft. turn on.hose and .240 return. 25. Rinse weigh tank. 1-519 24. Walk 5 ft. turn off water and .225 return. 25. Place strainer. '144 26. Place dump guard. ~114 27. Place other half of guard. '15? 28. Place right cover. ~151 29. Place left cover. ° Total Cycle Time Performance Rating 110% Allowances 20; Total W 150% u I! N N fl " I! .156 .152 .084 .084 .267 .501 1.850 .157 1.190 .156 4.559 .269 1.241 1.240 5.515 .542 .551 .296 1.625 .598 .845 .512 1.714 .292 .187 .148 .150 .157 .170 22.744 -39- Appendix C Table 0-2. Dairy "C" Homogenizer Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 10 ft. turn on water .199 100% .199 in hose and return to homogenizer. 2. Place hose in homogenizer .096 " .096 port. 5. Rinse homogenizer while .527 " .527 running. 4. Screw on cleaning solution pot. .225 " .225 5. Make pipe connection to pot. .547 " .547 6. Fill homogenizer and solution .795 " .795 pot with water. 7. Walk 10 ft. turn off hose, pick .286 " .286 up dipper of powder and re- turn to homogenizer. 8. Place powder in pot. .057 " .057 9. Turn pressure to 1000#, .502 " .502 machine clean for 15 minutes. n 10. Break cleaning connection. .112 ' .112 11. Walk 10 ft. turn on hose and .205 ' .205 return to homogenizer. " 12. Place hose in pot. .067 " o067 15. Circulate rinse. .657 " 0557 14. Wash outside homogenizer. .554 u .554 15. Walk 10 ft. turn off hose and .207 .207 return to homogenizer. " 16. Turn off homogenizer and re- .175 .175 move solution pot. 4.605 Total Cycle Time Performance Rating 80% Allowances 20; Total fl -40- Appendix C Table 0-5. Dairy "C" 2500 Gallon Storage Tank Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Open manhole. .206 140% .288 2. Disassemble outlet valve. .152 " .212 5. Walk 15 ft. and turn on.hose, .250 " .550 return to tank. 4. Rinse tank. 2.021 " 2.829 5. Walk 15 ft. to hose valves. .114 " .159 6. Fill bucket with water. .106 " .148 7. Turn off water. .070 " .098 8. Walk 5 ft. and get dipper of .126 " .176 powder and return. 9. Place powder in bucket. .057 " .079 pick up brush on way. 11. Wash outlet valve. .871 " 1.219 12. Wash inlet connection. .551 " .745 15. Crawl into vat with bucket and .260 " .564 brush. " 14. Wash inside of vat and manhole 6.056 8.450 cover. " 15. Crawl out of vat. .292 " ~408 16. Walk 15 ft. turn on hose and .265 .568 return to tank. 17. Rinse tank. 2.105 a 2.947 18. Assemble outlet valve. .240 n .556 19. Close manhole. .885 " 1°259 20. Walk 15 ft. turn off water and .276 .586 return to tank. Total Cycle Time 210014 Performance Rating 138% Allowances 0 Total IZO% Table 0-4. Dairy "C" 500 Gallon.Round PasteuriZing Vat 1 Aver- Allowed Actua Time in age Time in Element Npmber Element Description Minutes Rating Minutes 2 .177 1. Remove left cover. ‘iéi 130/ .186 2. Remove right cover. ’151 u: .195 5. Remove stem thermometer. '157 t! .225 4. Remove agitator. I156 " .254 5. Remove outlet plug valve. -41- Appendix C Table C -4 . (C ont inued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 6. Walk 10 ft. to hose, pick up .658 150% .987 bucket, place dipper of cleaning powder in bucket, fill bucket with water. 7. Walk 10 ft. to vat. .109 " .165 8. Climb in vat with bucket and .207 " .510 brush. 9. Wash.inside of vat. 1.999 " 2.998 10. Wash underside of center cover. .297 " .445 11. Wash top center of cover. .995 " 1.492 12. Climb out of vat. .181 " .271 15. Wash outside vat. 2.855 " 4.282 14. Wash right cover. .557 " .805 15. 'Wash left cover. .557 " .855 16. Wash thermometer. .127 " .190 17. Wash agitator. .472 " .708 18. Wash outlet valve. .177 " .265 19. Assemble outlet valve. .528 " .492 20. Replace thermometer. .096 " .144 21. Replace agitator. .241 " .561 22. Walk 10 ft. turn on hose, .246 " .569 return to vat. 25. Rinse inside and outside vat. 2.019 " 5.028 24. Walk 10 ft. turn off water, .248 " .572 return to vat. " 25. Replace right cover. .218 fl 0529 26. Replace left cover. .254 __;§§l Total Cycle Time 20-215 Performance Rating 150% Allowances 20% Total 13-535; Table 0-5. Dairy "0" 500 Gallon square 0011 V31; Actual Aver- gilowid Element age Time in me n Number Element Description Minutes Rating Minutes of 1. Raise right cover. 0800 1&0” '33: 2. Walk 5 ft. to other side of .820 . tank. :1 5. Raise left cover. 'BSg n 1.33% 4. Walk 10 ft. to hose. turn on '25 ' water and return to vat. "1 Ala IQV‘ 6|». T... an. 11 l.- -42- Appendix C Table C-5. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 5. Rinse vat and fill bottom 2.859 120% 5.406 with water. 6. Walk 10 ft. turn off water .240 " .288 and return to vat. 7. 'Walk 15 ft. get dipper of .551 " .597 powder, return to vet and place powder in vat. 8. Wash inside of vat. 2.070 " 2.484 9. Wash coil. 5.756 " 6.907 10. Wash cover. 1.026 " 1.251 11. 'Wash outside of tank. 5.089 " 5.706 12. Disassemble outlet valve. .124 " .148 15. Wash outlet valve. .785 " .942 14. Assemble valve. .248 " .297 15. Walk 10 ft. turn on water .245 " .291 and return to vat. t 16. Rinse tank. 1.068 L 1.281 17. Walk 10 ft. turn off water .245 .291 and return to vat. Total Cycle Time 24.911 Performance Rating 100% Allowances 2 2 Total 120% Table 0-6. Dairy "0" Positive Displacement Pump ‘ ' Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes a 1. Loosen holding screws with .558 100p .558 mallet. n . 77 2. Remove screws. '33; .. .190 5. Remove outside plate housins- ° 69 ,. .569 4. Pick up wrench and loosen .5 upper and lower rotor nuts. 805 n .805 5. Remove rotor nuts. .166 n .166 6. Remove top rotor, spring: and ' packing ring. I! .179 7. Remove lower rotor, spring, '179 - and packing ring. 899 :1 .899 8. Wash outside plate housing- -45- Appendix C Table 0-6 . (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 9. Wash top rotor. .518 100% .518 10. ‘Wash bottom rotor. .555 " .555 11. Remove pump body. .275 " .275 12. Remove rotary seal nut. .646 " .646 15. Remove rotary seal nut. .641 " .641 14. wash.back plate housing. .076 " 1.076 15. ‘Wash top packing ring. .771 " .771 16. Wash bottom packing ring. .764 " .764 17. ‘Wash both back plate seal rings. .452 " .452 18. 'Wash both springs. .427 " .427 19. ‘Wash rotor lock nuts and screws. .462 2 .462 20. Wash pump frame. .724 :1 .724 21. 'Walk 10 ft. turn on water in .266 .266 hose, return hose to pump. 22. Rinse pump. .648 3 .648 25. Walk 10 ft. return hose, turn .585 .585 off water, return to pump, picking up gaskets on way. 24. Place gaskets and grease. .808 3 .ggg 25. Place top seal ring. ~553 " '541 26. Place bottom seal ring. ~541 ,, .487 27. Grease shafts. ~487 " ~124 28. Place back plate. ~124 " “545 29. Grease top packing ring and .545 . lace. n 50. Grgase bottom packing ring and '575 ’575 lace. " 51. Pugh.packing rings into place. '826 " 'ggg 52. Place top rotor and spring. .255 " .741 55. Place rotor holding nut and .741 . ti hten nut. . u . 54. P1ac§ bottom rotor and sprlne- ~22? ,. .323 55. Place bottom.rotor holding nut .7 and ti hten nut. . .. .842 56. Grease ogtside plate hou31n8 1'842 1 seat. 289 H .289 57. Walk 10 ft. get gasket and ' return. 484 t! .484 58. Place gasket. .265 n .253 59. Place outside plate housing. 1°149 u 1.149 40. Place plate holding screws. .460 It .450 41. Tighten screws. ‘ 257544 Total Cycle Time Performance Rating 80% Allowances 20% Total 150% -44- Allowed Time in Rating Minutes Appendix C Table 0-7. Dairy "0" Tubular Preheater Actual Aver- Element age Time in Number Element Description Minutes 1. Open end cover. .177 2. Open end cover. .167 5. Remove both paper gaskets. .246 4. Walk 10 ft. to other end of .115 heater. 5. Open and cover. .159 6. Open and cover. .168 7. Remove both paper gaskets. .262 8. ‘Walk 10 ft. to front of heater. .125 9. Pick up brush rod. .086 10. Dip brush in wash tank and run 5.850 through tube - total 24 tubes. 11. Pick up sponge and wash cover .466 ports and return bends. 12. Walk 10 ft. to other end of .155 heater. 15. Wash cover ports and return .490 bends. 14. Walk 20 ft. to hose, turn on .460 water and return to heater. 15. Rinse heater. .414 16. Walk 20 ft. turn off water, .456 return to heater. 17. Walk 20 ft. and get gaskets, -505 return to heater. 18. Place both gaskets. .204 19. Close ports and tighten. .272 20. Walk 10 ft. to other end of .158 heater. 21. Place both gaskets. ~254 22. Close ports and tighten. .255 Total Cycle Time Performance Rating 100% Allowances 200 Total ‘I§5% 120% N N " H H II I! I! H 3! fl 8' I! .212 .200 .295 .155 .190 .206 .514 .147 .105 7.020 .559 .159 .588 .552 .496 .525 .606 .244 .526 .165 .280 .505 15.625 -45- Appendix C Table C-8. Dairy "0" Bottle Filler Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Remove float level control, .256 120% .507 carry 15 ft. to wash tank and return to filler. 2. Remove filler cover. .120 " .144 5. Remove filling valve suction .185 " .222 rubbers and place in bucket - 24 rubbers. 4. Disassemble capping headers - 2.096 " 2.515 8 headers. 5. Walk 15 ft. turn on.hose and .261 " .515 return to filler. 6. Rinse filler. 1.801 " 2.161 7. Rinse conveyor. 1.114 " 1.556 8. Walk 15 ft. turn off water in .269 " .522 hose and return to filler. 9. Remove filling valves and 2.610 " 5. 155 place on rack - 24 valves. " 10. Place valves in bucket. .661 u .795 11. Walk 15 ft. to hose, turn on .451 .517 water and walk 50 ft. with hose to wash tank. u 12. Fill wash tank with water. .074 " 2.488 13. Walk 15 ft. to filler. .118 " ~141 14. Fill 2 buckets with water. .622 n .746 15. Walk 15 ft. return hose, shut .268 .321 off water and return to filler. " 44 16. Walk 15 ft. to cupboard and .287 .5 get dipper of will powder and return to f er. 17. Place handful of wash powder .095 " .111 in each bucket. 18. Walk 15 ft. to wash tank and .161 " .193 place wash powder in tank. 280 n .556 19. ‘vaSh float. .279 u .534 20. Wash float cover. ' 84 ,, .220 21. Wash float inlet tube. 01 3 u .147 22. Walk 15 ft. to filler. 5&2 ,, .614 25. Wash cap chute. .828 .. .993 24. Wash filler cover. . .466 n .559 25. Pour bucket of solution on . ca 1 headers. .. . 53 26. Put afickgt of solution in -111 l filler bowl. u 1.550 27. Wash filler valve portS - inSidai'ifjg H 1.406 28. Wash inside bowl. ‘494 t! .592 29. Wash outside bowl. ' -45- Appendix C Table 0-8 . (Cont inued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 50. 'Wash outside valve ports. 1.191 120% 1.429 51. Wash cap food. .452 " .518 52. wash bottle conveyer guards .871 " 1.045 and guides. 55. Wash bottle assembly table, 5.861 " 7.055 lifter plates, motor cover and filler frame. 54. Wash.star wheels. 1.062 " 1.274 55. Disassemble filling valves, 8.660 " 10.592 wash.all parts, assemble valves, place in bucket — 24 valves. 56. Place all valves on rack. .926 " 1.111 57. Rinse filler, conveyors, 4.746 " 5.695 filling valves and frame work. . " 335 58. Walk 15 ft. and get hose With .278 . boiling water and return to filler. " 59. Walk 15 ft. return hose and .172 .205 shut off water. Assembly 40. Walk 15 ft. turn on.hoiling .279 " .554 water in hose and return with hose to fil er. " 41. Sterilize filler. 50125 " S’ggg 42. Walk 15 ft. turn off water .278 . and return to filler. " 45. Place valves, springs and 5.251 5.877 clips in filler bowl and assemble valves. " 44. Place valves in filler - 2-580 3°216 24 valves. " 45. Place headers and assemble - 4.800 5-760 8 headers. 106 it .127 46. Place cover. .456 n .547 47. Assemble float. .165 ,. .195 480 Place float. 1.040 [I 1.248 49. Place filling rubbers on ' valves. VITEQI Total Cycle Time Performance Rating 138% Allowances ' 0 Total 20% -47- Appendix C Table C-9. Dairy "C" 500 Gallon Round Pasteurizing Vat Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes 1. Walk 20 ft. turn on water, .412 150% .618 return to vat with hose. 2. Rinse vat. 1.400 " 2.100 5. Walk 20 ft. return hose, turn .451 " .646 off water, return to vat. 4. Walk 50 ft. get bucket of .575 " .859 cleaning solution, return to vat. 5. Climb into vat. .250 " .575 6. Wash underside of cover. .907 " 1.560 7. Wash inside vat. 1.505 " 2.254 8. Climb out of vat. .275 " .409 9. Wash outside vat. 2.107 :: 5.160 10. Disassemble outlet valve. .412 n .618 11. Wash outlet valve. .552 " .828 12. Assemble outlet valve. .556 n .804 15. Walk 20 ft. turn on water, .407 .610 return to vat with hose. " l4. Rinse vat. 1.150 n 1.725 15. Walk 20 ft. return hose, turn .426 .659 off water, return to vat. Total Cycle Time 17.005 ' Performance Rating 150% Allowances 20% Total [Sap Table C-lO. Dairy "C" 1000 Gallon Upright Milk Storage Tank Actual Aver- éllowid n Element 856 Time in firm Npmber Element Description Minutes Rating Minutes 4 1. Walk 15 ft. turn on wager: '561 110” '59? return to tank with ose. " .553 2. Climb in tank with hose and .505 brush. 1: 7.150 5. Wash inside tank with clear 6-504 water and brush. 551 .. .564 4. Climb OHt Of tank. 2.405 " 2.643 5. Wash outside tank. 1°507 :1 1,557 6. Wash dump connection. hi.“ .- u u u’ Jen... —- I'd -48- Appendix C Table 0-10. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 7. Rinse tank. 2.571 110% 2.828 8. Walk 15 ft. return hose, turn .554 " .589 off water, return to tank. Total Cycle Time 15.761 Performance Rating 90% Allowances 20% Total 110% Table 0-11. Dairy "0" Vertical Coil Round Pasteurizing Vat Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes RatingpMinutes 1. Walk 5 ft. turn on water, .195 150% .289 return with hose to vat. 2. Rinse vat. .525 3 .223 5. Walk 5 ft. return.hoie, tgrn .187 . off water return 0 va . 4. Walk 15 ft.’get bucket of .551 " .496 cleaning solution and return to vat. " 5. Wash inside vat. 1.805 " 107540 6. Wash vertical coil. 7.050 n l 129 7. Wash underside of cover. .755 " .675 8. Wash thermometer stem. .450 " 50100 9. Wash outside of vat. 50403 " 5:225 10. Disassemble, wash, and 2-15 assemble outlet valve. 185 u .274 11. Walk 5 ft. turn on water, - return to vat with hose. 1 807 '. 2.710 12. Rinse vat. .196 ,. .294 15. Walk 5 ft. return.hose, turn . off water, return to vat. -—————- 28.495 Total Cycle Time Performance Rating 130% a Allowances 20W Total 150% -49- Appendix C Table C-12. Dairy "C" 1000 Gallon Cottage Cheese Vat Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. walk 25 ft. turn on water, .481 150% .721 return to vat with hose. 2. Rinse vat. ' 4.901 " 7.551 5. Wash inside of vat with 5.815 " 8.719 water and metal sponge. 4. Wash outside of vat. 1.505 " 2.254 5. Wash cheese rake, strainer, 2.197 " 5.295 funnel, and scoop. 6. Rinse vat. 1.051 " 1.546 7. Walk 25 ft. return hose, .495 " .759 turn off water and return to vat. Total Cycle Time 24-525 Performance Rating 150% Allowances _29% Total 150% Table 0-15. Dairy "0" 800 Gallon Cottage Cheese Vat Actual Aver- gllowid Element age Time in 1me n Nkmber Element Description Minutes Rating Minutes 1. Walk 20 ft. turn on water, .592 150% .588 return to vat with hose. 2. Rinse vat. 2.970 :: é.$gg 5. Yash inside of vat with water 4.507 . and metal sponge. n 4. Wash outside of vat. 1.051 " 2.238 5. Wash cheese rake, strainer, 2.255 . 6. Riggingit.and scoop. .851 :: 1-gfg 7. Walk 20 ft. return hose, .415 . turn off water, return to vat. 19.567 Total Cycle Time Performance Rating 150% Allowances 20; Total 5 fl -50- Appendix C Table 0-14. Dairy "C" Surface Cooler Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes 1. Walk 20 ft. turn on water, .457 150% .655 return to cooler with hose. 2. Place hose in distributor .565 " .844 pipe, allowing water to run over cooler. 5. Wash cooling section. 5.816 " 5.720 4. Wash bottom trough. 1.950 " 2.925 5. Rinse cooler. 1.040 " 1.560 '6. Walk 20 ft. return.hose, .445 " .664 turn off water and return to cooler. Total Cycle Time 12.560 Performance Rating 150% Allowances 20% Total 150% Table C-l5. Dairy "C" 40 Gallon Surge Tank for H.T.S.T. Pasteurizer. Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 15 ft. turn on water, .257 150% ~555 return to tank with hose. " .155 .229 2. Rinse tank. 5. Walk 15 ft. return.hose, turn .241 " .561 off water return to tank. 4. Walk 25 rt.'get bucket of .505 " .754 cleaning solution and re- turn to tank. ' 5. Wash tank cover. .950 :. oggi 6. Wash inside tank. .621 " 1 870 7. Wash outside tank. 1.245 " .566 8. Walk 15 ft. turn on water: ~244 ’ return to tank with hose. 457 " .685 9. Rinse tank. - ', .578 10. Walk 15 ft. return.hose, turn .252 off water, return to tank. -____ 6.504 Total Cycle Time Performance Rating 150% 20% Allowances a Total 50N (\5 0" 05‘- (II -51- Appendix C Table 0-16. Dairy "C" Multiple Section Cabinet Cooler Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Open cabinet. 1.051 120% 1.257 2. Remove brine and water 1.561 " 1.655 headers. 5. Walk 10 ft. turn on water, .254 " .280 return to cooler with hose. 4. Rinse cooler. 2.507 " 2.768 5. Walk 10 ft. return hose, turn .245 " .291 off water, return to cooler. 6. Walk 20 ft. get bucket of .597 " .476 cleaning solution, return to cooler. '7. Wash inside of left shield. .401 " .481 8. Wash left side of first .615 " .755 section. " 9. Pull back section. .155 " .185 10. Wash right side of first .651 .757 section. " 11. Wash left side of second .596 .715 section. " 175 12. Pull back section. .146 '. .778 15. Wash right side of second .649 . section. 14. Mash left side of center .619 " -742 section. 15. Wash inside of right shield. .421 : .Sgg 16. Wash right side of fifth .503 ° section. u 17. Pull back section. .156 " o%gg 18. Wash left side of fifth .654 - section. " R 19. Wash right side of fourth .629 ”“4 section. 148 .. .177 20. Pull back section. .628 n .753 21. Wash left side, fourth section. 1.421 't 1.705 22. Wash.top trough. 1'541 n 1.509 25. VJaSh bOttom trough. 2.153 I. 2.580 24. Wash outside cooler. '25? ., .508 25. Walk 10 ft. turn on water. ' return to cooler with hose. 2 506 ', 4.207 26. Rinse cooler. .267 a: .520 27. Walk 10 ft. turn off water, . return to cooler. 4 060 :: 4.872 28. Replace brine and water - headers. ._-.. l_l -52- Appendix 0 Table 0-16. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 29. Replace top trough. .479 120% .574 50. Close cabinet. 1.460 " 1.752 Total Cycle Time 55.059 Performance Rating 100% Allowances 20% Total 120% Table 0-17. Dairy "0" Clarifier Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes 1. Remove coupling nut. .155 130% ~229 2. Remove outlet connection .229 .545 and supporting plate. 5. Raise frame cover. .251 :: 1.233 4. Remove bowl coupling ring. .864 " .165 5. Remove bowl top. ~110 ,, .610 6. Remove milk inlet assembly. .407 ‘. '451 7. Remove disc carrier and discs. .501 u 1-210 8. Remove bowl locking nut and bowl .815 - shell. 9. Walk 15 ft. turn on water},l re- .556 " .504 turn to clarifier with 086. u 10. Rinse all parts. 5552: ,. 4'22? 11. Walk 15 ft. return.hose: turn '56 ' off water. " 12. Place all parts in wash tank. .23; " 2:332 15. Wash bowl top. 1'15?) .. .229 14. Wash bowl coupling ring. '141 .g .211 15. Wash coupling nut. 1 611 :1 2,415 16. Wash bowl shell. '257 t! .585 17. Wash bowl rubber. ‘541 v. .511 18. Wash inlet Connection. '514 n .471 19. Wash supporting plate. ’951 :1 1,420 20. Wash disc carrier. 4 981 it 7,470 21. Wash discs. Average time for ' 1 disc is .06 - total discs - 85. 145 " .214 22. Place discs on disc rack. l 062 t: 1.590 25. Disassemble and wash milk - inlet assembly. -55- Appendix C inble 0-17. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 24. Wash.olarifier frame work. .715 150% 1.069 25. Walk 15 ft. turn on water, re- .514 " .471 turn to clarifier with hose. 26. Rinse all parts. 2.416 " 5.624 27. Raise frame cover. .107 " .160 28. Place bowl shell. .205 " .504 29. Tighten holding screws and .425 " .654 place bowl lock nut. .151 " .221 50. Place disc carrier. 51. Remove discs from disc rack. .225 " .554 52. Place discs on disc carrier. 2.490 " 5.755 Average time for 1 disc is .05 - total discs 85. n 55. Place bowl rubber. .105 u .154 54. Place bowl top. .201 u .501 55. Place bowl coupling ring. .755 n 1.129 56. Lower frame cover. .102 " ~§55 57. Tighten frame cover look screws. .557 " .558 58. Place supporting plate. .107 n ~15 59. Place milk outlet connection. .255 u .333 40. Place coupling nut. .201 " .504 41. Assemble milk inlet connection. .205 t: '5 4 42. Place milk inlet connection. .156 __;2§_ Total Cycle Time 42-485 Performance Rating 150% Allowances 20% Total I36% Table 0-18. Dairy "0" Separator Actual Aver- Allowed Element age Time in fiémetig Number Element Description Minutes Rating, inn 6 d . o 1. Remove milk inlet assembly' '854 120” l 01 and disassemble. 574 .. .448 2. Remove control valve head. -224 ,, .268 5. Remove valve body- . .061 " .075 4. Remove valve seat disc. '223 n .267 5. Remove coupling nut. .291 " .549 6. Remove coupling ring. '102 I! .122 7. Remove cream outlet. :093 1! .111 8. Remove cream control base. -54.. Appendix C Table 0-18. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 9. Remove skim milk outlet. .112 120% .154 10. Remove cream seal. .051 " .051 11. Remove check valve. .065 " .075 12. Remove reinforcing cup and .099 " .123 outlet seal. 15. Raise frame cover. .185 " .222 14. Remove bowl ring. .655 " .785 15. Remove bowl top and top disc. .185 " .218 16. Remove disc carrier and discs. .295 " .551 17. Remove bowl locking nut. .201 " .241 18. Remove bowl shell. .292 " .550 19. Walk 25 ft. turn on water, re- .491 " .589 turn to separator with hose. 20. Rinse separator parts. 5.612 " 4.555 21. Wash separator frame with 5.571 " 4.285 with brush and water. 22. 'Walk 25 ft. return hose, turn .509 " .610 off water, return to separator. - u 25. Carry parts to wash tank — 5 1.175 1.407 trips - total 100 ft. walked. " 24. Wash valve body. .151 n .181 25. Wash valve stem. .152 u .158 26. Wash.ooupling nut. .102 a .122 27. Wash coupling ring. .115 n .155 28. Wash cream control base. .216 n .259 29. Wash.milk outlet. .291 n .53: 50. Wash cream seal. .161 " .158 51. Wash reinforcing cup and seal. .152 n 1 669 52. Wash bowl top. 1.591 " ~591 55. Wash top disc. .495 n 1.594 54. Wash disc carrier. 1.162 n 1 407 55. Wash bowl shell. 1.175 n .555 56. Wash bowl rubber. .296 " 1 549 57. Wash.mi1k inlet assembly. 1.291 n 29 764 58. Wash discs. Average time for 24.804 . 1 disc is .20 - total discs 124. n 59. Walk 5 ft. turn on water, re- .170 " .207 turn to wash tank with.hose. 5 n 2.523 40. Rinse all parts. 2.10 n 226 41. Walk 5 ft. return.ho:e,tt::n .189 . off water, return 0 a . n 42. Carry parts to separator - 7 1.775 2.127 trips - total 140 ft. walked. -55... Appendix C Table 0-18. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Ratinnginutes 45. Place bowl shell. .551 120% .597 44. Place bowl lock nut. .591 " .469 45. Place disc carrier. .155 " .185 46. Place discs. Average time for 6.205 " 7.445 1 disc is .05 - total discs 124. 47. Place top disc. .115 " .155 48. Place bowl rubber. .155 " .185 49. Place bowl top. .215 " .255 50. Place bowl coupling ring. .907 " 1.088 51. Lower frame cover. .209 " .250 52. Place reinforcing cup and seal. .165 " .195 55. Place milk outlet. .241 " .289 54. Place cream seal and check .251 " ..277 valve. 55. Place cream control base. .196 " .255 56. Place coupling nut. .105 " .125 57. Place valve body. .215 " .255 58. Place valve stem. .106 " .127 59. Place control valve head. .516 " .579 60. Assemble and place milk inlet 1.951 " 2.517 assembly. Total Cycle Time 74.445 Performance Rating 100% Allowances 20% Total 120% Table 0-19, Dairy "C" Raw Milk Plate Cooler Actual Aver- Allowed Element 389 Time in Time in Number Element Description Minutes Rating Minutes 1. Loosen press. 1.809 130% 2.552 2. Walk 10 ft. turn on hose, .428 ~599 fill bucket with water, turn off hose. - 5. Walk 5 ft. pick up dipper of ~229 " '020 wash powder, return to bucket, place powder in bucket. -55- Appendix C Table 0-19. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 4. Pick up bucket and brush and .122 140% .170 return 10 ft. to press. 5. wash one side of first plate, 29.088 " 40.722 pull back plate, wash other side of plate. Average time - 1 plate is .125 - total plates 144. 6. Walk 10 ft. turn on hose, re- .265 " .568 turn to press. 7. Rinse plates. .829 " 1.160 8. Walk 10 ft. turn off hose, .259 " .562 return to press. 9. Tighten press. 2.422 " 5.590 Total Cycle Time 49.625 Performance Rating 120% Allowances 20% Total 140% Table 0-20. Dairy "0" Centrifugal Milk Pump Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Disassemble pump. .510 190% 0510 2. Walk 50 ft. get bucket of .589 .589 cleaning solution, return to pump. 5. Walk 20 ft. turn on water, .445 " .445 return with hose. 4. Rinse pump. .527 2 '55; 5. Wash milk inlet and outlet .612 .6 housing. 6. Wash back plate. .581 :: .32; 7. Wash impeller. .226 " ~562 8. Wash pump frame. ~55? n .461 9. Rinse pump. -45 u '472 10. Walk 20 ft. return hose, turn .472 . off water, return to pump. 11. Walk 25 ft. pick up gasket. re- .516 " "515 turn to pump. ,, 2 4 12. Assemble pump. 1°294 5:535 Total Cycle Time Performance Rating 287; Allowances % Total I007; -57- Appendix C Table 0-21. Dairy "0" High Temperature Short Time Pasteurizer Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes 1. Walk 10 ft. turn on water, .279 100% .279 return to pasteurizer with hose. 2. Place hose in surge tank and 5.560 " 5,350 circulate rinse pasteurizer. 5. Carry hose 15 ft. and place .205 " .205 in circulating cleaning tank. 4. Fill tank with water. 5.115 " 5.115 5. Walk 20 ft. return hose, turn .461 " .461 off water, return to pasteurizer. 6. Connect circulating system. 2.651 " 2.651 7. Walk 50 ft. pick up jar of .654 " .654 acid cleaning powder, re- turn to circulating unit. 8. Place powder in circulating 1.051 " 1.051 tank and mix solution. 9. Turn on circulating pump, .155 " .155 circulation time about 20 minutes. 10. Walk 20 ft. turn on water, .475 " .475 return to circulating tank with hose. " 11. Hold hose in tank until 5.561 5.561 solution runs clear. n 12. Walk 20 ft. return hose, turn .451 .451 off water, return to tank. n 15. Walk 20 ft. pick up jar of .612 ~51? alkali, return to circulat- i unit. 14. Flag? powder in circulating .984 " .984 unit and mix solution - circulating time - 20 minutes. 15. Walk 20 ft. turn on water, re- .485 " .485 turn to tank with hose. 16. Hold hose in tank until 4.056 " 4.056 solution runs clear. 17. Walk 20 ft. return hose; Itfllirn .496 " .496 off water, return to a . u 18. Disconnect circulating system. 2.564 " $.33: 19. Loosen press. 1.753 n 1 670 20. Pull back plates. 1-67 " 375,7 21. Remove and disassemble flow .757 ° diversion value. ..58- Appendix C Table 0-21. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Ratinnginutes 22. Walk 15 ft. get bucket of .541 100% .541 solution and return to pasteurizer. 25. Wash flow diversion valve. 2.970 " 2.970 24. Walk 20 ft. turn on water, .505 " .505 return with hose to press. 25. Wash one side of plate, pull 44.156 " 44.156 back plate, wash other side, rinse plate. Average time for 1 plate is .615 - total plates 72. 26. 'Wash press frame work. 2.460 " 2.460 27. Rinse frame work. 1.614 " 1.614 28. Walk 20 ft. return.hose, turn .465 " .465 off water, return to press. 29. Assemble and place flow 1.645 " 1.645 diversion valve. 50. Close press and tighten. 5.062 " 5.062 Total Cycle Time 88.764 Performance Rating 80% Allowances 20% Total 155% Table 0-22. Dairy "0" Preparing Buckets of Cleaning Solution Actual Aver- Allowed Element age Time in . Time in Number Element Description Minutes Ratlng Minutes 1. Walk 15 ft. get dipper of .561 100% .561 cleaning powder, return to hose. 2. Turn on hose and fill bucket. .476 3 .222 5. Place powder in bucket and .254 . mix. 1.071 Total Cycle Time Performance Rating 80% 4 Allowances 20% Total 100% -59.. Appendix C Table 0-25. Dairy "0" Sterilizing Equipment Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes 1. Walk 20 ft. turn on.water, .456 100% .456 return to short time pas- teurizer, place hose in surge tank. 2. Turn on circulating pump. .155 " .155 5. Walk to homogenizer and .721 " .721 turn on. 4. Circulate 170 degree water 7.105 " 7.105 through system and to bottle filler. 5. walk 20 ft. return hose, .448 " .448 turn off water. 6. Drain system. 2.105 " 2.105 Total Cycle Time 10.966 Performance Rating 80% Allowances 20% Total % Table 0-24. Dairy "0" Filling Small Wash Tank Actual Aver- Allowed Element age Time in . Time in Number Element Description Minutes Rating Minutgg 1. Walk 10 ft. turn on water, _ .275 100% .275 return with hose to tank. ' 2.051 " 2.051 2. F111 tank. .289 " .289 5. Walk 10 ft. return hose, turn off water, return to tank. 4. Walk 20 ft. get jar of wash .452 " .452 powder return to tank. 5. Place poWder in tank and mix. .524 " .524 Total Cycle Time 5.569 Performance Rating 80% Allowances 20; T0133]. 00/0 -60- Appendix C Table C ‘25 0 Dairy "0" Filling Large Wash Tank Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 1. Walk 15 ft. turn on water, re- .574 100% .574 turn with hose to wash tank. 2. Fill tank. 4.651 " 4.651 5. Walk 15 ft. return.hose, turn .581 " .581 off water, return to tank. 4. Walk 25 ft. get jar of wash .515 " .515 powder, return to tank. 5. Place powder in tank and mix .416 " .416 solution. Total Cycle Time 6.515 Performance Rating 80% Allowances 20% 100% Table 0-26. Dairy "0" 2" Valves Actual Aver- Allowed Element age Time in . Time in Number Element Description Minutes Rating Minutgg 1. Disassemble valve. .110 130% .165 2. Wash valve. .550 n .800 5. Assemble valve. .210 _;§$§ Total Cycle Time 1.275 Performance Rating 138% Allowances % Total 150% Table 0-27. Dairy "c" 1%" Valves Actual Aver- Allowed Time in age Time in Element . Number Element Description Minutes RatinaMinutes l. Disassemble valve. 02%: 190% :21: 2. Wash valve. ~501 ,, .501 5. Assemble valve. ° ————— .941 Total Cycle Time 80% 204 106% Performance Rating Allowances Total -51- Appendix C Table C-28. Dairy "C" Assembly and Disassembly of 2" Pipe at Short Time Pasteurizer Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes RatinggMinutes l. Loosen hex nut with wrench. .130 100% .130 2. Unscrew hex nut by hand. .197 " .197 3. Pick up pipe. .122 " .122 4. Place gasket. .107 " .107 5. Pick up mating pipe and place. .143 " .143 6. Screw hex nut by hand. .221 " .221 7. Tighten hex nut with wrench. .108 " .108 8. Carry sections of pipe to wash 6.370 " 6.370 tank - 30 trips - ft. walked 600. 9. Carry sections of pipe from 13.375 " 13.375 wash tank to pipe rack - 60 trips - ft. walked 1200. 10. Carry sections of pipe from 9.240 " 9.240 pipe rack to assembly position - 40 trips - ft. walked 800. 11. Walk 10 ft. turn on water, .278 " .278 return to pipe rack with 11039. H 12. Rinse pipe. 4.674 n 13. Walk 10 ft. return hose, turn .284 off water, return to rack. 14. Walk 80 ft. around assembly .706 to tighten and loosen hex nuts. 4.674 .284 " .706 Performance Rating 80% Allowances 20% Total 100% Table C-29. Dairy "C" Washing 2" Pipe and Fittings at Short Time Pasteurizer Actual Aver- giiowid ' e n Element age Time in ' Number Element Description Minutes Rating Minutes Pipe Lengths 6" to_2i c1 1. Pick up pipe and run brush .131 100p .131 through pipe. " .103 2. Wash outside of pipe. .103 Table C-29. -62... Appendix C (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Ratinnginutes Pipe Lengths 2' to 4' 1. Pick up pipe and run brush .191 100% .191 through pipe. 2. Mash outside of pipe. .213 " .213 Pipe Lengths 4' to 7' 1. Pick up pipe and run brush .271 " .271 through pipe. 2. Wash outside of pipe. .413 " .413 Pipe Lengths 7' to 10' 1. Pick up pipe and run brush .415 " .415 through pipe. ' n 2. Wash outside of pipe. .532 ' .532 3" Short Time Holding Tube 1. Disassemble tube. 4.401 3 4.401 2. Wash tube. 5.321 " 5.321 3. Assemble tube. 6.412 6.412 1. Pick up ell, run brush .174 " .174 through place on rack. 2. Pick up tee, run brush .179 " .179 Dairy "C" Wash through, place on rack. Performance Rating 80% Allowances. 20% Total 100% Element Number 1. 2. Element_Description 1%" Sanitary Pipe and Fittings - Table C “’30. Actual Aver- Allowed age Time in Time in Minutes Rating Minutes Pipe Lengths 6" to 2' Pick up pipe and run brush through pipe. Wash outside of pipe. .128 100% .128 .090 " .090 -53- Appendix C Table C-30. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes Pipe Lengths 2' to 4' 1. Pick up pipe and run brush .184 100% .184 through pipe. 2. Wash outside of pipe. .207 " .207 Pipe Lengths 4' to 7' 1. Pick up pipe and run.brush .256 " .256 through pipe. ' 2. Wash outside of pipe. .364 ' .364 Pipe Lengths 7' to 10' 1. Pick up pipe and run brush .389 " .389 through pipe. 2. Wash outside of pipe. .476 " .476 1. Pick up all, run brush .163 " .163 through, place on drain board. " 1 2. Pick up tee, run brush .158 .158 through, place on drain board. .' 083 3. Pick up cap, wash, place on .083 . Table C-Sl. drain'board. Performance Rating 80% Allowances 20% Total lIfiwé Pipe and Fittings Dairy "C" Assembly and Disassembly 1%" Sanitary Actual Aver- gilowid me n Element age Time 111. Number Element Description Minutes Rating_Minut98 d l. Loosen hex nut with wrench. °i§§ 190p 2&3: 2. Unscrew hex nut by hand. 0115 n .113 3. Pick up pipe. ‘102 n .102 4. Place gasket. '130 u .130 5. Pick up mating pipe and Place' '213 " .213 6. Screw hex nut by hand. ’102 u: .102 7. Tighten hex nut with wrench. - -64- Appendix C Table C-3l. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes 8. Carry sections of pipe to 6.102 100% 6.102 wash tank - 29 trips - total ft. walked 600. 9. Carry sections of pipe from 3.710 " 3.710 wash tank to pipe rack - 15 trips - total ft. walked 350. 10. Walk 15 ft. turn on.hose, re- .347 " .347 turn with hose to pipe rack. 11. Rinse pipe. 2.156 " 2.156 12. Walk 15 ft. return hose, turn .361 " .361 off water, return to pipe rack. 13. Carry sections of pipe from 3.261 " 3.261 pipe rack to assembly area - 25 trips - total ft. walked 300. 14. Walk 100 ft. around pipe to .864 " .864 tighten and loosen hex nuts. Performance Rating 80% Allowances 20% Total 150% Table C-32. Dairy "C" 2" Pipe Washed on Power Driven Brush Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating Minutes Pipe Lengths 6" to 2' 1. Pick up pipe from tank and .061 100% .061 move back into position. " 054 2. Run pipe over revolving brush. .054 n .121 3. Wash outside of pipe With .121 . sponge. 4. Pull pipe off brush and place .102 " .102 on pipe rack. Pipe Lengths 2' to_41 .073 " .073 1. Pick up pipe from tank and move back into position. 71 n .071 2. Run pipe over revolving brush. .0 -65- Appendix C Table C-32. (Continued) Actual Aver- Allowed Element age Time in Time in Number Element Description Minutes Rating_Minutes 5. wash outside of pipe with .552 100% .552 sponge. 4. Pull pipe off brush and place .113 " .113 on pipe rack. Pipe Lengths 4' to 7' 1. Pick up pipe from tank and .083 " .083 move back into position. 2. Run pipe over revolving brush. .102 " .102 3. Wash outside of pipe with .456 " .456 sponge. " " 4. Pull pipe off brush and place .136 .136 on pipe rack. Pipe Lengihs 7' to 10' 1. Pick up pipe from tank and .103 " .103 move back into position. " 2. Run pipe over revolving brush. .124 n .124 3. Wash outside of pipe with .553 .553 sponge. 4. Pull pipe off brush and place .172 " .172 on pipe rack. 1. Carry sections of pipe to 31.450 " 31.450 wash tank - 42 trips - total ft. walked 3000. 2. Carry sections of pipe to 27.310 " 27.310 assembly position - 36 trips - total ft. walked 2500. 3. Yalk 830 ft. around pipe tot 8.930 " 8.930 tighten and loosen hex nu s. 4. Valk 20 ft. turn on hose, re; .457 " .457 turn with hose to pipe rac . ,, 60 5. Rinse pipe. 4.15% n 4.463 6. Walk 20 ft. return hose, turn .46 -— off water, return to pipe rack. Performance Rating 80% / Allowances 20% Total 100% ‘3'?) A: \ ~‘.' ‘.J~ .. 1 b “ I; a ., Nu 3. k («g 9'53 [RE 1.. iBfiLRY LGAN "03054 Dec 9 511 09 :f y; :1“). J‘ F47 MMWBI 4 78 z. 3. 31.434 M’- ' ”'Cll’iifiififlflifl'lflllfilflfljflifilififlifllfllflms