Importance of Operation Analysis in IE Practice
Operation analysis was made the central focus of IE department in the article "Value Creation Model for Industrial Engineering - Productivity Engineering" by Narayana Rao (Principles, Functions and Focus Areas of Industrial Engineering).
The complete operation analysis and design of new SOP has to be completed in 5 days to facilitate study of 50 operations in year by the IE team. All IE techniques and methods are to be applied on the operation as well as on the full system required within these 5 days allotted to an operation.
Operation - Process Component Analysis - The First Step in Process Productivity Analysis and Productivity Engineering
The first step in the study of any process/job is to resolve it into its component parts or elements. The component parts a process are called operations. Shigeo Shingo clearly gives the difference between process and operation.
Process is the course by which material (input into the process) is transformed into product (output). Process has stages and each stage is termed as operation.
Operation: In each operation, some work is carried on the input of the process. The work is done by machines, devices and workers (operators).
Process Analysis - ECRS
Approach to Operation Analysis
The Questioning Attitude.
Can the design be changed to facilitate machining or assembly without affecting the quality of the product/component/apparatus?
Are the specified tolerances correct for the use to which the part is to be put? Is the material the most economical for the job?
Are the correct feeds and speeds being used?
Can the operator run more than one machine or perform another operation while the machine is making a cut?
Would a bench of special design be better than a standard bench?
Is the work area properly laid out?
Are tools designed so as to insure minimum manipulation time?
Can eccentric clamps or ejectors be used?
Can a fixture be used?
Are the position and height of the fixture correct?
Is the fixture the best available?
Is the fixture designed in accordance with the principles of motion economy?
Would a fixture holding more than one piece be better than one holding a single piece?
Can the same fixture be used for more than one operation?
Can a clamp, a vise, or a fixture be substituted for the human hand for holding?
Are semiautomatic tools such as ratchet or power-driven wrenches or screw drivers applicable?
Are raw materials properly placed?
Are there racks for pans of material and containers for smaller parts?
Can the parts be secured without searching and selecting?
Are the most frequently used parts placed in the most convenient location? Are the handling methods and equipment satisfactory?
Would a roller or a belt conveyor facilitate handling? Can the parts be placed aside by means of a chute?
If not, why not?
Is the operator comfortable?
Sitting down as much as possible?
Has the stool or chair being used a comfortable back and a seat that is wide enough? Is the lighting good?
Is the temperature of the work station right?
Are there no drafts? Are there arm-rests for the operator?
If the operation can be done either seated or standing, is the height of the chair such that the elbows of the operator are the same distance from the floor in either case?
If so, are the operations symmetrical?
Do the hands move simultaneously in opposite directions?
Can two pieces be handled at one time to better advantage than one?
Can a foot device be arranged so that an operation now performed by hand can be done by foot?
The steps of systematic operation analysis will be discussed in this online book in sufficient detail to give a thorough understanding.
(An Illustration: Operation Analysis of Grinding - Examples of Improvement Opportunities in Elements of Grinding)
Making Suggestions for Improvement.
An example of a good presentation of a labor-saving idea is as follows :
In view of the savings that can be made, the suggestion is recommended for acceptance by you
Steps in Operation Analysis
Source: Maynard's Operation Analysis
Full Online Book - Method Study: Methods Efficiency Engineering - Knol Book
Next Article on the Topic - Scope and Limitations of Methods Efficiency Engineering
Journal of Intelligent Manufacturing
October 2006, Volume 17, Issue 5, pp 571-583
Evaluation of techniques for manufacturing process analysis
J. C. Hernandez-Matias, A. Vizan, A. Hidalgo, J. Rios
Updated 7 March 2020, 12 July 2019, 17 February 2019, 30 July 2017, 28 June 2015
First posted 16 Feb 2014