Operation and Flow Process Charts - Origin, Evolution and Application

INDUSTRIAL ENGINEERING is redesign (engineering) of Products, Facilities and Processes for Productivity increase.
Productivity Management Imperative for USA - McKinsey. Returning US productivity to its long-term trend of 2.2 percent annual growth would add $10 trillion in cumulative GDP over the next ten years (2023 - 2030).

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. E-Book FREE Download. 

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0

Motion-study, time-study, micromotion-study, fatigue-study, and cost-study are important measures of scientific management, by which the efficiency of each function and subfunction is determined, tested, and checked. The unit to be chosen for intensive study is determined by the amount of time and money that it is possible to save by the investigation. This unit is determined by the following method. The work selected is divided into natural subdivisions or cycles of performance. Each cycle is then subjected to motion study, to determine the best method to use in performing the work. This method is divided into the smallest practicable units. These units are timed. The timed units are then again subjected to motion study, for more intensive study of method. Subdivided motions result. These are again timed, and so the process proceeds until the further possible saving will no longer warrant further study, or the available appropriation of time or money is exhausted. The most efficient motions, as determined by the tests of motion-study and time-study are then synthesised into a method of least waste. 

As for the particular device by which the measurements are made, the choice depends mainly on the equipment available. Standards have been improved without using timing devices. Excellent work had been done with stop watches. But we advocate the use of micromotion-study in all work demanding precision. Micromotion study consists of recording the speed simultaneously with a two or three dimensional path of motions by the aid of cinematograph pictures of a worker at work and a specially designed clock that shows divisions of time so minute as to indicate a different time of day in each picture in the cinematograph film. Through micromotion-study not only is the measurement more accurate than it could possibly be through any other method, but also the records are so complete, permanent, and accessible that they may be studied at any time and place by any one. 

https://nraoiekc.blogspot.com/2021/10/the-practice-of-motion-study-gilbreth.html

The micro-motion method of making motion studies consists of recording motions by means of a motion picture camera, a clock that will record different times of day in each picture of a motion picture film, a cross-sectioned background, and other devices for assisting in measuring the relative efficiency and wastefulness of motions. These micro-motion records give all the data required except the continuous path of a cycle of motions. This lack is supplied by the chronocyclegraph method. The chronocyclegraph method of making motion study consists of fastening tiny electric-light bulbs to the fingers of the operator, or to any part of the operator or of the material whose motion path it is desired to study. If it is merely the orbit of the motion that is to be observed, a photograph is made of the moving part to which the light is attached, during the time that this part is performing the operation. 

If the direction, relative time, and relative speed are to be noted, the path of light, through controlled interruption of the circuit, is made to consist of dots or dashes, or a combination of the two, with single pointed ends, the point showing the direction. Through the micro-motion studies and the chronocyclegraph studies, then, the expert formulates the standard method. It is important to note the changes which the installation of a standard method implies. This method consists of improved motions, and implies, first, changes in surroundings, equipment, and tools; and, second, changes in the type of worker assigned to do the work. 

https://nraoiekc.blogspot.com/2021/10/part-2-practice-of-motion-study-gilbreth.html

MOTION STUDY AND TIME STUDY INSTRUMENTS OF PRECISION 

(Presented by Gilbreth at the International Engineering Congress. )

Both accurate time study and motion study require instruments of precision that will record mechanically, with the least possible interference from the human element, in permanent form, exactly what motions and results occur. For permanent use the records must be so definite, distinct, and simple that they may be easily and immediately used, and lose none of their value or helpfulness when old, forgotten, or not personally experienced by their user. 

It was not, however, until Dr. Taylor suggested timing the work periods separately from the rest periods that the managers tried to find accurate time-measuring devices. 

Being unable to find any devices anywhere such as the work of our motion study required, the problem that presented itself, then, to us who needed and desired instruments of precision, applicable to our motion study and to our time study, was to invent, design and construct devices that would overcome lacks in the early and existing methods. It was necessary to dispense with the human element and its attending errors and limitations. We needed devices to record the direction as well as the path or orbits of motions, and to reduce the cost of obtaining all time study and motion study data. These were needed not only from the scientific standpoint, but also from the standpoint of obtaining full co-operation of the mechanics and other workers. 

Through our earliest work in making progress records we recognised the necessity of recording time and conditions accurately and simultaneously, the records being made by dated photographs.

Fortunately, we are now able to use the motion picture camera with our speed clock, and other accessories, as a device for recording elements of motion and their corresponding times, simultaneously. Our latest microchronometer records intervals of time down to any degree of accuracy required. We have made, and used, in our work of motion study investigations of hospital practice and surgery, one that records times to the millionth of an hour. This is designed for extremely accurate work, but can be adjusted to intervals of any length desired, as proves most economical or desirable for the type of work to be investigated. 

https://nraoiekc.blogspot.com/2021/10/part-3-practice-of-motion-study-gilbreth.html

All the above devices and tools for recording motions and times were developed by Gilbreth before 1921.

Process Chart Method  - Gilbreths - 1921

Gilbreths presented their proposal or system of process charting in 1921 (Annual meeting ASME 5 to 9 December 1921 at New York). They did not use the terms operation flow chart and flow process chart.

Process Charts for Recording and Visualizing Processes in Industrial Engineering.

Process charts are the recording devices used by industrial engineers. 

Gilbreth used process charts and described them for wider audience in 1921. 

In the original description, Gilbreth described the process charts used in connection with motion study or human effort study. Later the scope of the process charts was extended and the contents of the chart were standardized by ASME.  Operation analysis sheet was used  by Maynard and Stegemerten in the process chart framework to do machine work study. 

In the process chart, five operations are depicted. They are: Operation (material processing) - Inspection - Material transport - Temporary Storage of the Material (Delay without any operation being done) - Permanent or controlled storage of the material.

Each operation has a cost and industrial engineer has to increase the productivity of each operation or step to reduce cost.

In each operations, machines, men and other facilities work to bring the desired result. The work of machines, men, robots, furnaces etc. are to be observed, studies and recorded. To study work of operators, Motion study of both hands and micromotion studies of both hands were developed by   by Gilbreths.  The process chart that shows the series of operations is further supported charts related to each operation that record activity of each machine and man working in that operation. To do detailed investigation based on process chart, more recording formats need to be used. There is a need for machine work study and operator work study in each of the five steps shown in the flow process chart. Recording devices are to be used machine and operator work studies in each step.  Value Adding Operation, Inspection, Transport, Temporary Delay and Permanent Delay. Frank Gilbreth is given credit for the development of process chart system in industrial engineering to study and improve processes.

Process Charting for Improvement - Gilbreths' View

Frank Gilbreth developed process analysis and improvement also along with motion study. In 1921, he presented a paper in ASME, on process charts. Lilian Gilbreth was a coauthor of this paper.

PROCESS CHARTS: FIRST STEPS IN FINDING THE ONE BEST WAY TO DO WORK
By Frank B. Gilbreth, Montclair, N. J. Member of the Society
and L. M. Gilbreth, Montclair, N. J. Non-Member
For presentation at the Annual Meeting, New York, December 5 to 9, 1921,
of The American Society of Mechanical Engineers, 29 West 39th Street, New York.
https://ia800700.us.archive.org/5/items/processcharts00gilb/processcharts00gilb_bw.pdf

THE Process Chart is a device for visualizing a process as a means of improving it. Every detail of a process is more or less affected by every other detail; therefore the entire process must be presented in such form that it can be visualized all at once before any changes are made in any of its subdivisions. In any subdivision of the process under examination, any changes made without due consideration of all the decisions and all the motions that precede and follow that subdivision will often be found unsuited to the ultimate plan of operation.

The use of this process-chart procedure permits recording the existing and proposed methods and changes without the slightest fear of disturbing or disrupting the actual work itself.

The aim of the process chart is to present information regarding existing and proposed processes in such simple form that such information can become available to and usable by the greatest possible number of people in an organization before any changes whatever are actually made, so that the special knowledge and suggestions of those in positions of minor importance can be fully utilized.

Further detailed studies based on process chart

If any operation of the process shown in the process chart is one that will sufficiently affect similar work, then motion study (human effort study) should be made of each part of the process, and the degree to which the motion study should be carried depends upon the opportunities existing therein for savings.

If the operations are highly repetitive or consist of parts or subdivisions that can be transferred to the study of many other operations, then micromotion studies already made can be referred to; also new and further micromotion studies may be warranted in order that the details of method with the exact times of each of the individual subdivisions of the cycle of motions, or ''therbligs," as they are called, that compose the one best way known, may be recorded for constant and cumulative improvement.

These synthesized records of details of processes (motion studies and micromotion studies) in turn may be further combined and large units of standard practice become available for the synthesis of complete operations in process charts.

Similarly we have to add that if an operation is done or repeated multiple times, machine effort study or machine work study needs to be done and work of the machine has to be recorded using a format used in process planning of the machine.

At the end of the paper, the conclusion made by Gilbreths is as follows:

The procedure for making, examining and improving a process is, therefore, preferably as follows:

a.  Examine process and record with rough notes,  the existing process in detail.

b. Have draftsman copy rough notes in form for blueprinting, stereoscopic diapositives, photographic projection and exhibition to executives and others.

c. Show the diapositives with stereoscope and lantern slides of process charts in executives' theater to executives and workers.

d. Improve present methods by the use of —
1 Suggestion system

2 Motion study
3 Micromotion studies and chronocyclegraphs for obtaining and recording the One Best Way to do Work.
4 Written description of new methods or 'write-ups," "manuals," ''codes," ''written systems," as they are variously called
5 Standards
6 Standing orders

e. Make process chart of the process as finally adopted as a base for still further and cumulative improvement.

We have to add now machine work study to the list of activities of examining process charts for process industrial engineering (We will discuss each step or operation of the process chart in forthcoming lessons in detail)

We see in the method described above the method study steps of record, and examine. The practice of involving the workers in analyzing the process chart which was later popularized by Alan Mogensen is also present in the method suggested by Gilbreth to improve a process.  Motion study as a later step in the process analysis method, which was emphasized by H.B. Maynard as part of the operation analysis proposed by him is also visible in the procedure described by Gilbreths.

H.B. Maynard proposed "Operation Analysis" for process improvement.

So, we can see the methods engineering and methods study which became popular subsequently were further development of Gilbreth's process improvement procedure only.

ASME used the terms flow process chart and operation process charts.



A.S.M.E. standard operation and flow process charts, developed by the A.S.M.E. Special committee on standardization of therbligs, process charts, and their symbols, 1947.
Corporate Author: American Society of Mechanical Engineers.
Published: New York, N.Y., The American society of mechanical engineers [1947]
Physical Description: 21 p. incl. forms, diagrs. 26 1/2cm.
https://babel.hathitrust.org/cgi/pt?id=mdp.39015039876274;view=1up;seq=9

ASME Operation Process Chart

An operation process chart is a graphic representation of the points at which materials are introduced into the process, and of the sequence of inspections and all operations except those involved in material handing.  It may include any other information considered desirable for analysis, such as time required and location.  (point 13 of the report)


A recent example

Leaf spring - parabolic spring manufacturing process
http://www.bineetauto.com/images/flow.jpg


Niebel discussed the analysis of operation process chart as well as operation analysis in detail his book "Motion and Time Study."

https://babel.hathitrust.org/cgi/pt?id=wu.89038754164&view=1up&seq=9

Barnes

In text books, Barnes did not mention the term operation process chart in his Motion and Time Study Book.

ILO

ILO Work Study, used the term outline process chart.

They describe its utility:

In an outline process chart, only the principal operations carried out and the inspection made to ensure their effectiveness are recorded, irrespective of who does them and where they are performed.

The outline process chart is intended to provide a first "bird's-eye" view of the activities involved, for the purpose of eliminating unnecessary ones or combining those that could be done together.


Book -  Fundamentals of Work Measurement: What Every Engineer Should Know
Anil Mital, Anoop Desai, Aashi Mital
https://books.google.co.in/books?id=uW4NDgAAQBAJ


Poor choice of manufacturing process can add to the work content.
p.3 of  Fundamentals of Work Measurement: What Every Engineer Should Know
Anil Mital, Anoop Desai, Aashi Mital
CRC Press, 03-Oct-2016 - Technology & Engineering - 210 pages


I agree with Mital et al. and propose that operation process chart analysis has to evaluate each manufacturing process.



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Number of Pages 242
Author  Frazelle, Edward H., Ph.d.
Publisher  McGraw-Hill
Publication Date January, 1970
ISBN-13  9780071376006
ISBN-10  0071376003



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I now feel production planning and control is a component of process chart analysis as far as process improvement is concerned. Industrial engineers have to improve production planning routines as part of process chart analysis. Such an emphasis is not there in IE curriculum, as process chart is method is taught in work study or time and motion study courses.

Updated 27.6.2022,  1 Nov 2021, 16 August 2020,  28 June 2019,  5 Feb 2019
Published 1 July 2017