H.B. Maynard - Ralph Barnes - Gerald Nadler - MACHINE EFFORT INDUSTRIAL ENGINEERING - Operation Analysis - Machine Work Study

Lesson 33 of Industrial Engineering ONLINE Course 

IE Case Study  33 Operation Analysis and Improvement: Application of Tribos Toolholder for Productivity Improvement

H.B. Maynard - A Great Industrial Engineer Who Built a Popular Consultancy Organization in Industrial Engineering

MAYNARD's MACHINE EFFORT INDUSTRIAL ENGINEERING

MAYNARD's HUMAN EFFORT INDUSTRIAL ENGINEERING

H.B. Maynard did a lot of development work and contributed to further development of industrial engineering. His handbooks are well known to all industrial engineers.  Maynard contributed significantly to both machine effort industrial engineering and human effort industrial engineering.

Operation Analysis (McGraw-Hill book Company, Incorporated, 1939 ) authored by Harold Bright Maynard, Gustave James Stegemerten, provides the description of machine effort industrial engineering proposed by Maynard.

We introduce operation analysis in this essay and will discuss it in more detail in process industrial engineering module.

Ralph M. Barnes has given the following steps as the problem solving methodology for developing the preferred method or the best method or the most productive method.

A. Eliminate all unnecessary work

B. Combine Operations or elements

C. Change the Sequence of Operations

D. Simplify the Necessary Operations.  

Description of Process Analysis by Barnes

The process chart is a device for recording a process in a compact manner. The process chart assists in showing the effects that changes in one part of the process will have on other parts or elements. Moreover, the chart may aid in discovering particular operations in the process which should be subjected to more careful analysis.

Note carefully, the terms "operations" and "elements." We have to say a part is produced through a process. The process has operations. Within each operation there are elements. Process improvement involves improvement of elements, improvement of operations and certain improvements in the process, which are elimination of operations, change in sequence of operations and combining or splitting of operations.

First three steps are part of process analysis. Fourth step studies the operation, which is a component of processes. Barnes discussed "operation analysis" in a separate chapter. Completing the first three steps gives the operations which are considered necessary. Now it is time to investigate specific operations to improve them (Operation Analysis). 

Barnes - Operation Analysis

One approach to the problem of finding a better of doing the work is to subject the operation to specific and detailed questions. In operation analysis, materials, machine tools, cutting tools, jigs, fixtures, material handling equipment, working conditions, motions of the operators, and other factors affecting the job are to be analyzed. Finding the best way is not always easy, and in addition to updated knowledge about all the factors and resources, considerable imagination, ingenuity, and inventive ability are required. There industrial engineers have to involve and seek the cooperation of such persons as the supervisor, shop engineer, the tool designers and the operator (the same was recommended by Gilbreth in his 1921 paper on process charts). Motion study is a step in operation analysis to study activities of operators in each operation. 

Gerald Nadler also discussed operation analysis in his book on Motion Study.

H.B. Maynard - Operation Analysis Book

Maynard and Stegemerten authored a full book on "Operation Analysis" and discussed each factor in more detail. To study the operation, process chart is to be supplemented by more information regarding each operation.  Gilbreth, himself wrote in his 1921 article that process chart is only for visualizing the complete process in a simplified view. For study of each operation, different recording means are to be employed.  Maynard proposed operation analysis sheet for this purpose.

Nine Points of Primary Analysis. 

There are nine main points or factors that should be considered in every operation analyzed.

These are as follows :

1. Purpose of operation.

2. Complete survey of all operations performed on part.

3. Inspection requirements.

4. Material.

5. Material handling.

6. Setup and tool equipment.

7. Common possibilities for job improvement.

8. Working conditions.

9. Method.

The Operation Analysis Sheet

Operation Analysis procedure was first used in Westinghouse where Maynard worked. Subsequently, the "operation analysis sheet" has been designed by the Methods Engineering Council which was established by Maynard. In the operation analysis sheet, the data related to items examined during the analysis are recorded. In the sheet, the data related to machine effort and human effort are separately recorded.

At the top of the sheet, the operation details for identifying completely the analysis, the part, and the operation have to be recorded.


Item 1.  The purpose of the operation and reason why it is essential.

Item 2. The operation - inspection chart of the part.  The purpose of this is to determine just how the operation being analyzed fits in with the other operations that are performed on the part.  It provides a ready reference all the time to consider all operations in the process

The flow process chart,  also attached would indicate transportation and delays involved.

Item. 3. The inspection, finish and tolerance requirements of the job.  The design of the part is analyzed in this item

Knowledge Base for Process Productivity Improvement - News - Information for Inspection Operation Analysis

Item 4. The material of which the part being studied.

Item 5. Equipment, Tools, Workholding, Setup, Work Place Layout

The equipment and tools used on any operation is the most important item of operation analysis and it is worthy of careful study. Jigs, fixtures, and other work holding devices have an effect on productivity.  "Setup" is the the workplace layout, the adjusted machine tool, or the elemental operations performed to get ready to do the job and to tear down after the job has been done. More exactly, the arrangement of  the material, tools, and supplies that is made preparatory to doing the job may be referred to as the " work-place layout." Any tools, jigs, and fixtures located in a definite position for the purpose of doing a job may be referred to as "being set up'  or as "the setup." The operations that precede and follow the performing of the repetitive elements of the job during which the workplace layout or setup is first made and subsequently cleared away may be called " make-ready" and "put-away" operations. Energy- or effort-wasting layouts are encountered frequently where methods studies have not been made and it is important to emphasize the importance of and the necessity for systematic operation Analysis.

(This analysis of Equipment, Tools, Workholding, Setup, Work Place Layout is to be termed Machine Work Study and has to be made with special focus on the technology of the machine)

Knowledge Base for Process Productivity Improvement - News - Information for Value-Adding Material Processing Operation Analysis

Machine Work Study - Areas of Study and Improvement
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Narayana Rao, 20 Sep 2018

Item 6. Material handling. The current or proposed method is to be recorded first. Then the  application of conveyers, cranes, trucks, and other mechanical handling devices and manual handling alternatives needs to be analyzed.

Knowledge Base for Process Productivity Improvement - News - Information for Material Handling and Transport Operation Analysis

Item 7. Analysis of the use of 10  frequently used productivity devices and solutions.

1. Install gravity delivery chutes.

2. Use drop delivery.

3. Compare methods if more than one operator is working on same job.

4. Provide correct chair for operator.

5. Improve jigs or fixtures by providing ejectors, quick-acting clamps, etc.

6. Use foot-operated mechanisms.

7. Arrange for two-handed operation.

8. Arrange tools or parts within normal working area.

9. Change layout to eliminate backtracking and to permit coupling of machines.

10. Utilize all improvements developed for other jobs.

These improvements are comparatively easy to make. If the analysis  is systematically done,  the possibility of applying them can be recognized.

Item 8. Working conditions have an important influence on production.  Conditions that are unhealthy, uncomfortable, or hazardous breed dissatisfaction. Besides lowering production, they increase labor turnover and accidents and often lead to labor unrest.

Item 9. The analysis of the operator method followed in performing the operation is the part of the study dealing with human effort in the production system or engineering activity system.

Item 10. The new method. The method that is established after machine work study and operator work study is attached to this analysis sheet to provide a complete record of the job, although, strictly speaking, this information does not belong under the head of analysis.

Usually the analysis of the operation requires the drawing of one or more types of additional process charts, and often a number of computations are involved. This information should be attached to the analysis in the form of a supplementary reports and identified in various items through references.

Operation analysis sheet proposed by Maynard and Stegemerten is mainly focused on "operation" or value adding operation of the process chart. For other operations in the process like inspection, transportation, temporary delay and permanent also require separate records and analysis procedures.

Based on the data or information recorded in the operation analysis the following questions, separate for various factors are to be asked and answered to get ideas for improvement of the operation.

Questions on Machine, Equipment and  Tools

The tools  and equipment used to perform the operation needs to analysed logically. The following questions are the sort that will lead to suggested improvements:

1. Is the machine tool best suited to the performance of the operation of all tools available? (Alternative machines, new machines)

2. Would the purchase of a better machine be justified?

3. Can the work be held in the machine by other means to better advantage? (Alternative fixtures)

4. Should a vise be used?

5. Should a jig be used?

6. Should clamps be used?

7. Is the jig design good from a motion-economy standpoint?

8. Can the part be inserted and removed quickly from the jig?

9. Would quick-acting cam-actuated tightening mechanisms be desirable on vise, jig, or clamps?

10. Can ejectors for automatically removing part when vise or jig is opened be installed?

11. Is chuck of best type for the purpose? (Alternatives)

12. Would special jaws be better? (Alternatives for jaws)

13. Should a multiple fixture be provided?  (To reduce setup time)

14. Should duplicate holding means be provided so that one may be loaded while machine is making a cut on a part held in the other?

15. Are the cutters proper?  (Alternative cutting tools)

16. Should high-seed steel or cemented carbide be used? (Now there are more alternatives)

17. Are tools properly ground? (Geometry of cutting tool - Taylor's experiments)

18. Is the necessary accuracy readily obtainable with tool and fixture equipment available?

10. Are hand tools pre-positioned ?

20. Are hand tools best suited to purpose? (Alternatives)

21. Will ratchet, spiral, or power-driven tools save time?

22. Are all operators provided with the same tools?

23. Can a special tool be made to improve the operation?

24. If accurate work is necessary, are proper gages or other measuring instruments provided? (Alternative inspection devices - Inspection operation of operation-inspection chart)

25. Are gages or other measuring instruments checked for accuracy from time to time?

Questions which will lead to suggestions for improvement of "Make-ready" and "Put-away" Elements  are:

1. How is the job assigned to the operator (job card or ticket issue to operator)?
2. Is the procedure such that the operator is ever without a job to do (delays in giving job ticket)?
3. How are instructions imparted to the operator? (Instruction card)
4. How is material secured?
5. How are drawings and tools secured?
6. How are the times at which the job is started and finished checked?
7. What possibilities for delays occur at drawing room, toolroom, storeroom, or time clerk's office? (Analysis of delays in flow process chart)
8. If operator makes his own setup, would economies be gained by providing special setup men?
9. Could a supply boy get tools, drawings, and material?
10. Is the layout of the operator locker or tool drawer orderly so that no time is lost searching for tools or equipment? (Work place orderliness - 5S)
11. Are the tools that the operator uses in making his setup adequate?
12. Is the machine set up properly?  (Is inspection necessary/)
13. Is the machine adjusted for proper feeds and speeds?  (Instruction card - machine adjustment)
14. Is machine in repair, and are belts tight and not slipping?
15. If vises, jigs, or fixtures are used, are they securely clamped to the machine?
16. Is the order in which the elements of the operation are performed correct?
17. Does the workplace layout conform to the principles that govern effective workplace layouts?
18. Is material properly positioned?
19. Are tools prepositioned?
20. Are the first few pieces produced checked for correctness by anyone other than the operator?
21. What must be done to complete operation and put away all equipment used?
22. Can trip to return tools to toolroom be combined with trip to get tools for next job?
23. How thoroughly should workplace be cleaned?
24. What disposal is made of scrap, short ends, or defective parts?
25. If operation is performed continuously, are preliminary operations of a preparatory nature necessary the first thing in the morning?
26. Are adjustments to equipment on a continuous operation made by the operator? (Total productive maintenance - Maynard)
27. How is material supply replenished?
28. If a number of miscellaneous jobs are done, can similar jobs be grouped to eliminate certain setup elements? (Sequencing issue)
29. How are partial setups handled?
30. Is the operator responsible for protecting workplace overnight by covering it or locking up valuable material?  (Responsibility of operator to take care of work pieces and equipment)


Related Case Studies

As part of  Industrial Engineering ONLINE Course, every one of the issues raised by Maynard and additional issues related to machine work study, operator work study, operation process chart and flow process chart will be discussed and case studies will be provided.

1. Process Industrial Engineering - Illustration - Investment in Sliding-Head Lathe with Chipbreaking Feature
2. Process Industrial Engineering - Illustration - Process Improvement via Toolholder Change
3. Process Industrial Engineering - Illustration -Alternative Lubricants and Productivity - Case Study
4. Case Study - Method Study - Welding Fixture Redesign - Productivity Improvement 2002
5. Industrial Engineering Exercise: Productivity Analysis of a Newly Introduced Machine
6. Prime Turning (TM) - New Turning Process with High Productivity
RE-INVENTING TURNING FOR THE FUTURE FACTORY, TODAY
SANDVIK COROMANT TECHNICAL PAPER, 2018
https://nraoiekc.blogspot.com/2020/06/sandvik-coromant-cutting-tools.html

Case studies are being provided everyday with the lessons of the course.
Industrial Engineering Case Studies

Questions for Productivity Analysis of Material:

1. Does the material specified appear suitable for the purpose for which it is to be used?

2. Could a less expensive material be substituted that would function as well?

3. Could a lighter gage material be used?

4. Is the material furnished in suitable condition for use?

5. Could the supplier perform additional work upon the material that would make it better suited for its use?

6. Is the size of the material the most economical?

7. If bar stock or tubing, is the material straight?

8. If a casting or forging, is the excess stock sufficient for machining purposes but not excessive?

9. Can the machinability of the material be improved by heat-treatment or in other ways?

10. Do castings have hard spots or burned-in core sand that should be eliminated?

11. Are castings properly cleaned and have all fins, gate ends, and riser bases been removed?

12. Is material sufficiently clean and free from rust?

13. If coated with a preserving compound, how does this compound affect dies?

14. Is material ordered in amounts and sizes that permit its utilization with a minimum amount of waste, scrap, or short ends?

15. Is material uniform and reasonably free from flaws and defects?

16. Is material utilized to the best advantage during processing?

17. Where yield from a given amount of material depends upon ability of the operator, is any record of yield kept?

18. Is miscellaneous material used for assembly, such as nails, screws, wire, solder, rivets, paste, and washers, suitable?

19. Are the indirect or supply materials such as cutting oil, molding sand, or lubricants best suited to the job?

20. Are materials used in connection with the process, such as gas, fuel oil, coal, coke, compressed air, water, electricity, acids, and paints, suitable, and is their use con- trolled and economical?

Questions Analysis of Tolerances and Finishes

1. What are the inspection requirements of this operation?

2. What are the requirements of the preceding operation?

3. What are the requirements of the following operation?

4. Will changing the requirements of a previous operation make this operation easier to perform?

5. Will changing the requirement of this operation make a subsequent operation easier to perform?

6. Are tolerance, allowance, finish, and other requirements necessary?

7. Are they suitable for the purpose the part has to play in the finished product ?

8. Can the requirements be raised to improve quality without increasing cost?

9. Will lowering the requirements materially reduce costs?

10. Can the quality of the finished product be improved in any way even beyond present requirements?

Observe the relation between succeeding operations is being evaluated in this case also.

In value engineering analysis techniques, Miles has indicated that giving a cost estimate for each tolerance will bring out excess cost created by tolerances.

This article is an initial note to bring out the important contribution made to industrial engineering and methods productivity engineering by Maynard. The details will be covered in "Process Industrial Engineering Module" of the course.

MTM - Global Standard for Work Systems Design
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https://www.youtube.com/watch?v=p8aAx-5XnRA
6 June 2015
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An interesting operation analysis question in current times in machine operation analysis?

Can we use a robot for productivity improvement in the operation?
Robots in Automotive Assembly - Use Case Collection
https://nraoiekc.blogspot.com/2020/06/robots-in-automotive-assembly.html

Ud. 3.7.2023, 3.7.2022

Pub. 2.7.2021