Gilbreth - ASME Process Chart Activities
PROCESSING - INSPECTION - TRANSPORT - TEMPORARY DELAYS - STORAGE
The process chart based industrial engineering, that is industrial systems improvement starts with preparing the process chart. In a discrete manufacturing factory, manufacturing of each part is a process. The process starts with issuing the material from the raw material stores, moving it to the specified shop, keeping it in the shop inventory till it is loaded on a machine, inspecting it during processing or when processing is stopped. After the part is made, it is moved to the parts inspection station. It is inspected and sent to parts stores. There are transport activities between machine to machine.
Industrial systems engineering, that is design of the process also can use the same activities and develop processing, inspection, transport and storage elements. When we look at the steps in process chart today, we may think of including information activity also. It is based on a dispatching instruction, that activities are initiated. Also, there is provision of drawings, instruction sheets and oral communication from planners as well as shop supervisors. It is necessary to include information activities in the process chart.
Process chart based industrial engineering looks at the sequencing of various activities and examines the possibilities of rearranging them to increase productivity or to achieve good change. Once that exercise is done, the attention shifts to improving each activity or operation. The cost of each activity has to be reduced as part of industrial engineering study of the process. Hence industrial engineers need to be educated in each of the activities or operations and continuing education has to be there.
Operation improvement requires engineering and technology knowledge related to that operation.
Prof. Mikell Groover, Professor of Industrial Engineering, Lehigh University covered the technical details of each operation included in the process chart in more detail in his book, Automation, Production Systems, and Computer-Integrated Manufacturing, 5th edition.
Picture Source: https://engineering.lehigh.edu/ise/faculty/joint-emeriti-faculty
Professor Groover's book is a must reading for industrial engineers. It has to be further deepened by full books on manufacturing processes (authored by Groover himself), Inspection/metrology, mechanical handling and warehousing. The literature related to lean is the recommended reading for eliminating temporary delays.
Relevant Chapters from Automation, Production Systems, and Computer-Integrated Manufacturing, 5th edition.
Source: https://www.pearson.com/store/p/automation-production-systems-and-computer-integrated-manufacturing/P100000251090/9780134605463?tab=table-of-contents
Processing - Manufacturing
PART IV MANUFACTURING SYSTEMS
Chapter 13 OVERVIEW OF MANUFACTURING SYSTEMS
13.1 Components of a Manufacturing System
13.2 Types of Manufacturing Systems
Chapter 14 SINGLE-STATION MANUFACTURING CELLS
14.1 Single-Station Manned Cells
14.2 Single-Station Automated Cells
14.3 Applications of Single-Station Cells
14.4 Analysis of Single-Station Cells
Chapter 15 MULTI-STATION MANUFACTURING SYSTEMS: MANUAL ASSEMBLY LINES
15.1 Fundamentals of Manual Assembly Lines
15.2 Analysis of Single-Model Assembly Lines
15.3 Line Balancing Algorithms
15.4 Workstation Details
15.5 Other Considerations in Assembly Line Design
15.6 Alternative Assembly Systems
Appendix 15A Batch-Model and Mixed-Model Lines
Chapter 16 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED PRODUCTION LINES
16.1 Fundamentals of Automated Production Lines
16.2 Applications of Automated Production Lines
16.3 Analysis of Transfer Lines
Appendix 16A Transfer Lines with Internal Storage
Chapter 17 AUTOMATED ASSEMBLY SYSTEMS
17.1 Fundamentals of Automated Assembly Systems
17.2 Analysis of Automated Assembly Systems
Chapter 18 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING
18.1 Part Families and Machine Groups
18.2 Cellular Manufacturing
18.3 Applications of Group Technology
18.4 Analysis of Cellular Manufacturing
Appendix 18A Opitz Parts Classification and Coding System
Chapter 19 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED FOR FLEXIBILITY
19.1 Manufacturing Flexibility Defined
19.2 Components of an FM
19.3 Analysis of Flexible Manufacturing Systems
19.4 Alternative Approaches to Flexible Manufacturing
Inspection
Chapter 21 INSPECTION PRINCIPLES AND PRACTICES
21.1 Inspection Fundamentals
21.2 Sampling versus 100% Inspection
21.3 Automated Inspection
21.4 When and Where to Inspect
21.5 Analysis of Inspection Systems
Chapter 22 INSPECTION TECHNOLOGIES
22.1 Inspection Metrology
22.2 Conventional Measuring and Gaging Techniques
22.3 Coordinate Measuring Machines
22.4 Surface Measurement
22.5 Machine Vision
22.6 Other Optical Inspection Methods
22.7 Noncontact Nonoptical Inspection Techniques
Appendix 22A Geometric Feature Construction
For More Detailed Reading
BOSCH.A., Editor, Coordinate Measuring Machines and Systems, Marcel Dekker, Inc., New York, 1995.
BROWN & SHARPE, Handbook of Metrology, North Kingston, Rhode Island. 1992.
Transport
Chapter 10 MATERIAL TRANSPORT SYSTEMS
10.1 Overview of Material Handling
10.2 Material Transport Equipment
10.3 Analysis of Material Transport Systems
KULWIEC, R. A., Editor, Material Handling Handbook, 2nd Edition, John Wiley & Sons, Inc., NewYork,1985
MULCAHY, D. E., Materials Handling Handbook, McGraw-Hili, New York. 1999
TOMPKINS, J. A., J. A. WHITE. Y. A. BOZER, E. H. FRAZELLE, J. M. TANCHOCO, and J. Travino, Faciliiies Planning, Second Edition,John Wiley & Sons. Inc., New York, 1996.
Permanent Storage or Storage/Warehousing
Chapter 11 STORAGE SYSTEMS
11.1 Overview to Storage Systems
11.2 Conventional Storage Methods and Equipment
11.3 Automated Storage Systems
11.4 Analysis of Storage Systems
Chapter 12 AUTOMATIC IDENTIFICATION AND DATA CAPTURE
12.1 Overview of Automatic Identification Methods
12.2 Bar Code Technology
Material Handling Institute, AS/RS In the Automated Factory, Pittsburgh, Pennsylvania, 1983
Material Handling Institute, Consideration for Planning and installing an Automated Storage/Retrieval System, Pittsburgh, Pennsylvania, 1977
Temporary Delays - Analysis
Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION
26.1 Lean Production and Waste in Manufacturing
26.2 Just-in-Time Production Systems
26.3 Autonomation
26.4 Worker Involvement
Knowledge Management
New engineering and technical developments in each operation are to be monitored, acquired and properly filed and indexed by the industrial engineering department. Digital databases can be created or acquired. Each new technical development must be assessed for its utility in the processes of the organization and remarks are to be written against each new technical development.
Suggestions of various persons in the organization regarding new or existing technologies are also to be recorded as part of the knowledge base.
Information regarding utilization of the new technology also has to be acquired and filed.
Industrial engineering department must invite all technology related vendor to come and make presentations to them.
Knowledge Management Tools
https://www.apo-tokyo.org/publications/ebooks/knowledge-management-tools-and-techniques-manual/
More detailed articles on the chapters of Prof. Groover's book will be posted in due course.
Knowledge Base for Process Productivity Improvement - News - Information for
Process Industrial Engineering - Course Lessons
Introduction to Process Industrial Engineering Module
News - Information for Value-Adding Operation Analysis
Flow Process Chart - Value-Adding Operation - Inspection - Transport - Temporary Delay - Storage - Information
45
IE Research by Taylor Part 1 - Productivity of Machining
News - Information for Inspection Operation Analysis
46
Part 2 - IE Research by Taylor - Productivity of Machining
News - Information for Material Handling and Transport Operation Analysis
47
Part 3 - IE Research by Taylor - Productivity of Machining.
News - Information for Analysis of Delays in Processes
48
Part 4 - IE Research by Taylor - Productivity of Machining
https://nraoiekc.blogspot.com/2020/07/part-4-ie-research-by-taylor.html
News - Information for Storage/Warehousing Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-storagewarehousing.html
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Part 5 - IE Research by Taylor - Productivity of Machining
https://nraoiekc.blogspot.com/2020/07/part-5-ie-research-by-taylor.html
News - Information for Information Generation & Transmission - Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-information.html
Information on Metal Cutting Processes for Industrial Engineers
50
Metal Cutting Processes - Industrial Engineering and Productivity Aspects
https://nraoiekc.blogspot.com/2020/07/metal-cutting-processes-industrial.html
Machine Tools - Industrial Engineering and Productivity Aspects
52
Machining Cutting Tools - Industrial Engineering and Productivity Aspects
53
Machine Tool Toolholders - Industrial Engineering and Productivity Aspects
54
Metal Cutting Temperatures - Industrial Engineering and Productivity Aspects
55
Machining Process Simulation - Industrial Engineering and Productivity Analysis
56
Cutting Tool Wear and Tool Life Analysis - Industrial Engineering and Productivity Aspects
57
Surface Finish - Industrial Engineering and Productivity Aspects
58
Work Material - Machinability - Industrial Engineering and Productivity Aspects
59
Machine Rigidity - Industrial Engineering and Productivity Aspects
60
Machining Time Reduction - Machining Cost Reduction - Industrial Engineering of Machining Operations
61
Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects
62
High Speed Machining - Industrial Engineering and Productivity Aspects
63
Design for Machining - Industrial Engineering and Productivity Aspects
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