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Part of Main Topic: Analysis of Items in Operation Information Sheet
Analysis of Material in Processing Operations
Material cost is a very important part of the total cost of any product. In the processing operation minimum quantity of the material has to be used and wastage in the process has to be minimized. Also certain aspects of the input increase processing time. They have to be identified and analyzed.
Industrial engineers should check the material for the possibility of using lower cost materials. You do it with more focus in product industrial engineering/value engineering.
The following questions will help in 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 the care to be taken in operating the machine or handtools or the skill 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 controlled and economical?
Special materials used in the processes may require special questions specific to those processes, but the list given indicates the kind of questions that should be asked and will identify issues or areas that are to be redesigned by industrial engineering department. It will stimulate the improvement initiative on many kinds of the more common materials.
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Invite readers to suggest additional questions to be evaluated.
Ud. 27.8.2023
Pub 13.8.2020
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