Tuesday, September 8, 2020

Operation Productivity Analysis Sheet for Process Operations

Lesson 83 of  

Industrial Engineering ONLINE Course -  Process Industrial Engineering Module



The entire process commonly known as "operation analysis" consists principally of finding out all known facts that affect a given operation and redesign the operation to give better efficiency.

Importance of Systematic Procedure in Operation Analysis


Data and information in the operation information sheet is subject to productivity analysis to do productivity engineering in operation analysis.

The productivity hypotheses judged as useful, productivity science laws and best practices based on them provide standards for analysis. Benchmarking through published news, special industry level benchmarking reports and specially commissioned benchmarking studies by the organization provide another set of measures to do productivity analysis of operations. Engineering knowledge is continuously increasing. It is reported in research papers, in patents and in new commercially available equipments, devices, tools and accessories. The potential benefit of each of them has to be assessed for the operation and has to be used for productivity analysis of the operation. The suggestions and complaints of the users, operators, supervisors and engineers is another route that provides the basis for analysis. Consultants provide the possible areas of improvement that they can initiate and they also respond to queries. Inputs of consultants is another basis for productivity analysis.

The knowledge of industrial engineers themselves being accumulated over improving many other operations needs to assembled systematically in files and they must be accessed to find suitable concepts for improving the current operation under study.

For each element of the operation about which information is collected, there has to be a set of predetermined questions that are asked and answered by the operation analysis team. It has to provide opportunity to every body in the organization to contribute their knowledge even though they are not directly members of the operation analysis team. In theory every body in the organization is informed of the project of improving an operation and in the current digital communication era, is provided full data and current information of the operation and is invited to contribute digitally improvement ideas. An operation analysis team with specified members is formally responsible to do an intensive search and interaction activities to realize the operation improvement within the project life span, prespecfied.

In making operation analysis, a systematic procedure is to be followed  so that points of cardinal importance are analyzed without giving a miss.

The basic format of the analysis sheet is similar to the information sheet designed for each specific machine with a common format for each category of machines. But for each item there is a check list that prompts the operation analysis team to bring to analysis each and every path that has the potential for increasing productivity. It is possible that a new line of enquiry is recently realized and it is now part of the analysis check list. We will describe the procedure for doing it in articles that specifically discuss each item.

Items of Operation Sheet for Machine Tools


1. Purpose of operation.

2. Whether process analysis related to the operation was completed: Yes/No

3. Design - Part drawing available (Yes/No)

4. Tolerances,

5. Material.    - Supply chain operation process chart of the material.   https://nraoiekc.blogspot.com/2020/09/supply-chain-industrial-engineering.html

6. Production Machine/Equipment,

7. Fixture

8. Cutting Tools

8a. Cutting tool holders

9. Cutting Parameters

10. Cutting fluid

11. Material handling. Loading and unloading of work pieces

12. Inspection requirements; Gages used.

13. Working conditions.

14. Operator method.

15. Common possibilities for job improvement.

a.  gravity delivery chutes.

b.  drop delivery.

c. correct chair for operator.

d. Ejectors, quick-acting clamps, etc. in jigs & fixtures

e. foot-operated mechanisms.

f. Two-handed operation.

g. Tools and  parts within normal working area.

h. Coupling with other machines.



This lesson was used in the course:
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