Operation Information Sheet for Productivity Analysis of Processing Operations

Lesson 82 Industrial Engineering ONLINE Course -  Process Industrial Engineering Module

Lesson 83. Operation Analysis Sheet for Finding Process Productivity Improvement  Opportunities

Productivity Analysis - Comparison of Current Process to Ideal or the Best Process has to be done from System level up to Element level.

A process consists of operations. Five types of operations are specified by ASME/IISE to be recorded on process charts - Material processing - Inspection - Transport - Storage - Delays. A process to produce a part may have many operations. In the process analysis, for each operation, the possibility of eliminating it is discussed. The possibilities for combining two adjoining operations or dividing an operation into more steps are examined. The sequence of operations can be altered to increase productivity. After these analyses are complete, the operation is given for detailed study to improve machine work, operator work, work station layout etc. Thus process analysis is to be followed by operation analysis. The operation analysis requires detailed information on all inputs going into the operation and the steps or elements used to complete the operation.

The operation analysis of the processing operation starts with collecting information on the processing information. In the developing this complete procedure, initially machine tool operation is being used for illustrating the details to be collected and analyzed. Subsequently, analysis of other machine operations will be added as annexures.

What is "operation analysis"?

The task in "operation analysis" is to improve productivity consists principally of finding out all known facts about equipment and operators that affect a given operation, and compare it with the possible alternatives to identify improvement opportunities and redesign the operation to give better efficiency, productivity and lower cost. Both machine effort and human effort that go into an operation are studied at element level and improved.

Importance of Systematic Procedure in Operation Analysis

In making operation analysis, a systematic procedure is to be followed  so that points of cardinal importance are analyzed without giving a miss. The information to be collected is likely to differ from machine to machine or equipment used in operations.

Operation Information Sheet

Information to be collected about the following items/elements (Case of Machining Operations).

1. Purpose of operation.

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

Productivity Measurements of the Operation

Time taken for machining cuts  (Machine Work Measurement - Estimation)

Time taken by the operator (Operator Work Measurement)

Total cycle time

Output of the component per machine hour

Cost of operation per hour  (Cost Measurement)

Cost per piece (Cost Measurement)

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

4. Tolerances  -  Analysis Note

5. Material. - Analysis Note

Operation Drawing/Operation Instruction Sheet Available: Yes/No

6. Production Machine/Equipment, - Analysis Note

7. Fixture - Analysis Note

8a. Cutting Tools - Analysis Note

8b. Tool Holder  -  Analysis Note

9. Cutting Parameters - Analysis Note

10. Cutting fluid - Analysis Note

11a. Machine Setup - Analysis Note

b. Material handling. Loading and unloading of work pieces - Analysis Note

12. Inspection requirements; Gages used. - Self Inspection Gages - Analysis

13. Working conditions. (Human Effort Industrial Engineering)

14. Operator method. (Human Effort Industrial Engineering)

15. Common possibilities for job improvement.

a. Coupling with other machines - Multiple machines for man.  (Human Effort Industrial Engineering)

b1.  gravity delivery chutes. - Analysis Note

b2.  drop delivery. - Analysis Note

c. Ejectors, quick-acting clamps, etc. in jigs & fixtures  Analysis Note

d. correct chair for operator. (Human Effort Industrial Engineering)

e. foot-operated mechanisms. (Human Effort Industrial Engineering)

f. Two-handed operation. (Human Effort Industrial Engineering)

g. Tools and  parts within normal working area. (Human Effort Industrial Engineering)

16. Operation Defects Analysis

17. Operation Batch Quantity Analysis  (Production Planning Analysis)

Productivity analysis of machine tool elements is based on productivity science of machining.

Productivity Science of Machining - Taylor to Current Times

The Operation Analysis 

(To be rewritten as per the new item numbers)

In order to structure the work of making written analyses, " analysis sheet" has to be used. In asking questions based on operation information sheet,  securing the information needed to complete the analysis of each item to fill out the form completely, one will understand the operation more thoroughly that will help to make a complete analysis and come out with alternatives to increase productivity.

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 first point considered is the purpose of the operation. If analysis shows that the operation serves a definite purpose, various other means of accomplishing the same result are considered to see if a better way can be found.

Item 2. If operation or flow process charts have not been constructed, all the operations performed on the part are next listed.

Item. 3 to 5 Design 

Item. Material handling.

Although it is commonly thought that conveyers can be used to advantage only in mass-production work, there are types on the market that are equally successful in jobbing work.



Item 6. 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 too often are designed without thought of the motions that will be required to operate them. Unless a job is very active, it may not pay to redesign an inefficient device, but the factors that cause it to be inefficient may be brought to the attention of the tool designer so that future designs will be improved.

"Setup" is loosely used throughout industry to signify 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.

The workplace layout and the setup, or both, are important because they largely determine the method and motions that must be followed to do the job. If the workplace layout is improperly made, longer motions than should be necessary will be required to get materials and supplies. It is not uncommon to find a layout arranged so that it is necessary for the operator to take a step or two every time he needs material, when a slight and entirely practical rearrangement of the workplace layout would make it possible to reach all material, tools, and supplies from one position. Such obviously energy-wasting layouts are encountered frequently where methods studies have not been made and when encountered serve to emphasize the importance of and the necessity for systematic operation Analysis.

The manner in which the make-ready and put-away operations are performed is worthy of study, particularly if manufacturing quantities are small, necessitating frequent changes in layouts and setups. On many jobs involving only a few pieces, the time required for the make-ready and put-away operations is greater than the time required to do the actual work. The importance of studying carefully these non-repetitive operations is therefore apparent. When it can be arranged, it is often advisable to have certain men perform the make-ready and put-away operations and others do the work. The setup men become skilled at making workplace layouts and setups, just as the other men become skilled at the more repetitive work. In addition, on machine work it is usually possible to supply them with a standard tool kit for use in making setups, thus eliminating many trips to the locker or to the toolroom.

Item.  Common possibilities for job improvement.

There are a number of changes that can be made to workplace layouts, setups, and methods which are brought to light by job analysis. Of these, there are 10 that are encountered frequently, and one  or more may be made on nearly every job studied.

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 analyst is observant and on the alert for inefficient operating practices, the possibility of applying them can be recognized without resorting to detailed motion or time study.

Item. Working conditions have an important influence on production. 

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

The method that is established after analysis and motion study is recorded under 9 in order that the analysis sheet may 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 method requires the drawing of one or more types of process chart, and often a number of computations are involved. This information should be gathered together in the form of a supplementary report and identified by a note on the analysis sheet.

The foregoing gives a general description of the items on the analysis sheet.

This Article was used in the Course: 

Industrial Engineering for Productivity - NITIE International Online Management Development Program
31 August to 4 September 2020
Course Leader: Prof. K.V.S.S. Narayana Rao

Updated on 24.8.2023,  27.9.2022,  2 September 2020

First published in 6 August 2020