Process IE Methods - Part 4. Recording Operations Using The Motion-Picture Camera and Video Camera

Process Industrial Engineering - Methods and Techniques - Part 1 -  Part 2 -  Part 3 -  Part 4 -  Part  5

Lesson 76 of Industrial Engineering ONLINE Course

Lesson 77. Process IE Methods - Part 5. Toyota IE - Process Maps - Process Improvement - Process Metrics.

Part 4: Process Industrial Engineering - Methods and Techniques - Recording Operations Using The Motion-Picture Camera  and Video Camera

For recording many kinds of work, motion-picture camera is to be used.  Motion pictures record movements and also show the elemental time intervals for each movement. 

A complete analysis of the motions of an operator or a machine is made possible through the use of the motion-picture camera. The entire operation can be recorded permanently on the film and by the use of a projector it can be reproduced on the screen when desired. Furthermore, the motions can be examined in great detail on the film itself. It is often desirable to project a single frame or a few frames on the screen, as this makes it easier in many cases, to study the motions shown by the enlargements. 

Video Recording of Process in Action

Video recently has entered the process of motion study. Organizations are seeing the value in establishing a permanent record of the task as it was being performed.  Any question about work method can be determined by reviewing the video.

According to Timer Pro  website: "Video time and motion accurately documents and times any task while simultaneously isolating the nonvalue-added work content. Video supported analysis creates an unchallengeable history of the current process state. Each and every task observation can be instantly replayed for review and analysis."

Issues such as camera placement, work methods and playback capability are important. Without careful planning and execution, videos can provide an incomplete record of the task being performed.

Video offers additional enrichments for motion study.  With video equipment being much more affordable than in the past, almost anyone can afford at least some basic equipment, such as a digital camcorder or cellphone video.

We can improve the motion study (method study) process by incorporating video in several ways.  It may be best to conduct a few in-person studies to establish line(s) of sight, working relationships with subjects, motion patterns, etc. Sample video can be collected and reviewed for content at this time as well. As with any project of this type, industrial engineer's relationship with the study subjects is of the utmost importance. IEs have to make sure to  establish a good working relationship with the study subjects before video is introduced.

Careful consideration of video angles allows capture of multiple views that enable more comprehensive analysis (e.g., in conjunction with MTM or other predetermined time systems), ergonomic analysis and potential improvement in the process itself. Angles for consideration include bird's eye (directly above looking down on the process for study), eye level, rear view and lateral (side) views. Often, multiple views (and therefore multiple cameras) may be necessary to capture the entire work process. These videos can later be edited so that viewers can see multiple angles at the same time. Different lens options, such as wide-angle lenses, also might provide better options for capturing clear visual information.

Static video, i.e., from a tripod or otherwise mounted camera, gives good results.  There are a variety of mounting options for small cameras and even adjustable tripods for cell phones.

Video offers many benefits that increase the flexibility of motion studies. With video, we gain the ability to add "instant replay" to our repertoire. Engineers can review discrepancies and verify times if needed. Having the option of watching video again also allows the engineer to collect multiple sets of data on the same process observation, such as times and activity counts. Engineers also can study the same process observation from different angles, and they have the potential to expand scope later in the project without needing additional studies.

Another benefit is the ability for practically unlimited people to view the process. In a live study you are limited by space, but a good video allows unlimited viewing and study. Additionally, with basic editing, you can tie video clips to standard work, post it on websites, distribute it for training purposes and more.

Video also gives us the ability to calibrate multiple engineers for a study using the same data sample. It also offers the potential to save costs because it allows a non-engineer to collect data via video, organize it and submit only the relevant portions for motion study.

Study subjects/operators can review the video for a greater understanding of the study process, their contribution and the opportunity to provide feedback or insight. And video time-stamps allow quick access to specific tasks for reference or study.

And last, but not least, if best practices are captured during the study process, there is no need to film the operations again later for documentation or training materials.
https://connect.iise.org/blogs/lawrence-aft/2017/11/08/for-work-study-lets-go-to-the-video

Computer Aided Process Information Recording

In the Industry 4.0 production systems, process information required to study and understand process elements can be obtained through the information being collected through manufacturing execution systems (MES). Software can be developed to prepare various process charts based on the information from MES. Thus process chart creation can be automated providing industrial engineers more time evaluate the process for improvements.


13.8.2021
1.8.2020