Process Industrial Engineering - Methods and Techniques
Presentation by Professor K.V.S.S. Narayana Rao, NITIE, Mumbai on 1 September 2020PGDIE(NITIE), PhD(IIT Bombay)
Industrial Engineering Knowledge Center
Process Industrial Engineering
Process industrial engineering is data collection, study, visualization, analysis, engineering improvement and improvement of related aspects of the existing and proposed processes to improve their productivity further. - Narayana Rao
Taylor - Process Industrial Engineering
Taylor explained productivity improvement of machines and men through a new system of management in his 1895 paper.
Elementary rate-fixing method for operations having machine effort and human effort.
Work done by metal-cutting tools can be improved by developing the law governing the proper cutting speed of tools only.
Improvements in small details such as belts, shape of cutting tools, tool materials etc. increase productivity.
Speed Boss of the Shop for Productivity
Speed of machines determines productivity (Feed, Depth of Cut).
The speed boss has to be there in machine shop.
He must see that the proper cutting tools are used for each piece of work, that the work is properly driven, that the cuts are started in the right part of the piece, and that the best speeds and feeds and depth of cut are used.
Favorable Circumstances for Productivity
A first-class man under favorable circumstances can give two times production.
Favorable circumstances:
Well planned and maintained equipment and tools.
Instruction card for each operation on each job with detail.
Specific tool, jig, speed, feed, depth of cut, and the time required to do it.
For Taylor, time study is the means to understand the maximum speed with which a task can be done on machine or by a first class worker without any discomfort.
Man for Improvement - Industrial Engineering
One man should be especially charged with the work of improvement in the system and the running of the plant.
This one man for improvement became industrial engineering department as the factories became big and bigger.
Planning Activity
The shop, and indeed the whole works, should be managed, not by the manager, superintendent, or foreman, but by the planning department.
Taylor is the father of production planning and control function.
It is his contribution in industrial management.
Methods Described by Taylor in the Paper "Scientific Management"
In process industrial engineering, certain improvements have to occur at elementary operation level and certain improvements are factory level decisions and implemented across the factory (example, plant layout in a job shop).
In process improvement, industrial engineer must be able to explain his improvement clearly with numbers.
Otherwise many will not accept the new method.
Productivity Science
Machining - Productivity Science.
The Art of Metal Cutting - 1906 by F.W. Taylor
Shoveling Productivity Science and Engineering
Load of 21 pounds of whatever material is to be shoveled.
Different shovel design for different materials.
Taylor on Frank Gilbreth
Gilbreth applied the principles of scientific management to the art of bricklaying.
He experimented with every minute element which in any way affects the speed and the tiring of the bricklayer.
He improved method and motions.
He reduced movements required for bricklaying from eighteen motions per brick to five.
Increased output to 350 bricks laid per hour from 120 earlier.
Taylor - Productivity and Quality
One of the dangers to be guarded against, when the pay of the man or woman is made in any way to depend on the quantity of the work done, is that in the effort to increase the quantity, the quality is apt to deteriorate.
It is necessary therefore, to take definite steps to insure against any falling off in quality due to process industrial engineering.
Gilbreth on Methods Study, Motion Study and Time Study
Motion-study, time-study, micromotion-study, fatigue-study, and cost-study are important to measure the efficiency of each function and subfunction.
Micromotion study. Recording the speed of a two or three dimensional path of motions by the aid of cinematograph pictures and a specially designed clock.
Where eighteen braiders were assembled by one man in a day, sixty-six braiders per day, with no increase in fatigue done.
Quality of the output
The quality of the output is maintained through a new type of inspection.
Inspect not only the output itself, but the elements, material and human, which produce that output.
Nothing is a higher guarantee of quality than insistence on a standard method.
The engineer must secure the co-operation of the educator, the psychologist, the physiologist and the economist to understand his shop observations.
Motion study -has Three Parts
1. Study of the variables of the worker.
2. Study of the variables of the surroundings, equipment and tools.
3. Study of the variables of the motion itself.
Motion Study: The operator can apply the same method of attack to the minutiae of motions in his own work that the management has not had the time or the money to investigate.
Process Charting for Improvement - Gilbreths' View (1921)
The Process Chart is a device for visualizing a process as a means of improving it.
Process-chart procedure permits recording the existing and proposed methods and analysis of it without disturbing or disrupting the actual work itself.
Show process charts - Engineers, foremen, operators.
Use special knowledge and suggestions of those even in positions of minor importance.
Motion study (Operation Analysis)
Do motion study (operation analysis) of each part of the process.
The degree to which the motion study should be carried depends upon the opportunities existing therein for savings.
Improve present methods by the use of —
1. Suggestion system
2. Motion study
3. Micromotion studies and chronocyclegraphs
Communicate best method or SOP through
1. Written description of new methods or 'write-ups," "manuals," ''codes," ''written systems," as they are variously called.
2. Standards
3. Standing orders
Process Charts, Maps, Diagrams and Operation Analysis Sheet - Maynard & Stegemerten (1939)
Process Charts. A process chart may be broadly defined as any charted presentation of information connected with a manufacturing process or any other engineering process or business process.
If process chart is prepared and every member of the study group is given a copy to study, the discussion proceeds systematically without waste toward the end.
Major types of charts
1. Operation process charts.
2. Flow process charts.
3. Man and machine process charts.
4. Operator process charts.
5. Progress process charts.
Operation process chart
The operation process chart shows the value addition activity more clearly.
After redesign of processing and inspection, flow charts can be made to visualize tranport and delays.
After process level analysis, a refined analysis needs to be performed upon the operations themselves.
This analysis requires more information and operation analysis sheet needs to be used.
Maynard Operation Analysis - Narayana Rao
Maynard described operation analysis in detail in a book.
But industrial engineering discipline has not made good use of it.
Operation analysis is a method that has immense potential to implement Taylor's advocacy of planning each small detail related to machine tool to increase productivity.
Prof. Narayana Rao, highlighted this aspect.
He is promoting operation analysis/machine work study.
Process Charts and Other Recording Devices - R.L. Barnes (1931).
“Process charts are used to record in a simple, compact form and to visualize the elements of a process in sequence and in relation to the entire process.
Barnes did the first PhD in Industrial Engineering.
His studied motion economy in his research.
Wrote a popular book on Motion and Time Study.
He promoted Gilbreth's ideas of micromotion study in process improvement
Toyota Process Maps - Process Improvement - Process Metrics - Ohno - Shigeo Shingo
Japanese productivity is high because of fundamental production systems (production system and production control system) and highly qualified work force. - Shingo.
1. Process - The course by which material is transformed into product. Processing, inspection, transport and storage.
2. Operation - The action performed on the material by machines and workers.
Process Charts - Toyota
Flow Process Chart: All production activities can be analyzed using the flow process chart and its five symbols - Shigeo Shingo.
Material and Information Flow Mapping (Value Stream Mapping)
Process Improvement
Processes can be improved in two ways.
The first improves product itself through improvement of product design from engineering design point of view and efficiency point of view or productivity point of view.
The second improves manufacturing methods from the standpoint of manufacturing technology and industrial engineering.
Details of Operations to be Observed and Recorded
Setup operations - Removal of old dies and tools, mounting new dies and tools, adjustments of dies and tools.
Principal operations - Actually changing the form of the material.
Incidental operations - Loading and unloading work pieces.
Margin allowances or operations - Lubricating the machine, arranging finished items on pallets etc.
Toyota Process Metrics
Taiichi Ohno created the concept of 7 wastes.
Efforts to improve the processes and facilities to eliminate wastes is continuously made in Toyota.
Flow process is used for it (Shigeo Shingo)
Mike Rother and John Shook
Rother and Shook,in the book, Learning to See, book on VSM said, in Toyota, infinite attention is given to establishing flow and eliminating waste in adding value.
Toyota people talk about three types of flow, material, information and flow in process and operations (Shigeo Shingo uses the terms, flow of equipment and people).
Material and information flow map covers on material and information.
Process and operation related issues are analyzed using different maps or charts.
Flow Kaizen
How can we flow information so that a supplier operation knows what is the requirement of the customer operation in the tact time of the process (Kanban)?
The authors gave an interesting explanation, "flow kaizen" as the purpose of material and information flow map.
Flow kaizen is a higher level responsibility.
Task level kaizen responsibility of foreman and operators.
Next Topic
Maynard - Narayana Rao Operation Analysis Technique (MNOAT)
Operation Information Sheet for Productivity Analysis of Processing OperationsOpen for Discussion.
Narayana Rao
Industrial Engineering Knowledge Center
http://nraoiekc.blogspot.com
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