Happy to See the caption.
"In celebrating 100 years to the presentation of the process charts"
in "Moshe Eben-Chaime (2022) On the relationships between the design of assembly manufacturing and inspection systems and product quality," IISE Transactions, 54:3,227-237.
DOI: 10.1080/24725854.2021.1905196
Link to this article: https://doi.org/10.1080/24725854.2021.1905196
Process Chart Method - Gilbreths - 1921
Process Charts for Recording and Visualizing Processes in Industrial Engineering.
Process charts are the recording devices used by industrial engineers.
Gilbreth used process charts and described them for wider audience in 1921.
In the original description, Gilbreth described the process charts used in connection with motion study or human effort study. Later the scope of the process charts was extended and the contents of the chart were standardized by ASME. Operation analysis sheet was used by Maynard and Stegemerten in the process chart framework to do machine work study.
In the process chart, five operations are depicted. They are: Operation (material processing) - Inspection - Material transport - Temporary Storage of the Material (Delay without any operation being done) - Permanent or controlled storage of the material.
Each operation has a cost and industrial engineer has to increase the productivity of each operation or step to reduce cost.
In each operations, machines, men and other facilities work to bring the desired result. The work of machines, men, robots, furnaces etc. are to be observed, studies and recorded. To study work of operators, Motion study of both hands and micromotion studies of both hands were developed by by Gilbreths. The process chart that shows the series of operations is further supported charts related to each operation that record activity of each machine and man working in that operation. To do detailed investigation based on process chart, more recording formats need to be used. There is a need for machine work study and operator work study in each of the five steps shown in the flow process chart. Recording devices are to be used machine and operator work studies in each step. Value Adding Operation, Inspection, Transport, Temporary Delay and Permanent Delay. Frank Gilbreth is given credit for the development of process chart system in industrial engineering to study and improve processes.
Process Charting for Improvement - Gilbreths' View
Frank Gilbreth developed process analysis and improvement also along with motion study. In 1921, he presented a paper in ASME, on process charts. Lilian Gilbreth was a coauthor of this paper.
PROCESS CHARTS: FIRST STEPS IN FINDING THE ONE BEST WAY TO DO WORK
By Frank B. Gilbreth, Montclair, N. J. Member of the Society
and L. M. Gilbreth, Montclair, N. J. Non-Member
For presentation at the Annual Meeting, New York, December 5 to 9, 1921,
of The American Society of Mechanical Engineers, 29 West 39th Street, New York.
https://ia800700.us.archive.org/5/items/processcharts00gilb/processcharts00gilb_bw.pdf
THE Process Chart is a device for visualizing a process as a means of improving it. Every detail of a process is more or less affected by every other detail; therefore the entire process must be presented in such form that it can be visualized all at once before any changes are made in any of its subdivisions. In any subdivision of the process under examination, any changes made without due consideration of all the decisions and all the motions that precede and follow that subdivision will often be found unsuited to the ultimate plan of operation.
The use of this process-chart procedure permits recording the existing and proposed methods and changes without the slightest fear of disturbing or disrupting the actual work itself.
The aim of the process chart is to present information regarding existing and proposed processes in such simple form that such information can become available to and usable by the greatest possible number of people in an organization before any changes whatever are actually made, so that the special knowledge and suggestions of those in positions of minor importance can be fully utilized.
Further detailed studies based on process chart
If any operation of the process shown in the process chart is one that will sufficiently affect similar work, then motion study (human effort study) should be made of each part of the process, and the degree to which the motion study should be carried depends upon the opportunities existing therein for savings.
If the operations are highly repetitive or consist of parts or subdivisions that can be transferred to the study of many other operations, then micromotion studies already made can be referred to; also new and further micromotion studies may be warranted in order that the details of method with the exact times of each of the individual subdivisions of the cycle of motions, or ''therbligs," as they are called, that compose the one best way known, may be recorded for constant and cumulative improvement.
These synthesized records of details of processes (motion studies and micromotion studies) in turn may be further combined and large units of standard practice become available for the synthesis of complete operations in process charts.
Similarly we have to add that if an operation is done or repeated multiple times, machine effort study or machine work study needs to be done and work of the machine has to be recorded using a format used in process planning of the machine.
At the end of the paper, the conclusion made by Gilbreths is as follows:
The procedure for making, examining and improving a process is, therefore, preferably as follows:
a. Examine process and record with rough notes, the existing process in detail.
b. Have draftsman copy rough notes in form for blueprinting, stereoscopic diapositives, photographic projection and exhibition to executives and others.
c. Show the diapositives with stereoscope and lantern slides of process charts in executives' theater to executives and workers.
d. Improve present methods by the use of —
1 Suggestion system
2 Motion study
3 Micromotion studies and chronocyclegraphs for obtaining and recording the One Best Way to do Work.
4 Written description of new methods or 'write-ups," "manuals," ''codes," ''written systems," as they are variously called
5 Standards
6 Standing orders
e. Make process chart of the process as finally adopted as a base for still further and cumulative improvement.
We have to add now machine work study to the list of activities of examining process charts for process industrial engineering (We will discuss each step or operation of the process chart in forthcoming lessons in detail)
We see in the method described above the method study steps of record, and examine. The practice of involving the workers in analyzing the process chart which was later popularized by Alan Mogensen is also present in the method suggested by Gilbreth to improve a process. Motion study as a later step in the process analysis method, which was emphasized by H.B. Maynard as part of the operation analysis proposed by him is also visible in the procedure described by Gilbreths.
H.B. Maynard proposed "Operation Analysis" for process improvement.
So, we can see the methods engineering and methods study which became popular subsequently were further development of Gilbreth's process improvement procedure only.
3 Micromotion studies and chronocyclegraphs for obtaining and recording the One Best Way to do Work.
4 Written description of new methods or 'write-ups," "manuals," ''codes," ''written systems," as they are variously called
5 Standards
6 Standing orders
e. Make process chart of the process as finally adopted as a base for still further and cumulative improvement.
We have to add now machine work study to the list of activities of examining process charts for process industrial engineering (We will discuss each step or operation of the process chart in forthcoming lessons in detail)
We see in the method described above the method study steps of record, and examine. The practice of involving the workers in analyzing the process chart which was later popularized by Alan Mogensen is also present in the method suggested by Gilbreth to improve a process. Motion study as a later step in the process analysis method, which was emphasized by H.B. Maynard as part of the operation analysis proposed by him is also visible in the procedure described by Gilbreths.
H.B. Maynard proposed "Operation Analysis" for process improvement.
So, we can see the methods engineering and methods study which became popular subsequently were further development of Gilbreth's process improvement procedure only.
ASME - Gilbreth Process Chart
Gilbreth proposed summarizing the data recorded on a process into process chart for providing the comprehensive starting point for process analysis for productivity improvement. Each step shown in the process has addition charts and data associated with it for detailed study and analysis by the productivity analysis and improvement team. Recording of data and preparation of process chart can be done by a limited number of persons. But productivity analysis team can be big and also they can be displayed so that more number of persons in the organization provide their suggestions for productivity improvement.
ASME appointed a committee to standardize the chart and the committee recommended the following steps.
Operation (Processing: Material Processing) - Inspection - Transportation - Delays - Storage
Each step has engineering knowledge and management (planning and control) knowledge associated with it. To do engineering process improvement for productivity, basic engineering knowledge and basic management knowledge are required.
In the area of manufacturing and machinery operation processes we can see the requirement of following subjects.
Material processing or machinery operation - Manufacturing processes, machinery operations manuals (For example hydraulic machinery, automobile engineering)
Inspection: Drawings, Specifications, Metrology and Measurement, Automated inspection
Transportation: Factory layout, Work station layout, Manual handling, Mechanical handling, Automated handling
Delays - Production quantity planning and control, Project planning and control, Maintenance, Rework
Storage: Storing parts, subassemblies, picking, kitting, issue procedures (Warehouse design, operation and management)
Process Industrial Engineering uses the process charts as the primary visualization devices for examining processes for industrial engineering (productivity engineering) them. The analysis of industrial engineering for process productivity improvement goes up to the lowest level like tool angles of a cutting tool. But the comprehensive process industrial engineering of a process begins by the creation of the process chart and its examination by each operation. That way to complete process is analysis without missing any operation.
Ohno's Seven Wastes
Overprocessing, Motion - Defects - Transport - Waiting - Inventory, Overproduction
You can clearly see Ohno expressed the wastes to be examined in process chart activities. That is why Shigeo Shingo explained Toyota Production System in terms of ASME process chart.
As part of of Operation (Processing: Material Processing), Overprocessing, Motion are to be eliminated. Defects also have to eliminated as part of operation.
As part of Inspection, either inline by the production operator or another operator or inspection the defect occurrences are assessed. Even here, there is the waste of Overprocessing and Motion.
As part of Transport Activity evaluation, transport has to be minimized.
As part of investigation of Delays, Waiting times are to be reduced.
As part of evaluation of storage to reduce storage quantity and cost, overproduction and inventory have to be eliminated.
Toyota Production System enriched industrial engineering theory and practice of 1945 to 1950 and gave us enriched industrial engineering.
Value Stream Mapping
Value stream mapping is a limited purpose chart which was unnecessarily hyped and many persons are misled.
The limited purpose of the chart in Toyota System was to examine, the delays in material due to information delays. Each process has to be examined with process chart only. Shigeo Shingo does not even mention this chart in his book.
But the data block representation in the VSM is interesting and such data blocks are to be used in process chart also. They can capture the seven wastes relevant for each activity or step in the process chart.
Knowledge Base for Process Productivity Improvement - News - Information for
Important Points from Gilbreth's Process Chart Paper - Original Statements
The Process Chart is a device for visualizing a process as a means of improving it. Every detail of a process is more or less affected by every other detail; therefore the entire process must be presented in such form that it can be visualized all at once before any changes are made in any of its subdivisions. In any subdivision of the process under examination, any changes made without due consideration of all the decisions and all the motions that precede and follow that subdivision will often be found unsuited to the ultimate plan of operation.
2. The process chart is a record of present conditions. It presents, in simple, easily understood, compact form, data which must be collected and examined before any improvement in existing conditions and methods is undertaken. Even if existing conditions are apparently satisfactory, the chart is useful as presenting much information in condensed form.
It is not only the first step in visualizing the one best way to do work, but is useful in every stage of deriving it.
4 This paper presents established working data used successfully in numerous installations for many years.
7 The use of this process-chart procedure permits recording the existing and proposed methods and changes without the slightest fear of disturbing or disrupting the actual work itself.
9 The aim of the process chart is to present information regarding existing and proposed processes in such simple form that such information can become available to and usable by the greatest possible number of people in an organization before any changes whatever are actually made, so that the special knowledge and suggestions of those in positions of minor importance can be fully utilized.
It shows the planned process as well as the present process, and therefore gains the cooperation of those affected. In many instances recording industrial processes in process-chart form has resulted in astonishing improvements. "
12 Process-chart notes and information should be collected and set down in sketch form by a highly intelligent man, preferably with an engineering training and experience, but who need not necessarily
have been previously familiar with the actual details of the processes. In fact, the unbiased eye of an intelligent and experienced process chart maker usually brings better results than does the study of a less keen man with more special information regarding present practices of the processes.
Any one can make this form of process chart with no previous experience in making such charts, but the
more experience one has in making them, the more certain standard combinations of operations, inspection and transporting can be transferred bodily to advantage to the charts of proposed processes.
13 A new viewpoint concerning old conditions invariably comes to members of the organization when they actually see the process in a new graphical form. After the rough notes of the process-chart
maker have been redrawn and blueprinted, they are later exhibited in the executives' theater.
14 If discussions arise as to the correctness of the presentation of the existing facts, or as to further details of the operations being studied, as shown by the simple symbols of the process chart, the
room can be darkened and inexpensive glass diapositives projected on the wall. In addition, those ' present may be supplied with a special small pocket folding stereoscope for use with the same glass
diapositives.
15 As soon as the old or existing process is understood, a process chart of a better sequence and kind of operations which compose it is made. The procedure for this is the same for all cases as far as they are carried for the time being, but of course those processes which warrant the most study should be carried farthest in the process-chart procedure. The more people who see the process chart and the greater detail into which the regular process charts are divided, the more suggestions for improvement will come in.
16 There is no process that warrants a process chart that does warrant a "write-up" or written system.
The better and the more detail in which the written system is developed, the better and easier will the standards and standing orders be developed.
19 If it is desirable to study, improve and still further identify the subject-matter of each part of the process chart, it should be submitted to the regular routine process of standardization.
30 If any operation of the process shown in the process chart is one that will sufficiently affect similar work, then motion study should be made of each part of the process, and the degree to which the motion study should be carried depends upon the opportunities existing therein for savings.
31 If the operations are highly repetitive or consist of parts or subdivisions that can be transferred to the study of many other operations, then micromotion studies already made can be referred to; also new and further micromotion studies may be warranted in order that the details of method with the exact times of each of the individual subdivisions of the cycle of motions, or ''therbligs," as they are called, that compose the one best way known, may be recorded for constant and cumulative improvement. Such motion study can be best visualized if seen in chart form and similar process charts can be made of any or all of the large or small circles, squares and diamonds shown on the process charts. These subdivided motion charts can be made of each and all of the cycles in any given operation. Much benefit can often
be derived, even if such motion charts are made roughly. For best results, and especially when complete
records are required, such, for example, as when the process charts are of work that is highly repetitive, micromotion charts can be made which will give the maximum amount of analysis and visualization of component parts of the existing and proposed processes. These can be still further visualized by the
chronocyclegraph processes.
32 The records of the micromotion study and the chronocyclegraph methods and devices present permanently all the facts in such form that they can be used at any time. These photographic records
can be studied as slowly as desired, regardless of how fast the motions of the process were actually made and the marvels of the details of superskill, unknown and unrecognized even by those who possess it,
can be studied at will, leisurely and intensively, by learners everywhere, far as well as near. If desired, these errorless records may be used only as far as to fill the need of present requirements, or they
may be laid away until further needs demand further study, such records being in such perfect detail that they are practically as usable When old as when new. These permanent records of complete sequences of details of complete processes furnish the foundation of the best kind of trade and industrial education, namely, the dissemination of detailed instructions as to the synthesized processes of the best workers obtainable.
33 These synthesized records of details of processes in turn may be further combined and large units of standard practice become available for the synthesis of complete operations in process charts.
MECHANISM OF MAKING PROCESS CHARTS
35 There are shown herewith:
a The symbols used with their meanings (Fig. 3)
h The mechanical devices for making the symbols on the process charts (Fig. 4)
c Completed process chart (Fig. 5)
d Accompanying forms (Fig. 6)
e Illustrations of collecting and using data.
SUMMARY
36 The procedure for making, examining and improving a process is, therefore, preferably as follows:
a Examine process and record with rough notes and stereoscopic diapositives the existing process in detail
b Have draftsman copy rough notes in form for blueprinting, photographic projection and exhibition to executives and others
c Show the diapositives with stereoscope and lantern slides of procesi charts in executives' theater to executives and workers
d Improve present methods by the use of —
1 Suggestion system
2 Written description of new methods or "write-ups," "manuals," ''codes," ''written systems," as they are
variously called
3 Standards
4 Standing orders
5 Motion study
6 Micromotion studies and chronocyclegraphs for obtaining and recording the One Best Way to do Work.
e Make process chart of the process as finally adopted as a base for still further and cumulative improvement.
37 Note that —
a Visualizing processes does not necessarily mean changing the processes
b Process charts pay.
https://archive.org/stream/processcharts00gilb/processcharts00gilb_djvu.txt
Rewritten Version of Important Points from Gilbreth's Process Chart Paper - Narayana Rao (14.1.2022)
The Process Chart is a device for visualizing a process as a means of improving it. Every detail of a process is more or less affected by every other detail; therefore the entire process must be presented in such form that it can be visualized all at once before any changes are made in any of its subdivisions. In any subdivision of the process under examination, any changes made without due consideration of all the decisions and all the motions that precede and follow that subdivision will often be found unsuited to the ultimate plan of operation.
2. The process chart is a record of present conditions. It presents, in simple, easily understood, compact form, data which must be collected and examined before any improvement in existing conditions and methods is undertaken.
It is not only the first step in visualizing the one best way to do work, but is useful in every stage of deriving it.
4 This paper presents established working data used successfully in numerous installations for many years.
7 The use of this process-chart procedure permits recording the existing and proposed methods and changes without the slightest fear of disturbing or disrupting the actual work itself.
9 The aim of the process chart is to present information regarding existing and proposed processes in such simple form that such information can become available to and usable by the greatest possible number of people in an organization before any changes whatever are actually made, so that the special knowledge and suggestions of those in positions of minor importance can be fully utilized.
It shows the planned process as well as the present process, and therefore gains the cooperation of those affected as they understand the improvement proposed and benefits to be derived from it. In many instances recording industrial processes in process-chart form has resulted in astonishing improvements.
12 Process-chart notes and information should be collected and set down in sketch form by a highly intelligent man, preferably with an engineering training and experience, but who need not necessarily
have been previously familiar with the actual details of the processes. In fact, the unbiased eye of an intelligent and experienced process chart maker usually brings better results than does the study of a less keen man with more special information regarding present practices of the processes.
Any one can make this form of process chart with no previous experience in making such charts, but the
more experience one has in making them, he will recognize the utility of certain standard operations, inspection and transporting and he can suggest using them directly in the charts of proposed processes.
16 There is no process that warrants a process chart that does warrant a "write-up" or written system.
The better and the more detail in which the written system is developed, the better and easier will the standards and standing orders be developed.
13 A new viewpoint concerning old conditions invariably comes to members of the organization when they actually see the process in a new graphical form. After the rough notes of the process-chart
maker have been redrawn and blueprinted, they are later exhibited in a theater (discussion hall).
14 If discussions arise as to the correctness of the presentation of the existing facts, or as to further details of the operations being studied, as shown by the simple symbols of the process chart, more details can be presented as available.
15 As soon as the old or existing process is understood, steps to improve the process with a better sequence and kind of operations which compose it is made. The suggestions of executives, engineers, and operators to whom the process chart is presented is the first step. The written notes accompanying the process chart help in giving more details to them. The involvement persons who participated in preparing the process chart is also important in generating suggestions.
The more people who see the process chart and the greater detail into which the regular process charts are divided, the more suggestions for improvement will come in.
There will be processes which warrant further studies based on the process-chart procedure.
19 If it is desirable to study, improve and still further identify the subject-matter of each part of the process chart, it should be submitted to the regular routine process of standardization. Standardization is examining all the conditions or elements of the job systematically and planning them.
30 If any operation of the process shown in the process chart is one that will sufficiently affect similar work, then motion study should be made of each such part of the process, and the degree to which the motion study should be carried depends upon the opportunities existing therein for savings.
31 If the operations are highly repetitive or consist of parts or subdivisions that can be transferred to the study of many other operations, then micromotion studies already made can be referred to; also new and further micromotion studies may be warranted in order that the details of method with the exact times of each of the individual subdivisions of the cycle of motions, or ''therbligs," as they are called, that compose the one best way known, may be recorded for constant and cumulative improvement.
Such motion study can be best visualized if seen in chart form and similar process charts can be made of any or all of the large or small circles, squares and diamonds shown on the process charts. These subdivided motion charts can be made of each and all of the cycles in any given operation. Much benefit can often be derived, even if such motion charts are made roughly.
For best results, and especially when complete records are required, such, for example, as when the process charts are of work that is highly repetitive, micromotion charts can be made which will give the maximum amount of analysis and visualization of component parts of the existing and proposed processes. These can be still further visualized by the chronocyclegraph processes.
33 The synthesized records of details of processes in turn may be further combined and large units of standard practice become available for the synthesis of complete operations in process charts.
MECHANISM OF MAKING PROCESS CHARTS
35 There are shown herewith:
a The symbols used with their meanings (Fig. 3)
h The mechanical devices for making the symbols on the process charts (Fig. 4)
c Completed process chart (Fig. 5)
d Accompanying forms (Fig. 6)
e Illustrations of collecting and using data.
SUMMARY
36 The procedure for making, examining and improving a process is, therefore, preferably as follows:
a Examine process and record with rough notes and stereoscopic diapositives the existing process in detail
b Have draftsman copy rough notes in form for blueprinting, photographic projection and exhibition to executives and others
c Show the diapositives with stereoscope and lantern slides of procesi charts in executives' theater to executives and workers
d Improve present methods by the use of —
1 Suggestion system
2 Written description of new methods or "write-ups," "manuals," ''codes," ''written systems," as they are
variously called
3 Standards
4 Standing orders
5 Motion study
6 Micromotion studies and chronocyclegraphs for obtaining and recording the One Best Way to do Work.
e Make process chart of the process as finally adopted as a base for still further and cumulative improvement.
37 Note that —
a Visualizing processes does not necessarily mean changing the processes
b Process charts pay.
Ud 14.1.2022
Pub 9.1.2022
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