Monday, May 1, 2023

Process Improvement - Process Chart Productivity Analysis Approach - Process Industrial Engineering

 




Process Chart approach was first developed by Gilbreths. It was standardized by ASME committee.


In the ASME process chart,   Processing (operation), Inspection, Transport, Temporary Delay and Permanent Storage are recorded. All these are termed operations in the process. 

Each of the operations are subjects to detailed operation analysis. In each operation, machines and men do the work on the work piece using tools, consumables, power (energy) and information.

Operation Analysis - Operation Information Sheet and Analysis Questions

https://nraoiekc.blogspot.com/2019/07/operation-analysis-operation.html


Analysis of Processing Operations

Processing is the core operation in an engineering process. In production processes, it is the material transformation operation done by machines, or men or by chemical reactions. Industrial engineers have to first improve the processing operation. It may be even be found in analysis that the existing process step or operation can be eliminated. Hence it is important in each operation to question whether the operation is effective. Is it useful to complete the objective of the process?

Industrial engineers have to use full knowledge of engineering related to the processing operation under analysis including recent developments to identify improvement opportunities. Besides that, they have to circulate the process chart and operation details to all engineers in the company, especially to engineers in production and process planning departments to get ideas for improvement of the operation. One does not who reads or sees a new development that is of use in the processes used by the company. Industrial engineers have to acquire engineering knowledge on their own and identify its relation to productivity. In addition they have to manage process improvement study in such a way that every person in the organization and supply have an opportunity to contribute their knowledge to the process improvement study. Gilbreth specifically indicated this point in 1921 itself.

In the case of machine operations, setting up the machine, loading the work piece in the machine and unloading it after the processing are par of processing operation. Hence set-up reduction is part of improvement of processing operation. Of course, there can be set up time for inspection and transport operations. So there also, setup time reduction would be involved.

Process capability improvement can be done in processing operation improvement.

Six sigma studies can be done for each processing operation to select the right combination of parameters for optimal or robust output in minimum time.

In maintenance processes, the work done the machine under maintenance is processing. There is inspection after a maintenance operation. There is transport of materials, spare parts and tools. We can see delays in maintenance processes. The spare parts etc. stay in storage for months or years. Thus in a maintenance process also five operations are there. In an engineering process, these five operations are present.

When a machine is used in the processing operation, machine work study needs to be done.


Processing Operation Analysis - Details

Machines and Tools Related Methods Efficiency Analysis - Machine Work Study

https://nraoiekc.blogspot.com/2013/11/tool-related-operation-analysis.html

Analysis of Tolerances and Inspection Standards - Methods Efficiency Engineering

https://nraoiekc.blogspot.com/2013/11/analysis-of-tolerances-and-inspection.html


Analysis of Material in Methods Efficiency Engineering

https://nraoiekc.blogspot.com/2013/11/analysis-of-material-in-operation.html


Analysis of Material - Methods Efficiency Improvement Analysis - Illustrations

https://nraoiekc.blogspot.com/2015/08/analysis-of-material-methods-efficiency.html


Machine Tool Improvement and Cutting Time Reduction

https://nraoiekc.blogspot.com/2017/07/machine-tool-improvement-and-cutting.html


Methods Efficiency Analysis of Setups

https://nraoiekc.blogspot.com/2013/11/operation-analysis-of-setups.html




Analysis of Inspection Operations

Inspection operations are done by the operator who is actually producing or processing, they are done by supervisors, done by specially designated inspectors and the user, in production processes,  another production worker can do inspection. Inspection operation is also examined first for effectiveness and elimination possibility.

Analysis of Transport Operation

Transport activity is determined by the layout of machines and facilities. To minimize transport in the factory or facility as whole, layout is to be modified based on the analysis to total material movement in a period. If a line layout is used, assembly line improvement methodologies are to be used. If group or cellular layout is used, improvement methods applicable to group layout are to be used. If a job shop layout is used, in each period, the job mix keeps changing. Accordingly recalculation is to be done and possible change of machine locations has to be attempted.

Replace materials handling equipment, improve or add to their specifications.

Replace materials handling methods, or evaluate alternative methods.

Reorganize for a better flow of materials and movement of products.

Reduce costs through better materials handling methods.


Material Handling - ILO Work Study Book

https://nraoiekc.blogspot.com/2019/07/material-handling-ilo-work-study-book.html


How to Plan & Design a Manufacturing Plant Layout? (Video Examples Included)

Our experts at Visual Components discuss how to plan and design a manufacturing plant layout with a simulation case. We review the benefits, process, and necessity for a high-quality plant layout in your business organization.

https://www.visualcomponents.com/resources/blog/how-to-plan-design-a-manufacturing-plant-layout-video-examples-included/




Analysis of Delays

Delays happen due to resource constraints and production planning problems. So resource study has to be done and planning procedure and policies are to be evaluated to reduce delays.

Value stream mapping diagram and its analysis help in reducing temporary delays.


Articles on Value Stream Mapping and Analysis

Value Stream Mapping - The Concept

https://nraoiekc.blogspot.com/2012/05/value-stream-mapping-concept.html


Learning to See: Inventories (Delays) Between Processes - Value Stream Mapping - Rother and Shook - Book Information

https://nraoiekc.blogspot.com/2013/11/learning-to-see-value-stream-mapping.html


Value Stream Mapping - Origins - Evolution and Applications

https://nraoiekc.blogspot.com/2013/10/value-stream-mapping-origins.html


The Seven Value Stream Mapping Tools - Peter Hines and Nick Rich - Brief Explanation

https://nraoiekc.blogspot.com/2012/01/seven-value-stream-mapping-tools-peter.html


Analysis of Value Stream Map (VSM)

https://nraoiekc.blogspot.com/2022/02/analysis-of-value-stream-map-vsm.html

Analysis of Storage Operation

Storage depends on batch quantity and safety stock decisions. There are to be reassessed.

Value stream mapping diagram and its analysis help in reducing batch quantities and safety stocks.


Knowledge Base for Process Productivity Improvement - News - Information



Automation for Productivity Improvement of Processes


Industrial engineers have to always consider increasing  engineering devices in the processes to increase productivity. Automation is to be considered for each step of the operation.

Automated Manufacturing - Production Operations in Manufacturing Processes
https://nraoiekc.blogspot.com/2020/12/automated-manufacturing-production.html

Automated Inspection - Bibliography  
https://nraoiekc.blogspot.com/2020/07/automated-inspection-bibliography.html

Automated Material Handling - Transport - Bibliography 
https://nraoiekc.blogspot.com/2020/12/automated-material-handling-transport.html

Automated Storage and Warehousing - Storage Operation Improvement in Engineering Processes
https://nraoiekc.blogspot.com/2020/12/automated-storage-and-warehousing.html

Automation for Preventing Temporary Delays - Lean WIP Processes - Systems
https://nraoiekc.blogspot.com/2020/12/automation-for-preventing-temporary.html

Computer Aided Industrial Engineering - Analyzing Process Chart Information Using AI Models - Computer Aided Process Chart Analysis

https://nraoiekc.blogspot.com/2023/04/computer-aided-industrial-engineering.html


Twelve Principles of Process Improvement - Kiyoshi Suzaki

https://nraoiekc.blogspot.com/2017/07/twelve-principles-of-process.html



Production Industrial Engineering - Industrial Engineering of Production Processes.

https://nraoiekc.blogspot.com/2023/04/production-industrial-engineering.html



https://asana.com/resources/process-improvement-methodologies


https://kissflow.com/workflow/bpm/process-improvement-techniques/






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