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Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."
I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.
Supporting Information.
Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.
Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.
The prime contribution of IE has to be cost reduction through productivity improvement.
Book: Productivity Through Process Analysis by Jinichi Ishiwata
Four basic principles for process improvements
1. Eliminate processes whenever possible.
2. Simplify them. (Operations analysis)
3. Combine them
4. Change the sequence
Questions
1. Eliminate - Can this be eliminated? What will happen if we eliminate it?
2. Simplify - Can this made simpler? - the task of operations analysis
3. Combine - Can two or more processes be consolidated into one?
4. Change sequence - Can this operation be switched with another one?
Big three problems in process: waste, irrationality, and inconsistency
5W1 Analysis for Product Process Analysis
Operation - Why - Who is doing it - Which machine - where - when - How
Can the layout be changed to reduce the transportation?
Can number of inspections be reduced?
Are any inspections unnecessary?
Can necessary inspections be done while the product is being processed?
Can number of delays be reduced?
Book: Motion and Time Study - Improving Productivity by Marvin E. Mundel
Checklist for Process Chart - Product Analysis
Basic principles
1. Reduce number of steps.
2. Arrange steps in best order.
3. Make steps as economical as possible (operation analysis).
4. Reduce handling.
5. Combine steps if economical.
6. Shorten moves.
7. Provide most economical means for moving (operation analysis)
8. Cut in-process inventory to workable minimum
9. Use minimum number of control points at most advantageous places
Questions
1. Can any step be eliminated?
a. As unnecessary. (Ask: Why is it done?)
b. By new equipment (Ask: Why is present equipment used?)
c. By changing the place where it is done or kept. (Ask: Why is it done there?)
d. By changing the order of work. (Ask: Why is it done in its present order?)
e. By changing the product design. (Ask: Why is it made as it is?)
f. By changing the specifications of the incoming supply. (Ask: Why is it ordered in its present form or used at all)
2. Can any step be combined with another?
a. By changing the specifications of supplies, or of any raw material?
b. By changing the design of the product, even if only the tolerances?
c. By changing the order of the steps of production, or doing inspection at any operation station so as to avoid an inventory of faulty product?
d. By changing the equipment used (e.g., using a multifunction machine, or creating a multimachine work cell served by a single person or by a robot)/
e. By redesigning one or more work places?
3. Can steps be rearranged so as to make any shorter or easier?
4. Can any step be made easier?
Methods Redesign for Efficiency/Productivity - Material, Product Design, Material Transformation Steps, Machine Effort, Human Effort
Marvin Mundel, Gerald Nadler
Nadler credits Mundel for the following steps to be followed in methods redesign.
1. Change the material being used or contemplated to help meet the goal for the operation being studied. 2. Change the present or contemplated design of product to help meet the goal for the operation being studied. 3. Change the present or contemplated sequence of modification work on the material or product to help meet the goal of for operation being studied. 4. Change the equipment used or contemplated for the operation to help meet the goal for the operation being studied. 5. Change the method or hand pattern used or contemplated for the operation to help the goal for operation being studied.
(Source: Gerald Nadler, Motion and Time Study, McGraw-Hill Book Company, New York, 1955, p.193. Nadler in turn gives credit to Marvin E. Mundel, Motion and Time Study Principles and Practice, Prentice-Hall, New York, 1950, pp. 23-26.)
Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."
I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.
Supporting Information.
Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.
Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.
The prime contribution of IE has to be cost reduction through productivity improvement.
Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."
I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.
Supporting Information.
Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.
Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.
The prime contribution of IE has to be cost reduction through productivity improvement.
Method Study is Efficiency Improvement Technique of Industrial Engineering Method study is production, service or business process improvement technique
Method study term study is popular in Europe and in many Asian countries who are associated with England or Britain. ILO productivity missions also promoted work study. Method study and Work Measurement constitute Work Study. Hence Method Study became popular term in many countries. Method study has its foundation in "Motion and Time Study" books and is therefore has more focus on man's work. The evaluation work machine work is not given the attention it requires. Hence machine work study or machine method study has to be developed separately and an attempt is done by Narayana Rao.
Lowry, Maynard and Stegemerten might have used the term "Method Study" in their book of 1927. In the third edition of their book (1940), the term was used. The term "Method" was used by Frank Gilbreth in 1912. Maynard and Stegemerten advocated as detailed study of each operation under many heads as part of method study and this approach provides steps for examining various engineering elements that go into the method used by machine dominated work methods.
ILO Work Study book is mainly focused on human work as it is only some broader discussion of motion and time study. According to the book, work study contains method study and work measurement. Based on the coverage of the book, it will be better if we consider more areas under human work study or human effort study. They can be study of human sciences, (anatomy, physiology, psychology, sociology, biomechanics and ergonomics), Equipment and tools used by operators, human productivity improving devices, working conditions, method study, motion study and work measurement. We will cover all these areas in detail in the modules, Process Human Effort Industrial Engineering and Industrial Engineering Measurements.
Method study is the systematic recording and critical examination of ways of doing things in order to make improvements[1]. We can generalize it as: Method study is the systematic recording and critical examination of production, service and business processes in order to make improvements.
Method study is known by another term "methods engineering". The following definition, appears in the 3rd edition of the Industrial Engineering Handbook [2]:
The technique that subjects each operation of a given piece of work to close analysis to eliminate every unnecessary element or operation and to approach the quickest and best method of performing each necessary element or operation. It includes the improvement and standardization of methods, equipment, and working conditions: operator training; the determination of standard time; and occasionally devising and administering various incentive plans. Operation analysis using operation analysis sheet is advocated by Maynard and Stegemerten. The operation analysis sheet can be made for every step or operation recorded in process flow chart. Operation - Inspection - Transport - Temporary Delay - Controlled Storage Each of the above steps is actually an operation. Production or material shape changing operation - Inspection operation - Transport operation - Temporary storage operation - Controlled storage operation. Process improvement or method improvement requires improvement of every operation. Japanese industrial engineers or scientific managers improved every operation systematically and created world class companies going ahead of US companies in many industries. Shigeo Shingo's description of Toyota Production System captures the focus of Japanese in every step involved in the process and process flow and a must read for industrial engineers.
This definition, however, tends to define methods engineering rather narrowly. It states that methods engineering is limited to operations or pieces of work, but recently the trend has been to address broader areas, such as production processes, the factory in total, or large scale work systems that involve a lot of people and extensive equipment[3].
Frank Gilbreth's Mention of Method in His Writings
Frank B. Gilbreth. Discussion on "The present state of art of industrial management." Transactions of the American Society of Mechanical Engineering. Vol. 34 (1912). 1224-6
It is now possible to capture, record and transfer not only skill and experience of the best worker, but also the most desirable elements in the methods of all workers. To do this, scientific management carefully proceeds to isolate, analyze, measure, synthesize and standardize least wasteful elementary units of methods. This it does by motion study, time study and micro-motion study which are valuable aids to sort and retain all useful elements of best methods and to evolve from these a method worthy to be established as a standard and to be transferred and taught. Through this process is made possible the community conservation of measured details of experience which has revolutionized every industry that has availed itself of it. p. 1124-5
Method Study - Basic Approach
The basic approach suggested for the method study consists of eight steps.
1. SELECT
2. RECORD
3. EXAMINE
4. DEVELOP
5. EVALUATE
6. DEFINE
7. INSTALL
8. MAINTAIN
Brief explanation of the eight steps
1. SELECT
The process to be studied to selected and its boundaries are to be defined
2. RECORD
The process is to be recorded in specified charts and diagrams.
Process charts Flow charts Flow diagram String diagram
A variety of techniques for analysis and charting have for a long time been established as IE techniques. Among the methods of analysis, process analysis, operation analysis, motion study, time study, work sampling, and flow analysis are widely used. Similarly, among the charting techniques, process charts, pitch diagrams, multiple activity charts, process charts, and machine sequential charts are used. From among these various techniques, the appropriate one will be chosen, based on the object being analyzed [3].
Process charts were used and advocated by Frank Gilbreth in a paper presented to ASME in 1921.
3. EXAMINE
A process or method has activities. The activities are categorized into action activities and idle (inventory) activities. Action categories are subdivided into i) MAKE READY activities, (ii) Do operations iii) PUT AWAY activities
Each activity is subjected to a series of questions:
A. Purpose What is done? Why is it done? What else might be done? What should be done? B. Place Where is it done? Why is it done there? Where else might it be done? Where should it be done?
C. Sequence When is it done? Why is done then? When it might be done? When should it be done? D. Person Who does it? Why does that person do it? Who else might do it? Who should do it?
E. Means How is it done? Why is it done that way? How else might it be done? How should it be done?
These questions in the above sequence must be asked every time a method study is undertaken. They are the basis of successful method study.
4. DEVELOP
The shortcomings of the present process are brought out by the systematic questioning process that is combined with a knowledge relevant to the process being examined. Industrial may have the knowledge required or may not have the adequate knowledge. They need to have a knowledge library to support their effort as well as access to the experts during the study period. Alternatives to the current activities which have the shortcomings are to be generated during this stage.
Development requires new knowledge. Industrial engineers have to update their knowledge continuously.
Alternatives are to be evaluated at this stage to find their contribution to the efficiency of the process as well as effectiveness.
6. DEFINE
The new method or process suggested has to be put down standard process sheets that are issued to the shop or department.
7. INSTALL
Industrial engineers of methods study persons have to train the operators and their supervisors in the new method and participate in installing the method.
8. MAINTAIN
Industrial engineers have to conduct a periodic review of methods to observe modifications brought into the installed methods by operators and supervisors and if they are beneficial, they have to be made part of standard operating procedure (SOP). If they are not beneficial, supervisors are to be informed of the same to bring the method back to SOP.
Approaches to Analysis
Eliminate, Combine, Rearrange, Simplify (ECRS).
When thinking about how to improve a certain process or operation, an efficient way is to consider how to eliminate, combine, rearrange, and simplify (in that order) the components of the process or operation. If an operation can be eliminated, the elements and equipment related to that operation can be eliminated at the same time. For this reason, elimination of operation in a process or method usually produces the best improvement results, and should therefore be the first activity considered. Next consideration is how to combine. By finding opportunities to combine operations, tools, jigs, or parts and to perform simultaneous processing, we can often expect to reduce the amount of material handling as well. In addition, by rearranging, a better sequence for operations frequently results in the elimination of redundant work.
After these steps—eliminate, combine, and rearrange operations have been completed, simplify will be considered. Simplify implies operation improvement, operation analysis or kaizen (in Japanese terminology), and involves establishing the operation and its elements in a very concrete and practical way of positioning of parts and materials, the layout of the work area, the use of appropriate jigs and tools, etc.
The 5W1H Method.
This is a rationalizing step. For every operation and every element, the rationale of doing it and doing it in a particular way is identified in this step. The ideas is that some operations or elements do not have sufficient rationale to exist.
To accomplish the important step of verifying the necessity of existing work elements, the 5W1H method is effective.This method entails a clear definition of the conventional 4W1H (What? Where? Who? When? How?) in regard to the process or operation being studied, and in addition the question: Why? The technique of seeking improvement ideas through the combination of the 5W1H method and ECRS can be quite useful.
Principles of Methods Efficiency Engineering Or Industrial Engineering Review of Methods
For successful work in any field, it is important to define beforehand what is to be accomplished. The goal-determination step includes:
1. General goal: Most industries have as a goal a better product for a lower cost. For industrial engineering projects, the general goals most of the times are going to be cost reduction and increased productivity.
2.After the general goals is decided the next decision is "where to start the work?" Will it be single operation or full process.?
3. For each specific problem, a specific goal is to be determined.
Some of the specific goal alternatives are:
Eliminate time spent in obtaining and tools
Reduce discomfort of the operator
Improve the organization of the workplace
Eliminate some make-ready time.
Eliminate some put-away time.
Reduce operator delay
Reduce total cycle time.
Reduce scrap.
Principles of Methods Efficiency Design
1. Change the material being used or contemplated to help meet the goal for the operation being studied.
2. Change the present or contemplated design of product to help meet the goal for the operation being studied.
3. Change the present or contemplated sequence of modification work on the material or product to help meet the goal of for operation being studied.
4. Change the equipment used or contemplated for the operation to help meet the goal for the operation being studied.
5. Change the method or hand pattern used or contemplated for the operation to help the goal for operation being studied.
(Source: Gerald Nadler, Motion and Time Study, McGraw-Hill Book Company, New York, 1955, p.193. Nadler in turn gives credit to Marvin E. Mundel, Motion and Time Study Principles and Practice, Prentice-Hall, New York, 1950, pp. 23-26.)
Principles of Motion Economy.
These principles have been organized into the following categories: (a) body movements, (b) positioning of jigs, tools, and materials, and (c) design of jigs and equipment.The Gilbreth introduced these principles. Ralph M. Barnes, Benjamin W. Niebel, Marvin E. Mundel, have refined these principles. These principles apply to actual human motions and hence are applicable at elemental level.
Brainstorming is a method to involve many persons connected with the method in improvement process.
Brainstorming can be a powerful method for bringing out creative ideas from people. This technique was developed by A. F. Osborne. It is based on the formation of a team consisting of several members who will be working to come up with improvement ideas and plans. If the team is made up of representatives from different areas of the company, ideas created from synthesis of different perspectives will emerge and good results can be obtained. During brainstorming, to encourage creative thinking some rules for are specified. They include:keep a record of all ideas, do not criticize the ideas of others, it is acceptable to support the ideas of others, extreme ideas are permitted, try to generate as many ideas as possible and limit the brainstorming session to a set length of time.
Management of Method Study by Industrial Engineer
Management involves three categories of skills: technical, human and conceptual skills. An industrial engineer needs to know the potential of method study and the procedure of applying it. It is a conceptual skill. A method study is applied to a process having specific technology. To improve the process, the industrial engineer has to manage the participation of the persons with the deep knowledge of the technology. To contribute to the method study process in a meaningful way and also to manage the process of participation of various technology people, industrial engineer needs to have the required technical skill of the process or method to be improved. Human skills are required to create the ideal environment in which the operator, the supervisor, other technical experts and the industrial engineer interact, come out with the improved solution, install it successfully and provide the anticipated benefit of the new method.
Scope for Methods Studies and Methods Efficiency Engineering
Akiyama and Kamata write: "Present day work systems may not be perfect. In newly built work systems, many imperfect points remain, and there will be room for further enhancement through improvement activities. The function of methods engineering is then to be employed continuously to raise these imperfect work systems ever closer to perfect systems (or as Toyota expresses it:“The relentless pursuit of perfection”). '"[3]
Industrial Engineering Discipline has to promote Process Improvement Study
The process improvement study has to study material transformation, inspection, material handling/transport between machines and warehousing or storage. Each of these operations require machine effort and human effort apart from infrastructure. Time is involved and cost is involved in these operations. Apart from the delays are recognized in process charts that cost money and loss of time as jobs wait in shop floor inventory.
The process improvement study would involve facilities improvement, working conditions improvement, process machine effort studies, process human effort studies and productivity management (planning and control) studies.
References
1. George Kanawaty (Editor), Introduction to Works Study, Fourth (Revised) Edition, ILO Geneva, 1992
Effectiveness First and Efficiency Next. Organizations have to be effective and efficient simultaneously. Processes have to be effective and efficient simultaneously. Operations have to be effective and efficient simultaneously. - Narayana Rao
New. Popular E-Book on IE,
Introduction to Modern Industrial Engineering. #FREE #Download.
Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."
I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.
Supporting Information.
Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.
Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.
The prime contribution of IE has to be cost reduction through productivity improvement.
Process - Method - Motion - Machine Effort - Human Effort - Industrial Engineering Terms
Process describes the steps or operations involved producing a part or a product (Operation Process Chart and Flow Process Chart of Parts)
In the process chart, material transformation operations, inspection operations, material handling operations and storage operations take place. To facilitate the operations, we need production planning and communications.
We all know process plans. Process plan is the term used to describe the steps undertaken in material transformation operation to convert raw material into part especially using machine tools. We can extend the idea and say that process is described through process plan, inspection plan, material handling plan, storage plan, production plan (quantity plan) and communications plan.
Also in each operation there is machine effort and human effort. To describe human effort, we use the term motion. We study motions and improve human effort to make it more productive, comfortable and safe.
Method is another popular term. Method is basically the arrangement of raw material (input), machine, machine controls, cutting tools and hand tools, jigs & fixtures, finished parts disposal channels and bins and man at the work station. The method that is arrangement of the work station as well as the facilities design (if operator has to go fetch some inputs) determines the motions to be made by the operators. The selection of tools etc. also became part of method. But they are basically specified as part of the process. Hence motion study was extended as method study. Method and motion have to be studies together.
Process Analysis in Industrial Engineering
ECRS is the primary method of process analysis in industrial engineering. It determines the operations required to transform the input into the required output. An explanation of the process is that it starts from point an input is taken from the stores to the point a finished item is given back to the stores. The input can be raw material in which case in a discrete part assembly plant, a part is made and sent to parts warehouse. The parts input is taken by the assembly shop and a finished product is sent to finished proudct stores. During the process various operations are done on the input that comes to each operation in sequence. Operation analysis studies each operation to examine each element associated with the machine and man used in the operation.
The process itself can be changed totally. For example a part made inside presently can be changed to a bought out part process. In this case the complete existing process is totally changed. Similarly, if part currently made in machine shop can be changed to an additive manufacturing process. In this case, even the raw material gets changed and a total new process comes into existence. So we can see that a process analysis can change the current complete process by a new process based on a different core technology.
ECRS Method - Barnes
The Original ECRS Method can be now thought of as ECDRS Method (Narayana Rao).
Motion and Time Study: Design and Measurement of Work, 7 Edition
John Wiley and Sons
Chapter 6. Work Methods Design - Developing a Better Method
ECRS is primarily a method of process analysis in industrial engineering. ECDRS is now proposed.
Eliminate, Combine, Rearrange and Simplify steps are used at the level of operation and motion also.
At the level of analysis of the processes, it is operations which are subjected to ECRS.
At the level of operation, it is elemental operations which are subjected to ECRS.
In motion study, individual motions are subjected to ECRS.
If the technology of manufacturing a product is divided into processes, ECRS can be applied to even processes.
A. Eliminate all unnecessary operations/
The Procter and Gamble has found this step so profitable that is has established a formal procedure for the "the elimination approach."
1. Select the cost for questioning: Major costs must be selected first in order to get the greatest money returns. Labor costs, material costs, clerical costs, and overhead costs of all kinds are possible subjects for elimination.
2. Identify the basic cause: Find the basic cause which makes it necessary for doing the process/operations/element that results in the cost. A basic cause is the reason, purpose, or intent on which the elimination of the cost depends. The basic cause is the factor which controls the elimination of the cost. The key question is, "This could be eliminated if it were not for what basic cause?"
In more simple terms ask, "What makes this operation necessary?" You are asking what function is served by this operation? If once knows the function, the first question is whether the function is necessary. Second question is if it is necessary what are the alternate ways of doing this function and what do they cost. Then it goes into value engineering methodology which is same as productivity engineering methodology. If alternatives cost less, an engineering effort is to be undertaken to use the low cost alternative way in this application.
This question also examines the effectiveness of the operation. If the operation is not giving effective output that is valued by the customer, alternatives first have to be found for making the operation effective. Effectiveness designers have to be called in to examine and make the operation effective. The immediate issue that requires attention is not efficiency but effectiveness.
At this stage we do not ask the question "Why is this operation necessary?" This question is avoided because it tends to justify and defend the job's existence. Operation for which, there is no basic cause that adds value can be eliminated at once.
3. If the basic is identified, it can be questioned in two ways.
a. Disregard the basic cause:
b. Apply "why?" questioning:
Illustrations
Packing Lettuce in Cartons: In packing lettuce, ice was interspersed between the layers of lettuce in wooden crate. In the changed method, fiberboard carton was used and it was quickly cooled to 36 to 38 degree farenheit in a vacuum cooling plant. No ice is required and it saved $3 per box. The fiberboard carton was also cheaper than wooden crate.
Code Dating Cartons: Four dates were being stamped on the each carton of soap. The reason for it is know when the carton of soaps was manufactured. Only one date is sufficient and rest three were eliminated.
Splicing Insulated Wires: In the cables of the Bell system 250,000,000 splices were done between wires. The earlier method was to skin the insulation of the two wires to be connected, twisting the two bare wires together and slipping an insulation sleeve over the twist. In the revised method, a pneumatic tool is used that flattens and connects the two wires along with a phosphor-bronze tang. Skinning and twisting the bare wires was totally eliminated.
B. Combine Operations
Normally it is thought more efficient to break down a process into many simple operations. But, this division of labor may have been carried too far resulting in excessive handling of materials, tools and equipment. Such situations can be identified and corrected by simply combining two or more operations by making some changes in the operations.
Illustration
An operator was loading the input Wood at input side of the molding machine. At the output end another operator was collecting the output and loading them in the truck. Two short conveyors were installed that made it possible for one operator to take out and incoming material and load the outgoing material on the same truck. For facilitating this, in the truck four parts were made and only three were loaded with raw material. This arrangement reduced the number of trucks needed and also saved floor space.
B1. Divide/Split
Along with the evaluation of combine, evaluation of divide can be done. Combine and divide are examining the design of the process into operations which require a change of set up. A change of tool can also be thought of as change in set up. As part of process analysis, which looks into the operations design or the number of operations in the process, the need for further division of the operation also needs to be evaluated.
Can the present operation be divided further to increase productivity with present set of machines or new set of machines?
C. Change the Sequence of Operations
When production is scaled up, the original method may still be retained even though it can be improved. For this and for other reasons it is desirable to examine and question the order in which the various operations are performed.
Illustration
In one plant, small assemblies were made on semiautomatic machines in department A, were stored in department B, 10% of the assembles were inspected in department C, and were packed for shipment in department D. Whenever there were more defects found in 10% inspection, all the stock was inspected till the production system was adjusted to eliminate the defect.
The system was modified, and the inspectors were placed in department A at the end of each line and were asked to inspect 10% as production is coming out of the line. Whenever excessive defects were found, the line was corrected immediately. This simple arrangement was easy and inexpensive and saved the company tens of thousands of dollars in inspection and also reduced the number of scrapped parts.
D. Simplify the Necessary Operations.
After the steps of Eliminate, Combine, Rearrange are done, the step Simplify is taken up. In the step the operation is simplified or improved. In other words, the over-all process level issues are examined first and then the detail of the operation is studied.
Question every thing about the job being done using machines and operators in the operation under investigation. The design of the product, the material being used, tools and equipment, machining processes used, jigs and fixtures, speeds and feeds, the working conditions, the operator and the manual motions used. This activity has a more detailed analysis technique termed as operation analysis.
Simplifying or improving the operation by doing engineering and managerial actions takes bulk of time in process productivity improvement. Detailed information on each step or operation in the process needs to be collected. This information is to be for machines and operators as the main resources used. Machine effort industrial engineering and human effort engineering are important components of process productivity improvement. To do improvement of the existing machine effort, industrial engineers have to keep themselves abreast of relevant engineering knowledge. Knowledge management is very important for IE departments. Creativity is to be used to identify the engineering development, tool or accessory, method or machine that will improve productivity in an operation.
Operation analysis book was written by Maynard to explain the detailed analysis involved in the simplification step.
Ask questions
Regarding equipment. Which equipment is being used? What cutting tools and accessories are being used? Number of questions need to be asked regarding machine and its work. For the current engineering knowledge, the appropriate items are to be selected and questions are to be asked whether it is more productivity to replace the current methods, tools and machines. (Machine Work Study or Machine effort industrial engineering)
Regarding operators. Who is doing the job? Who could do it better? Can a person with less skill do the job? Can we change the job so that less skilled person can do the job? (Human Effort Industrial Engineering)
How is the work done? Eliminate, combine, rearrange and simplify motions.
Barnes has clearly indicated that as part of process improvement or operation improvement, the automatic method of doing each element has to be developed and it is to be compared with manual method and machine-man method. Industrial engineer have to ask the question for each element during every process improvement study, when an automatic method can be developed and whether its cost is less than the present method of doing the element (With thanks to Prof. Shahrukh Irani)
Comment by Prof. Shahrukh Irani in a Linkedin Topic
ECDRS ..... Prof, what is your bibl source for this plz? Am curious about where split comes. And you left out automate at the end?
My answer.
Shahrukh Irani, Thank you for noticing it and commenting. ECDRS. D is added by me. I feel both combine and divide can be thought of by the industrial engineer. We do it in assembly line balancing. As required, we combine basic activities to create the task for each work station. Some times we split them to increase output. Thank you for pointing "automate." In the simplify step, automate has to be there compulsorily. It has to be the primary industrial engineering task. To develop automatic mechanism for each engineering engineering element in an operation whenever possible. It has to be economically feasible.
Ask Questions. Process Analysis - Questions/Check List
Book: Productivity Through Process Analysis by Jinichi Ishiwata
Four basic principles for process improvements
1. Eliminate processes whenever possible.
2. Simplify them. (Operations analysis)
3. Combine them
4. Change the sequence
Questions
1. Eliminate - Can this be eliminated? What will happen if we eliminate it?
2. Simplify - Can this made simpler? - the task of operations analysis
3. Combine - Can two or more processes be consolidated into one?
4. Change sequence - Can this operation be switched with another one?
Big three problems in process: waste, irrationality, and inconsistency.
5W1 Analysis for Product Process Analysis
Operation - Why - Who is doing it - Which machine - where - when - How
Can the layout be changed to reduce the transportation?
Can number of inspections be reduced?
Are any inspections unnecessary?
Can necessary inspections be done while the product is being processed?
Can number of delays be reduced?
Book: Motion and Time Study - Improving Productivity by Marvin E. Mundel
Checklist for Process Chart - Product Analysis
Basic principles
1. Reduce number of steps.
2. Arrange steps in best order.
3. Make steps as economical as possible (operation analysis).
4. Reduce handling.
5. Combine steps if economical.
6. Shorten moves.
7. Provide most economical means for moving (operation analysis)
8. Cut in-process inventory to workable minimum
9. Use minimum number of control points at most advantageous places
Questions
1. Can any step be eliminated?
a. as unnecessary. (Ask: Why is it done?)
b. By new equipment (Ask: Why is present equipment used?)
c. By changing the place where it is done or kept. (Ask: Why is it done there?)
d. By changing the order of work. (Ask: Why is it done in its present order?)
e. By changing the product design. (Ask: Why is it made as it is?)
f. By changing the specifications of the incoming supply. (Ask: Why is it ordered in its present form or used at all)
2. Can any step be combined with another?
a. By changing the specifications of supplies, or of any raw material?
b. By changing the design of the product, even if only the tolerances?
c. By changing the order of the steps of production, or doing inspection at any operation station so as to avoid an inventory of faulty product?
d. By changing the equipment used (e.g., using a multifunction machine, or creating a multimachine work cell served by a single person or by a robot)/
e. By redesigning one or more work places?
3. Can steps be rearranged so as to make any shorter or easier?
4. Can any step be made easier?
Book: Motion and Time Study: Design and Measurement of Work by Ralph M. Barnes
Following approaches should be considered in developing preferred work method
Methods improvement is carried out by questioning every thing about the job being done now.
Questions are:
1. What is done? Why should it be done (Find the purpose of the operation)
2. Which machine is being used? Why? 3. Who does the work? Why this person? 4. Where is the work done? Why that place? 5. When is the work done? Why at that time and the step in the process? 6. How is the work done? Why is it done this way? Barnes highlights that a careful analysis and the application of principles of motion economy is needed in this step.
Process Productivity Analysis and Process Productivity Engineering.
There is a need for extending the steps in the process analysis of existing processes. Like in Value Analysis/Value Engineering, we need to identify two steps in process analysis. Process Productivity Analysis and Process Productivity Engineering.
Process Productivity Analysis
Eliminate
Is there any knowledge now which indicates that the operation can be totally eliminated?
Search
Is there a new technology that may increase the productivity of this operation?
Combine
Can the operations in sequence in the present process be combined with the use of existing machines only for increase in productivity? Can they be combined with different set of machines for increasing productivity?
Divide
Can the present operation be divided further to increase productivity with present set of machines or new set of machines?
Rearrange
Can this operation be done somewhere else in the sequence for increase in productivity?
Rearrange - Combine
After rearranging, can it be combined with other operation in sequence?
Rearrange - Divide
After rearranging, can it be divided for increase in productivity?
Simplify
Can we change tools, work holders, jigs and fixtures etc. and modify the operation to make it more productive?
Adopt new technology
Is there an opportunity to adopt new technology, machine for this operation?
The productivity analysis done to answer the questions will indicate the scope for redesign of the process. This will be done in the step of process productivity engineering/operation productivity engineering.
Updated 20.8.2023, 17.3.2022, 4.10.2021, 20 August 2021, 28 April 2021, 6 August 2020, 8 March 2020, 8 January 2020, 3 July 2019, 2 June 2019, 16 August 2018, 12 June 2016, 3 Sep 2013
Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."
I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.
Supporting Information.
Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.
Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.
The prime contribution of IE has to be cost reduction through productivity improvement.
Machine Work Study - Machines and Tools Related Efficiency/Productivity Analysis
The machines, accessories and tools used to perform the operation needs to analysed logically to identify process improvement opportunities to increase productivity and engineering has to be done to modify the process to use new equipment, accessories, tools and modified equipment, accessories or tools.
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Some Questions regarding Machines, Tools and Equipment - Introduction
Can a foot device be arranged so that an operation now performed by hand can be done by foot?
Are raw materials properly placed? Are there racks for pans of material and containers for smaller parts? Can the parts be secured without searching and selecting? Are the most frequently
used parts placed in the most convenient location? Are the handling methods and equipment satisfactory? Would a roller or a belt conveyer facilitate handling? Can the parts be placed aside by means of a chute?
Is the design of the apparatus the best from the viewpoint of manufacturing economy? Can the design be changed to facilitate machining or assembly without affecting the quality of the apparatus? Are tools designed so as to insure minimum manipulation time? Can eccentric clamps or ejectors be used?
Is the job on the proper machine? Are the correct feeds and speeds being used? Would a bench of special design be bettor than a standard bench? Is the work area properly laid out?
Such questions examine the machines, equipment and related aspects.
Relation of Machine Work Study - Industrial Engineering to Quality. Industrial Engineering and a method of it, machine work study focus primarily on eliminating waste and reducing costs. In so doing, it is imperative that nothing should be done to impair the quality of the finished product or
its saleability. F.W. Taylor particularly stated it explicitly and also in product industrial engineering method, value engineering L.D. Miles stated it explicitly. Industrial engineers exist and do their work to enhance the competitive position of his company's products, he quite naturally must take a keen interest in the factor of quality. Products of superior quality outsell products of inferior quality, other things being equal; hence, an improvement in quality is always desirable and efforts to preserve it are made by IEs. Industry engineer is quite likely to discover ways of making the product better. In addition, because he eventually sets up working methods that are easy, efficient methods, and because he trains all operators to follow those methods, a higher and more uniform quality of workmanship results than where each operator is left to develop methods for himself. As a result, therefore, methods study either of machine work or human work tends to raise the quality of the finished product.
Industrial engineers examines every detail in the engineering system or production system, that is likely to affect operating time and cost. Experience leads to the recognition of the points at which the greatest possibilities for improvement lie, and the major part of the study will be made on them.
In a machine shop, the term "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 " workplace 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. For the sake of clearness, the more exact phraseology will be used throughout this book, although the workplace layout, the setup, and the make-ready and putaway operations are all considered under item 6 on the analysis sheet.
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 hi 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 no-nrepetitive 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.
The tool equipment used on any operation is most important, and it is worthy of careful study. Repetitive jobs are usually tooled up efficiently, but there are many opportunities for savings
through the use of well-designed tools on small-quantity work which are often overlooked. For example, if a wrench fits a given nut and is strong enough for the work it is to do, usually
little further attention is given to it. There are many kinds of wrenches, however. The list includes monkey wrenches, openend wrenches, self-adjusting wrenches, socket wrenches, ratchet wrenches, and various kinds of power-driven wrenches. The time required to tighten the same nut with each type of wrench is different. The more efficient wrenches cost more, of course, but for each application there is one wrench that can be used with greater over-all economy than any other. Therefore, it pays to study wrench equipment in all classes of work. The same remarks apply to other small tools.
Jigs, fixtures, and other 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.
Under the head of "Setup," a description is given of the workplace layout and the arrangement of tools, fixtures, and so on. This description may be written if the setup is simple, but a photograph will be found more useful and infinitely clearer if the arrangement is at all complex. It would require several hundred words, for example, to describe the workplace layout pictured in Fig. 44, and even then it would be difficult to visualize the layout in its entirety. The picture tells the story at a glance and shows clearly the arrangement of the workplace at the time of the analysis.
When the machine setup is being considered, the tool equipment also is examined. The tools and the setup are so closely related that it is difficult to separate them, and nothing is gained by attempting to do so. In examining the setup of the milling machine, it is noted at once that a standard vise and a special side cutter are used. A description of these items of tool equipment is therefore recorded. Often, when tool equipment is examined with thoughts of job improvement uppermost in mind,
suggestions for improving the tool equipment will immediately occur to the analyst. These should be recorded as they arise, even though they may reoccur during the consideration of items 7 and 9. It is better to duplicate the small amount of writing involved than to risk the possibility of overlooking a good idea.
More Detailed Questions on Machine, Equipment and Tools
The tools and equipment used to perform the operation needs to analysed logically. The following questions are the sort that will lead to suggested improvements:
1. Is the machine tool best suited to the performance of the operation of all tools available?
2. Would the purchase of a better machine be justified?
3. Can the work be held in the machine by other means to better advantage?
4. Should a vise be used?
5. Should a jig be used?
6. Should clamps be used?
7. Is the jig design good from a motion-economy standpoint?
8. Can the part be inserted and removed quickly from the jig?
9. Would quick-acting cam-actuated tightening mechanisms be desirable on vise, jig, or clamps?
10. Can ejectors for automatically removing part when vise or jig is opened be installed?
11. Is chuck of best type for the purpose?
12. Would special jaws be better?
13. Should a multiple fixture be provided?
14. Should duplicate holding means be provided so that one may be loaded while machine is making a cut on a part held in the other?
15. Are the cutters proper?
16. Should high-seed steel or cemented carbide be used?
17. Are tools properly ground?
18. Is the necessary accuracy readily obtainable with tool and fixture equipment available?
10. Are hand tools pre-positioned ?
20. Are hand tools best suited to purpose?
21. Will ratchet, spiral, or power-driven tools save time?
22. Are all operators provided with the same tools?
23. Can a special tool be made to improve the operation?
24. If accurate work is necessary, are proper gages or other measuring instruments provided?
25. Are gages or other measuring instruments checked for accuracy from time to time?
Because of the wide variety of tools available for different kinds of work, this list could be extended almost indefinitely with specific questions. Foundries, forge shops, processing industries, assembly plants, and so on all have different kinds of tools, and different questions might be asked in each case. The list given above, drawn up principally and by no means completely for machine work, will indicate the kind of searching, suggestive questions that should be asked. A special list might well be drawn up by each individual plant to cover the kind of tools that might be advantageously applied upon its own work.
Equipment.—A study of existing equipment may suggest changes and improvements or repairs. Machine operations should be those which combine economy with uniformity of standard quality. Standard times and methods are dependent upon standardization of machines within each class (using the best machines for operations), and the maintenance of normal conditions with respect to their upkeep. (https://nraoiekc.blogspot.com/2019/07/operation-study-arthur-g-anderson-1928.html)
Tools: For the most part, it may be said that the tools do function properly from the standpoint of the finished job. But from a productivity angle, industrial engineer has to examine the productivity possible from the existing tool and has to compare it with productivity possible from alternative tools to decide the appropriate alternative. Industrial engineers have to receive information regarding new tools from purchase department, representatives of organizations selling tools, consultants and technical literature being procured by the company. Industrial engineers have to monitor technology and engineering developments on a continuous basis and have to set up libraries for their departments or there have to sections within the company library for industrial engineering materials.
Similarly, whether, the jigs and fixtures etc. function properly from a motion-economy standpoint is subject to evaluation by industrial engineers. The tool designer is usually more concerned with making a tool that will do a certain job than he is with the motions that will be required to operate it. Therefore, unless he has made a study of the principles of methods engineering or has had the importance of motion economy impressed upon him in some other way, it is probably safe to say that the motions required to operate the tool are the last thing he thinks of.
There can be alternative work holding methods that require less time to use. The common machine vise takes a lot of time set up the work piece. The quick-acting vise is far superior. On machining operations where the cutting time is short, it will save 20 to 40 per cent of the total operation time. The jaws of the vise are cam-actuated. They are tightened by moving the two levers in opposite directions which conforms to the principles of motion economy. They hold securely without hammering on the levers. They are adjustable to a variety, of sizes of work. In short, they possess many real advantages over the standard vise.
Suggestions that will improve the quickness of operation of tools should be made to tool designers as they are conceived. If they are presented with a summary of the yearly saving in dollars and cents that they will effect, interest in better tool design from a use-time standpoint will be aroused. Tool designers as a group are clever and ingenious, and if the importance of reducing the time required to operate tools is clearly demonstrated, they will be able to assist materially toward this end by producing more suitable designs.
Hand Tools. Too little attention to the hand tools used upon even the more repetitive operations. There is choice available in even simple hand tool as a screw driver from productivity point of view. Screw drivers vary widely in design, and some are more suitable than others. Screw drivers come in a number of different styles. There are the solid screw drivers, the ratchet screw drivers, the spiral screw drivers, and the various types of power-driven screw drivers. Even the variation among screw drivers of a given type is tremendous. They vary in size, of course, but in addition they vary in about every other way imaginable. The handles vary in diameter, length, cross section, shape, and nature of gripping surface. Points are wide, narrow, blunt, sharp, taper toward the point like a wedge, or are narrower right above the point than at the point. A lately introduced type has a special point to fit a special screw head which offers many advantages. When all these factors are considered, the choice of the screw driver is important from efficiency or productivity point of view.
There is a screw driver that is better for a given application. For medium work with the conventional screw-head if a solid screw driver is to be used, the one with the largest cylindrical handle which can be comfortably grasped by the operator should be chosen. The handle should, of course, be fluted to prevent slipping. The diameter of the handle will vary with the size of the operator's hand, but two or three standard sizes are sufficient for most hands. The diameter of the handle should be large, because the larger the handle within the limits of the human hand, the more easily can a given torque be applied. To prevent slipping, the point should not be wedge-shaped but should be slightly larger at the point than just above it.
If many screws have to be driven, a ratchet, spiral, or power-driven screw driver can often be used to good advantage. If many screws of the same size are to be driven, a piece of hardened tubing slipped over the end of the screw-driver point will make it much easier to locate the screw driver in the slot.
The same sort of searching analysis can be made for every type of hand tool used. Wrenches, hammers, chisels, saws, scissors, knives, pliers, and drills all come in a great variety of styles. Standardization on a limited number of the better styles within a plant will tend to prevent the use of the more inefficient tools. Tests must be made to determine which styles are actually the most efficient. Time taken for the element is the decision criterion.
Judgment must be used, of course, in determining the amount of time that can economically be spent in analyzing the tools used on any one job. Unless a job is highly repetitive, it will not pay to try to discover the best screw driver for that particular job. Instead, the whole subject of hand tools including screw drivers may be investigated in a general way, and good tools may be adopted for standard use. The tool supply should be plentiful, for it is not uncommon to see operators not only using the wrong size of tool, but also using a chisel for a hammer or a screw driver for a crude chisel merely because the proper tool is not available. An insufficient supply of proper tools may reduce the amount expended for tools, but it will prove costly in the long run.
Setup - Workplace Layout
The order in which tools are set up in a turret lathe, for example, will determine the order in which the various machining operations are performed. The position in which material is placed with respect to the point of use will determine the class and the length of the motions required to secure it.
Before any work can be done, certain preliminary or "make ready" operations must be performed. These include such elements as getting tools and drawings, getting material and instructions, and setting up the machine or laying out material and tools about the workplace. When the operation itself has been completed, certain clean up or "put-away" elements must be done such as putting away tools and drawings, removing finished material, and cleaning up the workplace or machine.
Questions on "Make-ready" and "Put-away" Elements. The procedure followed to perform the
'make-ready' and "putaway" elements may carry the operator away from his workplace and should be questioned closely. In small-quantity lot work, these operations may consume more time than productive operation work. The necessity for trips to other parts of the department should be minimized.
Questions which will lead to suggestions for improvement of "Make-ready" and "Put-away" Elements are:
1. How is the job assigned to the operator (job card or ticket issue to operator)?
2. Is the procedure such that the operator is ever without a job to do (delays in giving job ticket)?
3. How are instructions imparted to the operator?
4. How is material secured?
5. How are drawings and tools secured?
6. How are the times at which the job is started and finished checked?
7. What possibilities for delays occur at drawing room, toolroom, storeroom, or time clerk's office?
8. If operator makes his own setup, would economies be gained by providing special setup men?
9. Could a supply boy get tools, drawings, and material?
10. Is the layout of the operator Js locker or tool drawer orderly so that no time is lost searching for tools or equipment?
11. Are the tools that the operator uses in making his setup adequate?
12. Is the machine set up properly?
13. Is the machine adjusted for proper feeds and speeds?
14. Is machine in repair, and are belts tight and not slipping?
15. If vises, jigs, or fixtures are used, are they securely clamped to the machine?
16. Is the order in which the elements of the operation are performed correct?
17. Does the workplace layout conform to the principles that govern effective workplace layouts?
18. Is material properly positioned?
19. Are tools prepositioned?
20. Are the first few pieces produced checked for correctness by anyone other than the operator?
21. What must be done to complete operation and put away all equipment used?
22. Can trip to return tools to toolroom be combined with trip to get tools for next job?
23. How thoroughly should workplace be cleaned?
24. What disposal is made of scrap, short ends, or defective parts?
25. If operation is performed continuously, are preliminary operations of a preparatory nature necessary the first thing in the morning?
26. Are adjustments to equipment on a continuous operation made by the operator?
27. How is material supply replenished?
28. If a number of miscellaneous jobs are done, can similar jobs be grouped to eliminate certain setup elements?
29. How are partial setups handled?
30. Is the operator responsible for protecting workplace overnight by covering it or locking up valuable material?
It may be seen that an analysis of "make-ready " and "put-away" operations covers a rather wide field. Some are related to operator work also. But they are mentioned here as they form part of set up and make ready the equipment step. Some of the steps are standard for every job; and after it has been thoroughly analyzed for one job and improved as much as possible, it need not be considered so carefully again. Therefore, the subject should receive a thorough analysis at least once, and preferably so that irregularities will not be permitted to creep in and become standard practice more often, say at least every 6 months.
Make Ready - Allocation of Jobs and Giving Instructions
The methods followed in giving out jobs differ widely throughout industry. Some procedure for telling an operator what job he is to work upon next must be provided. In some cases, material to be processed is placed near the work stations of a number of operators. The operators go to the material and themselves select the jobs they wish to do. This procedure has certain serious disadvantages. Some jobs are more desirable from the operator's standpoint than others. They may be easier or lighter or cleaner, some jobs may carry looser rates than others, thus permitting higher earnings for a given expenditure of effort. If the operators are allowed to pick their own jobs, those who have stronger characters or are physically superior are likely to get the best jobs, and the weaker must take what is left. The least desirable jobs will be slighted altogether as long as there is any other work to do, which causes these jobs to lag and become overdue. There is no assurance that the operators will get the jobs for which they are best suited, considering the group as a whole.
Where the group system is used, these difficulties are minimized, but principally because the group leader assumes a function of management and hands out the work to the members of his group. The group knows that sooner or later it will have to handle all jobs sent to it, and so there is less tendency to slight undesirable work. In the interests of good performance as a group, the skilled men will do the more difficult jobs, leaving the easier tasks to the new or less skilled men. In short, the entire
situation is changed; when the group system is used, the selection of jobs may be left to the workers themselves.
Another common procedure is for the foreman to assign jobs. The foreman knows the work, and he knows his men. Therefore, he is in a good position to distribute the work so that it will be performed most effectively. The chief difficulty with this arrangement is that the modern foreman is so loaded
with duties and responsibilities that he often does not have time to plan his work properly. In moments of rush activity, instead of always having several jobs ahead of each operator, he is likely
to assign jobs only when men run out of work. When a man comes to him for a job, he is likely to glance at the available work and assign the first job he sees that he thinks the operator can do. It may not be the one best suited to the operator; perhaps even more important, it may not be the job that fits most important from a delivery standpoint.
With regard to this last point, in order to get work through the shop on schedule, the planning or production department must work closely with the foreman. Usually, chasers or expediters call to the attention of the foreman the job that is required next. If there are only a few rush jobs, the foreman may be able to have them completed as desired. In times of peak activity, however, when the shop is overloaded, all jobs become rush jobs. Each expediter has a long list of jobs to be completed at once.
Considerable pressure is brought to bear upon the foreman to get out this job and that, and he is likely to find himself devoting time to detailed production activities that could better be spent on taking steps to relieve the congestion.
In most up-to-date plants, the foreman is regarded as a very important man. He is called into conferences and meetings and often participates in educational programs. He is, therefore, away from his department at intervals and, if he has the responsibility of giving out jobs, must give out enough work to last until he returns. If he is called away suddenly or is unexpectedly detained, operators will run out of work. Then they either lose considerable time and hence money which creates dissatisfaction, or they help themselves to another job. If this latter practice is countenanced in a time of emergency, there is a danger that it will soon develop into a standard practice. If men get their own
jobs, the foreman is relieved of a certain amount of work and, if he is otherwise overloaded, may tend to allow operators to select their work with increasing frequency, until all the advantages gained by having the foremen hand out work are lost. The decisions with respect to the order in which jobs are to be put through the shop are made by the planning or production department. Since they know in what order jobs are wanted, it would, therefore, appear that a representative of this department should cooperate closely with the foreman in giving out the work. The foreman may specify the men who are to work on each job when the orders first reach his department, and a dispatch clerk may give the work to the assigned men in the order of its importance from a delivery standpoint. This arrangement is followed in a number of plants.In typical dispatching station system under the control of the production department, time tickets for each operation on each job are made out in a central planning department and are marked with the date the operation should be completed. The dispatcher arranges these time tickets in his dispatch board. Each group of machines within the department is assigned a pocket the dispatch board, and each pocket has three subdivisions.
The time tickets are received considerably in advance of the material. They are first filed in a subdivision of the proper machine pockets called the "work ahead " division. The number of tickets in the "work ahead" divisions at any time gives a rough idea of the load on the shop. When material for a given job enters the department, the dispatcher is notified. He then moves the time ticket for the first operation from the "work ahead" division to the "work ready " division. The time tickets in the latter pocket then show the jobs that are actually ready to be worked upon. When an operator completes one job, he goes to the dispatcher's station and turns in the ticket for that job. The dispatcher then gives him another job by taking the time ticket from the "work ready" division and handing it to him. He selects always the ticket marked with the date nearest to the current date and thus gets the work done in the desired order.
When the operator has received notification in one way or another of the job he is to do, he must next secure drawings, tools, and material. The way in which this is done also varies widely. In some cases, the operator must hunt everything for himself. In others, he goes to a tool- or drawing-room window
and waits while an attendant gets what he requires. In still other cases, everything is brought to him, and he does not have to leave his work station. The exact procedure that is followed will depend upon existing conditions; but if it is possible to work out an economical system for furnishing the operator with what he needs at his work station, it is desirable to do so. Besides reducing costs, this procedure increases the amount of time the equipment is utilized and thus increases the productive capacity of the plant. Often a low-rated worker can do the errands of the operators and bring tools, drawings, and materials.
Where the group system is used and no supply boy is available, the group leader commonly gets all necessary supplies and tools. By getting the necessary items for several jobs at one time, he is
able to effect economies.
A conveyer system can be employed and the jobs may be dispatched by the production department in the order wanted, and all material, tools, and drawings can be sent out at the same time on the conveyer. Thus the amount of time spent by the operator in getting ready to make the setup is reduced to a minimum.
The manner in which instructions are furnished with regard to how the job should be done is worthy of careful consideration. In many cases, no instructions at all are given. The operator is supposed to be familiar enough with the work to know how to do it. If not, he may ask the foreman. When no definite instructions are given or when the foreman gives only brief general advice, the method that the operator follows is likely to be one of his own devising which may or may not be effective. The fact that in so many cases different operators follow different methods in doing the same operation may be traced directly to insufficient instruction. To secure effective performance, the best method must first be worked out and then taught.
Some plants employ instructors or demonstrators to perform the teaching function. If these men know the best methods themselves and are good teachers, good results will be secured. Too often, however, the instructor is merely an experienced operator who knows only such methods as he himself used before he was promoted. Even though he was a highly skilled operator, the chances of his knowing and being able to impart a knowledge of the best methods are small, unless he has received additional
training himself in the principles of methods engineering. If he is a machine instructor, he is likely to teach feeds and speeds and the best way to grind tools, mentioning only briefly, if at all, the arrangement of the workplace and the motions that should be used.
Feeds, speeds, and the grinding of tools all are important, of course, but they constitute only part of the method. A lathe operator, for example, was engaged in turning shafts in an engine lathe. Each shaft had to be stamped with a number. The operator would remove a finished shaft from his lathe, turn to a bench, stamp the number, set aside the shaft, pick up another, and return to his machine. The turning required a long cut under power feed. A much better method is as follows: While a cut is being taken, the operator gets the next shaft to be machined; he places it on the machine ways in a convenient position; as soon as the cut is taken, he removes the finished shaft and inserts the other; he starts the cut and then while the machine is running, stamps and lays aside the finished shaft. Thus, the machine runs nearly continuously, and idle time on the part of both the operator and the machine is reduced. Instruction in some manner with regard not only to feeds and speeds but also with
regard to the proper motion sequence would be necessary to correct his difficulty.
Instruction sheets can be used to instruct operators and, under certain conditions, their use is not too costly.
Setup.
The setup of the machine and of any tools, jigs, or fixtures used should be studied in detail. The correctness and the adequacy of the setup should first be considered, followed by a brief review of the methods employed to make it. The correct setup is fixed by the nature of the operation, the nature of the part, the requirements of the job, and the mechanical features of the machine. Sometimes, it is possible to do a job in more than one way, and care should be taken to ascertain
that the best way is being used.
Many ingenious ways are tried to extend the time for doing a job during the course of a time study. Some changes are done in setup like belts may be loosened so that they slip under load, or a carbon steel cutter may be used in place of a higher speed alloy. In one incident of a time study on a milling-machine operation, the operator loosened the bolts slightly that held the vise to the machine table. When the cut was taken, the vise very slowly slid along the surface of the table, and of course, the time for taking the cut was extended. The time-study engineer, checked the feed and length of cut and found a discrepancy between his data and what the cutting time should be. It was difficult to detect at first where the trouble lay, but the vise eventually reached a point where it was noticeably out of position. Then it was reset it properly, and then restudied the job. Therefore industrial engineers have to examine the setuup and described it adequately in the standard process sheet.
When the setup is being made, certain tools are usually required. These should be suitable for the purpose. If each operator must make his own setup, he should be provided with the necessary tools. If only one or two wrenches are furnished to a group of 10 operators, for example, the time lost in hunting the wrenches and in waiting for a chance to use them will usually far offset the cost of additional equipment. If setup men are employed to setup machines ahead of the operators, their setup work is to them fairly repetitive work, because they are performing the same elements day after day. It will therefore be desirable to treat it as such and to furnish the setup men with special-purpose quick-acting tools.
The Workplace Layout.
The improvement of the layout of the workplace of the industrial worker is too often overlooked as
a means for effecting operating economies. The layout of the workplace partly determines the method the operator must follow in doing a given task, and it almost wholly determines the motions he must employ. For this reason, the principles which affect workplace layouts will be discussed briefly.
Two general concepts underlie workplace layouts. The first has to do with the classes of motions that a human being can make. There are five general classes, as follows:
1. Finger motions.
2. Finger and wrist motions.
3. Finger, wrist, and forearm motions.
4. Finger, wrist, forearm, and upper-arm motions.
5. Finger, wrist, forearm, upper-arm, and body motions.
It is usually stated that motions of the lower classes can be made more quickly and with less expenditure of effort than in motions of the higher classes.
The arc which bounds the maximum working area is traced by the fingers when the arm, fully extended, is. pivoted about the shoulder.
The principles of efficient work areas should be applied to all lines of work, for they are universal. It is customary to think of them in connection with bench operations; but they can and should be applied to the arrangement of tools and materials around machines or on work such as molding, forging, and the like, and to the arrangement of levers, hand wheels, and so on, when designing machine-tool equipment.
In work place layout, one of the most glaring faults commonly encountered lies in the arrangement
of containers of raw and finished material. If the placement is left to the operators, a body motion will often be used for getting or laying aside material, because the operator sets the material containers on the floor or the bench or in some other place that is available but not particularly convenient. Industrial engineers can design an arrangement that minimizes motions and fatigue and thus save time and increase productivity.
Put Away. The put-away elements usually consume less time than the make-ready elements. Tools are put away, the setup is torn down, and the workplace is more or less thoroughly cleaned up. Usually, some of the put-away elements can be combined with some of the make-ready elements for the next operation. Tools for one operation, for example, may be returned to the tool room when the tools for the next operation are obtained. The procedure that will prove most economical for the put-away
elements will depend to a large extent upon the manner in which the make-ready elements are performed. Where a number of similar operations are performed on a machine, it is sometimes possible to use 'the same or part of the same setup on two or more jobs. A part that is common to
several assemblies may be ordered separately for each and appear on several different orders. If these orders are grouped, one setup will care for them all. Again, in milling-machine work, for example, it may be possible to use the same cutter for several different jobs. The elements of "get cutter from
toolroom; "place cutter on machine, "remove cutter from machine/ and "return cutter to toolroom" will thus be performed but once for the several jobs.
Where possibilities of this sort exist, provision should be made when setting up the make-ready and put-away routine so that the economies will be made. If the operator does not know what job he is to do next, if he must completely tear down his setup before going for another job, and if neither the foreman nor the dispatcher attempts to group similar jobs, advantage cannot be taken of partial setups. This is wasteful, of course, and every attempt should be made to secure the benefit of partial setups. Whether or not the operator is paid for the complete setup or only for that part which he actually makes depends upon the difficulty in controlling setups and upon whether or not the saving is due to the operator's own initiative. In either case, more time is available for productive work which is a distinct gain.
