PERANCANGAN SISTEM KERJA DAN ERGONOMI (IEI2H3)

2. WHOLE PROCESS CHART

Prepared by:
Team teaching (DCO, YGN, IKP, ATU, MRY, YFN)

Prodi S1 Teknik Industri

Fakultas Rekayasa Industri
Universitas Telkom
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 5+ Systematic steps in problem solving
(Working methodology improvement)
• A systematic approach to find an easier way to finish a job

1. Problem identification

2. Problem analysis

3. Searching for solution alternatives

4. Evaluation of the alternatives

5. Decision taking

6. Solution implementation

7. Review
Source: http://inoholics.com/

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 SYSTEMATIC PROCEDURE OF WORK
SYSTEM DESIGN
1.
7.
Identify the
Review
problem

6. 2.
Solution Analyze the WORK PROCESS
implementation problem CHARTS

5. 3.
Take the Search for
optimal solution
solution alternatives
4.
Evaluation SOURCE: http://venivi.com/

alternatif
solusi 3
Introduction to Work Process Chart (1)
Tools used for describing
work activities (usually
production) clearly and
systematically
Function: (eliminate) the
unnecessary activities,
(combine), (simplify),
(re-arrange)

Tools used for

communicating work
activities.

Contains of information
needed for analyzing and
improving a work method
Source: http://www.city-data.com/

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Introduction to Work Process Chart (2)
A standardized description of a
work. It is constructed to be
understood by all workers and all
people in needs

A visual instrument, consists of all

phenomenon occurred in a work
system. The production process
from the raw material to the
finished product are described in a
work process chart Source: http://www.city-data.com/

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Work Process Chart Symbols (1)
The symbols used in Work process
chart were developed by Gilberth
From the original 40 symbols were simplified to 4
symbols.

In 1947, the American Society Of Mechanical

Engineering (ASME) convert the 4 symbols to be 5
symbols

The is one additional symbols represent the

combination of activities

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Work Process Chart Symbols (2)
Operation
Idle time
Transportation

Inspection
Independent working time
Waiting

storage
Combined working time
Operation and inspection
Additional Symbol
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Work Process Chart Symbols (3)
A large circle indicates an
‘operation’, such as: Drive nail mix Type letter

An Arrow indicates a
Move material Move material Move material
‘transportation’, such as: by truck by conveyor by carrying

A triangle indicates a Finished stock Protective

‘storage’, such as: Material in
factory store
stacked on filling of
pallets documents

A large capital D indicates Material in truck Papers

Wait for
‘delay’, such as: elevator
waiting to be waiting to be
processed tied

A square indicates an Examine material

Examine
Read system printed form
‘inspection’ such as: (quality/quantity)
gage on boiler of information
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Work Process Chart Types (1) OPC

Whole FPC
Macro Process Chart
WPC
Work FD
system
analysis AC
using
PROCESS
CHART
MMPC
Micro Local Process (PPM)
Chart
THPC
(PTKTK)
WORK IMPROVEMENT

Source: http://mljconsulting.com/

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 1. Operation
An object is transformed physically or chemically

Taking or giving some information into an event

Operation is the most often found in a process,

usually occurred in a machine or workstation

Some examples of Operation:

• Wood Scrapping using scrapper
• Steel hardening
• Assembly
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 2. Inspection
An object or tool is inspected either by quantity or
quality

An object is inspected according to the standard

Doesn’t transform a material into a finished good

E.g
• The dimension measurement of an object
• Examining the color of an object

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 3. Transportation

An object is moved without any operation involved

E.g
• The object is moved from mesin bubut (lathe) to scrapping machines to
have the next operation activity
• An object is moved from the first floor to the second floor through an
elevator

No operation and no inspection during the transportation

E.g
• The ceramic that was heated as moved on the conveyor → operation
instead of transportation. The moving of the ceramic is part of the of
the heating process (operation)

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 4. Waiting

An object worker or equipment wait without any

activity (usually for a moment)

Indicated that an object was left temporary

without any recording until it is needed

E.g
• An object wait for being processed or inspected
• A material wait for being transported to another place

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 5. Storage
An object is stored for quit a long time. Once that
object is needed, certain permission process was
conducted.

An object is stored permanently

Delay and storage is different according to

• Permission procedure
• Length of time

E.g
• Documents and recordings was stored in a locker
• Material was stored in a warehouse

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 6. Combination of activities
Operation and inspection were conducted in
the same time

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Work Process Chart (General Format)
Job description
Tittle
Existing Proposed

Figure of Work Process Chart

Main Body

Comparison between the existing and

Resume
the proposed process chart

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WHOLE PROCESS CHART

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1. OPERATION PROCESS CHART

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 1. OPC (Operation Process Chart)
Before detail research, the current process was identified using OPC
for every work activity.
OPC
• A diagram used for describing the steps of process conducted for an
object regarding the sequence of operation and inspection
Information found in OPC:
• The time spent
• The material used
• The place or machine used

The symbol used in OPC

• Operation
• Inspection
• Storage

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 1
Chart type &
identification
1. OPC
name (Operation Process Chart)
Materials
2 being OPC is used for:
processed,
in order Identifying machines
needed

Process
symbols, Estimating materials
in order needed

Identifying facility layout

3
Improving works

Training tools

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 OPC CONCEPT
Incoming Material

Material
Mt Mt Mt Mt

N: Number

The assembled part

O-N: Number of
assembled part
Part of the

operation

Order process operation

T O-N M

Main products
N: Number
I-N: Number of
Inspection
T I-N M

Machine or
time
place
Supporting Mt

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 Material Material
OPC

Components
Assembled
MODIFICATION

Component
Main
Process
Repetition

Other
alternatives
Source: http://dellakin-smith.com/

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 OPC ANALYSIS
There are four things need to be considered to obtain a good
work process using the OPS Analysis

1. Material
• Material alternatives (allowance and finishing process) must be
in accordance with function, reliability, service, and time.

2. Operation
• All alternatives feasible for machine processing or assembly
methods including the tools and equipment used
3. Inspection
• Having certain quality standard

4. Time
• Every alternatives of certain methods, equipment, and tools

Existing OPC vs proposed OPC

Source: http://www.translation-project-management.com/
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2. FLOW PROCESS CHART

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 FPC (Flow Process Chart)

Used for identifying/observing every component

of a product more completely and detail

It includes sequence of operation, inspection,

transportation, waiting, and storage of a process
as well as the time needed and the distance

What differentiate FPC from the OPC?

• It includes all basic activities

• Capable for analyzing every component more
completely
• It doesn’t involve the assembly process

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 FPC
(Flow Process Chart)

Identify the
Material material flow

FPC
Individual

People

Identify the
operator flow
Group →
WPC
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 FPC - MATERIAL

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 FPC - PEOPLE

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 FPC
FPC is used for:

Identifying the material or people

flow

Giving the information of finishing

time

Identifying number of activities

Conducting work methods

improvement

Identifying the place in where the

work inefficiency occurred
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 FPC ANALYSIS – Dot Check Technique
An effective technique for analyzing the FPC : using the following
questions for every event of an FPC

NO QUESTIONS NEXT ACTION

1 What is the objective?
2 Where is it done?
3 When is it done?
4 Who is doing?
5 How is it done?
Why? Removing the unnecessary activities.
Why? Integrate or modify the workplace.
Why? Integrate or change the time or process order.
Why? Integrate or change people.
Why? Simplify or improve the method.

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 FPC VS AC
The Flow Process Chart
can not be used for Assembly chart (AC)
describing the assembly • One type of whole process chart
job in a whole because that describes the assembly
in the assembly process, sequence of a product.
there is no material or The information obtained
workers flow. Thus, from an assembly chart:
other process chart is
• The components of a product
needed
• The assembly sequence of a
product
• The relation among components

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3. WORK PROCESS CHART

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 Work Process Chart
Tools used for describing
work activities (usually
production) involving
groups or workers who
works together, clearly and
systematically

Tools used for

communicating work
activities.

Contains of information
needed for analyzing and
improving a work method Source: http://www.city-data.com/
 WPC/WGPC 1 Chart type &
(Working identification
name
Group Process 2
Symbol
Chart) of WPC=
Symbol
WPC is used for: of FPC

Knowing Group activities 1 FPC =

part of
WPC
Independent or related
activities (delay time) WPC >1
parallel
Reduction of
cost/process production FPC

Improve completion time Change

/ process in
symbol=
change 3
Perform division of work Summary
in
activities
 Process Improvement in WPC

Eliminate workers
delay

Goal

• Reducing the production

cost
• Accelerating the processing
time
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4. FLOW DIAGRAM

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 Flow Diagram
Visualization of FPC in a layout. It provides the clearer visualization.

Tool of analysis to evaluate a layout using the principle of minimizing

the material handling activities

A visualization (in a certain scale) of a plan arrangement of a company

building that shows the location of all activities occurred in a FPC.

By identifying the object placement and movement, the moving

distance of an object can be minimized.

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 1
FD Chart type &
identification
(Flow Diagram) name

FD is used for:
Direction of flow material/person

Shorten the distance

An analysis to Improve workplace

layout

2
Symbol of FD = Symbol of FPC
Arrows=material flow direction
Different arrow = different flows

Source: http://mljconsulting.com/