CHAPTER 16 By

OPERATION CHARTS AND ROBOT Kanchala Sudtachat

e-mail: kanchala@sut.ac.th
ANALYSIS
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DEFINED
An operation chart is a graphic means of portraying the separable
steps of a person’s body members.
It is a schematic model of the method.

The Use of the Technique

Where the technique is used
The objective of a work method problem involving but a single
workstation.
The second step of the scientific approach is still
Analysis
Possessing known characteristics, or concerning whose performance
information is already available

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THE USE OF THE TECHNIQUE
Purposes served by the technique.
All manual work performed at a workplace can be studied.
No equipment is needed.
Significant improvements are usually possible
Not much time is necessary for the making of this type of analysis.
The results are often immediately installable.

Categorizing the types of jobs

The work has a single repeated cycle.
The work is cyclic, but there are several sub-cycles performed with
different frequency.
The work varies from cycle to cycle.
The task has no regular cycle

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THE STEPS SEPARATED WITH OPERATION
CHARTS

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CASE I: HAND-HOLE COVER ASSEMBLY
FOR DIESEL-ENGINE CRANKCASE
Aim The work was confined to on workstation; hence, the analyst
selected an operation chart as the most suitable person-analysis
technique.

Analysis The analyst, after becoming familiar with the job cycle,
selected the busiest hand, in this case , the left, and classified the first
step of that hand into the correct category from the symbols for
operation chart, and made an entry on a form such as used in Basic
Chart Form

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CASE I: HAND-HOLE COVER ASSEMBLY
FOR DIESEL-ENGINE CRANKCASE

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CASE I: HAND-HOLE COVER ASSEMBLY
FOR DIESEL-ENGINE CRANKCASE
Criticism An operation chart may be of an existing job or of a
job which has not yet started. Improvement is of three general kinds:
1. Checking the job environment
a) Ambient temperature
b) Ambient air
c) Glare, vibration, and noise
d) Exposure to energy sources

2. Checking the physical dimensions of the workplace

3. Checking the details of the job, as portrayed on the right- and
left- hand operation chart.

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CASE I: HAND- ① .

HOLE COVER
ASSEMBLY FOR
DIESEL-ENGINE
CRANKCASE

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CASE I: HAND-
HOLE COVER
ASSEMBLY FOR
DIESEL-ENGINE
CRANKCASE

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NORMAL WORK AREA

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 CHECKLIST FOR OPERATION CHART

Basic principles
จน ครบ ลดลง

A. Reduce total steps to a minimum

ดเ ยง นตอน การ งาน

B. Arrange in best order

C. Combine steps where feasible
ใ ายจน ไ ไหม
D. Make each step as easy as possible
.

E. Balance the work of the hands ลด holding ลง .

F. Avoid the use of the hands for holding

G. The workplace should fit human dimensions

11
ทำ
ทำ
ขั้
จั
ง่
รี
ด้
ห้
CHECKLIST FOR OPERATION CHART

Questions
1. Can a sub-operation be eliminated?
A. As unnecessary?
B. By a change in the order of work?
C. By a change of tools or equipment?
D. By a change of layout of the workplace?
E. By combining tools?
F. By a slight change of material?
G. By a slight change in product?
H. By a quick-acting clamp on jig, if jigs are used?

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CHECKLIST FOR OPERATION CHART

Questions
2. Can a movement be eliminated?
A. As unnecessary?
B. By a change in the order of work?
C. By combining tools?
D. By a change of tools or equipment?
E. By a drop disposal of finished material? (The less exact the release
requirements, the faster the release)
3. Can a hold be eliminated? (Holding is extremely fatiguing)
A. As unnecessary?
B. By a simple holding device or fixture?

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CHECKLIST FOR OPERATION CHART

Questions
4. Can a delay be eliminated or shortened?
A. As unnecessary?
B. By a change in the work that each body member does?
C. By balancing the work between the body members?
D. By working simultaneously on two items? (Slightly less than
double production is possible with the typical person.)
E. By alternating the work, each hand doing the same job, but out
of phase?

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CHECKLIST FOR OPERATION CHART

Questions
5. Can a sub-operation be made easier?
A. By better tools? (The analyst should investigate the vast range of
specialized tools available for many jobs.)
B. By changing leverages?
C. By changing positions of controls or tools?
D. By better material containers?
E. By using inertia where possible?
F. By lessening visual requirements?
G. By better workplace heights?

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CHECKLIST FOR OPERATION CHART

Questions
6. Can a movement be made easier?
A. By changing of layout, shortening distances?
B. By changing directions of movements?
C. By using different muscles?
D. By additional ergonomic considerations?
E. By making the movement continuous rather than jerky?

7. Can a hold be made easier?

A. By shortening its duration?
B. By using stronger muscle groups
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CHECKLIST FOR OPERATION CHART

Questions
8. Can mistakes be made relatively impossible or caught
soon after commission?
A. Design jigs and fixtures
B. Make it impossible for tools to go deeper that desired.
C. Mat it impossible to use the wrong tool.
D. Color code mating parts so that other, wrong parts are highly
visible.
E. Install low-cost, 100 per cent inspection.
F. Use sequential inspection, performed if possible during external
time.
G. Have the junior worker make the measurement, the senior
confirm it.
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18
INNOVATION

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INNOVATION

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THE CHECKLIST QUESTIONS

3. Can a hold be eliminated?

b) By a simple holding device or fixture
Note: A hexagonal socket will hold a hex-head bolt firmly erect.

4. Can delays be eliminated? (Removing the hold

crated a delay.)
d) By working simultaneously on two items
Note: It is possible to perform most tasks simultaneously with both
hands

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THE CHECKLIST QUESTIONS
5. Can a sub-operation be made easier?
f) By lessening visual requirements
Note: Small parts should be placed directly in front of the operator
so that the eyes may direct both hands and thus facilitate the work.
d) By better material containers
Note: Small materials should be put in bins with lips, so that material
may be picked up more easily and quickly.

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THE CHECKLIST QUESTIONS
5. Can a sub-operation be made easier?
b) By changing leverages
Note: A pull-up bar is easier to turn onto a both than a
bolt into a bar because the bar gives more leverage.
e) By using inertia where possible
Note: A heavy pull-up bar will continue spinning onto a
bolt when given a start. Bolts with low inertia will not spin

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WORK WITH
SUB-CYCLES
Original layout of workplace
for drill hinge channel

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WORK WITH SUB-
CYCLES
Hinge channel

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WORK WITH
SUB-CYCLES
Improved layout of workplace
for drill hinge channel

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WORK WITH
SUB-CYCLES
Modified operation chart

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WORK WITH
SUB-CYCLES
Basic Chart Form

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