Method Study
Flowcharting
Company
LOGO
Outline
1. Work Study 2. Method Study 3. Various Charts
November 5, 2012
Lab # 6: Method Study
Work Study
Work Study is a generic term for management services
and system engineering techniques, used to investigate:
Methods of performing work (Method Study).
The time taken to do it (Work Measurement).
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Lab # 6: Method Study
Work Study (Cont.)
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Lab # 6: Method Study
Method Study
Method study is a technique to reduce the work content mainly by eliminating unnecessary movements by workers, materials, or equipments. However, even after that, there could be substantial unnecessary time taken for the process because of lack of management control or inaction of worker. Method Study approaches and tools of Method Analyst: Flow Diagrams & Process Charts etc. Critical questioning techniques.
November 5, 2012
Lab # 6: Method Study
Method Study
Method study is the systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs. Used to analyze
Movement of body, people, or material Activities of people & machines
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Method Study Objectives
Improvement of processes and procedures. Improvement in the design of plant and equipment. Improvement of layout. Improvement in the use of men, materials and machines. Economy in human effort and reduction of unnecessary fatigue. Development of better working environment.
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Method study - Methodology
Procedure to accomplish method study, called "SREDIM" shall be as follow: 1. Select: the job or operation that needs improvement, 2. Record: all facts, how work is done by chart methods, 3. Examine: every aspect of the job by asking; what, why, where, when, who and how 4. Develop: review ideas, eliminate, simplify, combine, re-arrange, make new method which more safe, chart new method, submit for approval, 5. Install: the new method, consider best time to introduce, convince all, train users, 6. Maintain: check frequently, match results, correct deviations.
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Methodology (Cont.)
Select Record Examine
OK ? Develop
Install
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Maintain
Method Study Tools
Exploratory Tools
Pareto Analysis Fish & Bone Diagrams Gantt and PERT charts
Recording and Analysis Tools
Operation Process Chart Flow process chart Flow diagram Worker and Machine Process Charts Gang Process charts Synchronous Servicing
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Method Study Applications
The need for methods analysis can from a number of different sources : Changes in tools and equipment. Changes in product design or new products. Changes in materials or procedures Other factors (e.g. accidents, quality problems) come
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Recording Techniques
Charts 1. Outline process chart. 2. Flow process chart (man-type, material-type and equipment-type): This is the use of symbols and description to chart the sequence of work. The process, then, show what is happening at different stages. The distances and time may be given. 3. Two hands process charts. 4. Multiple activity charts: This technique is used to solve problems where a number of items are dependent on each other. The aim is to reduce idle times by using the optimum number of each item. It depicts the occupied times-broken down into the number of different activities and the idle times both for the original and proposed methods of doing the job.
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Recording Techniques
(Cont.)
Diagrams and models (2-D and/or 3-D) 1. Flow diagrams, which is the use of symbols for flow process charts, superimposed on drawings and the "descriptions" are not necessary. 2. String diagrams, which is used for solving movement problems since it shows congestions and excessive distances. 3. Cut-out templates (2-D models). 4. 3-D models. Photography 1. Photographs, 2. Films, 3. Video.
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Assembly Chart
It is an analog model of the assembly process. Circles with a single link denote basic components, circles with several links denote assembly operations/subassemblies, and squares represent inspection operations. The easiest method to constructing an assembly chart is to begin with the original product and to trace the product disassembly back to its basic components.
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Assembly Chart (Cont.)
Assembly Chart for producing Cheese Hamburger
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Assembly Chart (Cont.)
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Operation Process Chart
The operation process chart shows the chronological sequence of all operations, inspections, time allowances, and materials used in a manufacturing or business process, from the arrival of raw material to the packaging of the finished product. The chart depicts the entrance of all components and subassemblies to the main assembly. Two symbols are used in constructing the operation process Chart : an operation and an inspection.
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Operation Process Chart (Cont.)
Operations charts show the introduction of raw materials at the top of the chart on a horizontal line.
Operation Number
Pieces / Hr Hours / 1000
Some parts require no fabrication steps. These parts are called buyouts. Buyouts are introduced above the operation Tape
Carton
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Operations Chart Steps
Step by Step Procedures For Preparing Operations Chart: an
Identify the parts to be manufactured and purchased Determine the operations required to fabricate each part and sequence them Determine the sequence or assembly for buyouts and fabricated parts Draw the operations chart as explained Put time standards, operation numbers and descriptions Calculate and write down the total hours required per 1,000 units
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Operation Process Chart
Operation Process Chart for Refrigerator Support
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Operation Process Chart
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Flow Diagrams
A flow diagram is essentially a flow process chart drawn to: 1. Show the layout of a facility. 2. Show the flow of work through that area 3. Show overcrowding areas, crossing worker paths, total travel. 4. Identify how layout can be redesigned to reduce travel, motion, collisions, etc. 5. Store materials near where they are used. 6. Increase efficiency and safety. Usually, the objective is to look for spatial relationships. It depicts the probable movement of materials in the floor plant. The movement is represented by a line in the plant drawing.
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Flow Diagram (Cont.)
Buyer
75 ft.
You
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Flow Diagram (Cont.)
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Flow Process Charts
A flow process chart is a chart of all the activities involved in a process. It is similar to an operations process chart, except that more detail is shown by including transportations and delays as well as operations, inspections, and storages. Not usually used for entire assemblies, it is used for just one component (or operator) Add in information on: Operation duration (time to complete) Distance traveled (for transport operations) Good for showing savings of a new method.
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Flow Process Charts (Cont.)
Process charts summarizes the whole process They are used to compare the existing and the proposed methods Process is observed, who, what, where, when, and how questions are asked Every detail is understood and the chart of the existing situation is drawn
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Flow Process Charts (Cont.)
Quantity: Operations: Pieces per hour Transportation: How many are moved at a time Inspection: How many pieces per hour if under time standard and/or frequency of inspection Delays: How many pieces in a container Storage: How many pieces per storage unit
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Flow Process Charts (Cont.)
Time in Hours per Unit If 250 pieces are processed in an hour then 1 unit is processed in 0.00400 hours. Record 400 If 200 units are moved in 1 minute, then 1/200 = 0.005 minutes per part, and 0.005/60 hours/part =0.00008 hrs/part. Record 8.
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Flow Process Types: Product or Material type Worker (Man) type Machine type
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ASME Standard Symbols
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Flow Process Chart Symbols
Operation
Transportation
Delay Storage
Inspection
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Operation
Occurs when an object is intentionally changed in
one or more of its characteristics
Usually occurs at a machine or a work station
Drilling, Painting, Data Entry, Cutting, Sorting, etc.
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Transportation
Occurs when an object is moved from one place to
another
except when the movement is part of an operation
or an inspection
Using elevator, carrying, moving with material handling devices
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Inspection
Occurs when an object is examined for
identification or is compared with a standard as to
quantify or quality
Examine the quantity or quality, read steam gauge
on boiler, detect the defectives
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Delay
Occurs when the immediate performance or the
next planned action does not take place
Work In Process inventory waiting to be
processed, Employee waiting for an elevator,
Waiting for accumulation of a certain quantity for packaging
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Storage
Occurs when an object is kept under control such
that its withdrawal requires authorization
Bulk storage of raw material, finished products
inventory, archived documents
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Combined Symbols
Two symbols may be combined when two
activities are performed concurrently.
Operation and Inspection
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Flow Process Chart-An Example
Flow Process Chart Example
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Flow Process Chart-An Example
Process: Subject: Beginning: Ending: Emergency room admission Ankle injury patient Enter emergency room Leave hospital
Insert Step Append Step Remove Step Step no. Time (min) Distance
Summary
Activity Operation Transport Inspect Delay Store Number of steps 5 9 2 3 Time (min) 23 11 8 8 Distance (ft) 815
(ft)
15 40 40 60 200 200 60 180 20 X X X X X X X X X X X X X X X X X X X
Step description
Enter emergency room, approach patient window Sit down and fill out patient history Nurse escorts patient to ER triage room Nurse inspects injury Return to waiting room Wait for available bed Go to ER bed Wait for doctor Doctor inspects injury and questions patient Nurse takes patient to radiology Technician x-rays patient Return to bed in ER Wait for doctor to return Doctor provides diagnosis and advice Return to emergency entrance area Check out Walk to pharmacy Pick up prescription Leave the building
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
0.50 10.0 0.75 3.00 0.75 1.00 1.00 4.00 5.00 2.00 3.00 2.00 3.00 2.00 1.00 4.00 2.00 4.00 1.00
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Material Type - Example
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Man Type - Example
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Left-Hand-Right-Hand Charts
Useful in analyzing the work performed by one
person at one specific workstation. As the name
implies, the chart follows the motion of the left
and right hands of one operator .
Each hand of the worker is treated as an activity. Each hands activities are broken into work elements and plotted side by side on a time scale.
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Left-Hand-Right-Hand Charts (Cont.)
Lists the work performed simultaneously by each hand
To assist in finding a better method of performing the task and To train the operator in the preferred method.
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Symbols
Two symbols are used in this chart:
Transportation (either an arrow or a small circle) Action (e.g., grasp, position, use, release)
A sketch of the workplace is drawn, indicating the
contents of the bins and the location of tools and
materials.
Record the motions of one hand at a time Usually necessary to redraw the chart
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Left-Hand-Right-Hand Chart (An Example)
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L-R Hand Chart of Signing a Letter
LEFT HAND RIGHT HAND
Reach for pen Grasp pen
Carry pen to paper
Hold Letter
Sign letter
Return pen to holder Release pen in holder Move hand back to letter
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LEFT HAND
Reach for bolt in bin 1 Grasp bolt Carry bolt to work area Position bolt Hold Bolt Carry assembly to bin 3
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RIGHT HAND
Reach for nut in bin 2 Grasp nut Carry nut to work area Position nut Assemble nut
Release nut
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Man-machine chart
The worker and machine process chart (Man-machine
chart) is used to study, analyze, and improve one
workstation at a time. The chart shows the exact time relationship between the working cycle of the person and operating cycle of the machine. These facts can lead to utilization of both worker and machine time, and a better balance of the work cycle.
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Worker-Machine Chart for a Gourmet Coffee Store
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Worker-Machine Chart for a Gourmet Coffee Store
The customer, the clerk, and the coffee grinder (machine) are involved in this operation. It required 1 minute and 10 seconds for the customer to purchase a pound of coffee in this particular store. During this time the customer spent 22 seconds, or 31 percent of the time, giving the clerk his order, receiving the ground coffee, and paying the clerk for it. He was idle during the remaining 69 percent of the time. The clerk worked 49 seconds, or 70 percent of the time, and was idle 21 seconds, or 30 percent of the time. The coffee grinder was in operation 21 seconds, or 30 percent of the time, and was idle 70 percent of the time.
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Multiple Activity Charts
Also known as Gang Process Charts
Used when several workers operate a single
machine or render a single service
Used when a single worker is operating several
machines Used to show the exact relationship between idle and operating times of both workers and machines
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Multiple Activity Charts (Cont.)
An operation performed by one member of the
group may continue while another member is
performing more than one operation.
The chart should cover the complete cycle for the
longest performing member.
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Activity Chart
Subject: Semi-Auto Machine Present
Time
1
Operator
Load machine
Machine
Being loaded
2 3
4 5 6
Idle Unload
Run
Being Unloaded
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Activity Chart for Two-Person
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Activity Chart of Emergency Tracheotomy
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Any Question
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