Foundations of “Scientific”

Operations Management:
The Study of Work Systems
contd.

Analysis and Design of Work

Partly Chapter 7
 Activity Charts
(also known as Worker-Machine
Charts)
For capturing interactions of more than one
resource working together in same area
Worker-Machine Systems @ Work ..
.. Worker-Machine Systems: Cells
Machine
2
Machine
Machine 3
1

Materials in

Finished
goods out

Machine
Machine 4
5
 Worker-Machine Chart Example ..

• A semi-automatic machine runs by itself, but

requires an operator to load and unload

• Load time: 4’ (manual - both engaged)

• Unload time: 3’ (manual - both engaged)

• Run time: 6’ (self-running)

 .. Worker-Machine Chart Example
Operator Machine Another example
in Fig.7.5 (p.310)

4’

10’

13’

Cycle length: Throughput rate:

Machine usage: Operator usage:

 .. Worker-Machine Chart Example
Operator Machine

Load m/c Loading

4’

Idle Running
10’

Unload m/c Unloading

13’

Cycle length: Throughput rate:

Machine usage: Operator usage:

 Worker-Machine Assignment ..
Single operator tending multiple identical parallel
machines, each producing a complete unit

• t = Independent machine time (e.g. automatic run

time)

• b = Independent operator time (e.g. walking,

inspection, put-away)

• a = Concurrent activity time (e.g. load, unload)

• m = number of machines to assign to a single

operator
 .. Worker-Machine Chart Example ..

• A semi-automatic machine runs by itself, but

requires an operator to load and unload

• Load time: 4’ (manual - both engaged)

• Unload time: 3’ (manual - both engaged)

• Run time: 6’ (self-running)

• t = __ , a = _________ , b = __

• m=?
 .. Worker-Machine Chart Example ..

• A semi-automatic machine runs by itself, but

requires an operator to load and unload

• Load time: 4’ (manual - both engaged)

• Unload time: 3’ (manual - both engaged)

• Run time: 6’ (self-running)

• t = 6, a = 4+3 = 7, b = 0

• m=?
 .. Worker-Machine Assignment ..
m* = ideal number of machines to assign to one
operator (no idle time for machine or operator)

= (a + t) ÷ (a + b)
= _____÷ _____ = ___ ÷ __ = ____ ~ ?

Assumes perfect synchronization:

Possible? Advisable?

Output is function of m:
 .. Worker-Machine Assignment ..
m* = ideal number of machines to assign to one
operator (no idle time for machine or operator)

= (a + t) ÷ (a + b)
= (7+6) ÷ (7+0) = 13 ÷ 7 = 1.857 ~ ?

Assumes perfect synchronization:

Possible? Advisable?

Output is function of m: need to evaluate trade-off

between relative idle time vs. value of output
Modified Worker-Machine Chart Example (steady state)
Operator Machine 1 Machine 2

3’
4’

7’

10’

11’

14’

Cycle length: Throughput rate:

Machine usage: Operator usage:

Modified Worker-Machine Chart Example (steady state)
Operator Machine 1 Machine 2

Running
Load M1 Loading 3’
4’ Idle

Unload M2 Unloading
7’
Running

10’
Load M2 Loading
11’ Idle

Unload M1 Unloading Running

14’

Cycle length: Throughput rate:

Machine usage: Operator usage:

Changeover Management
 .. Worker-Machine Assignment
m < m* m > m*

Cycle length (a + t) m (a + b)

Machine Idle Time 0 m (a + b) - (a + t)

Operator Idle Time (a + t) - m (a + b) 0

No. of units per cycle m m

Max. production per m ÷ (a + t) 1 ÷ (a + b)
unit time

Calculations need to be adapted for serial operations, non-identical

machines (i.e. different a, b, t values), and sub-cell partitions if used
.. Worker-Machine Systems: Cells
Machine
2
Machine
Machine 3
1

Materials in

Finished
goods out

Machine
Machine 4
5