Method Study Flowcharting Company LOGO Outline 1 Work

Method Study Flowcharting Company LOGO

Outline 1. Work Study 2. Method Study 3. Various Charts 26 November 2020 Lab # 6: Method Study 2

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). 26 November 2020 Lab # 6: Method Study 3

Work Study (Cont. ) Work Study Work Measurements 26 November 2020 Method Study Lab # 6: Method Study 4

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. 26 November 2020 Lab # 6: Method Study 5

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 26 November 2020 Lab # 6: Method Study 6

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. 26 November 2020 Lab # 6: Method Study 7

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. 26 November 2020 Lab # 6: Method Study 8

Methodology (Cont. ) Select Record Examine OK ? Develop Install 26 November 2020 Maintain Lab # 6: Method Study 9

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 26 November 2020 Lab # 6: Method Study 10

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) 26 November 2020 Lab # 6: Method Study come 11

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. 26 November 2020 Lab # 6: Method Study 12

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. 26 November 2020 Lab # 6: Method Study 13

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. 26 November 2020 Lab # 6: Method Study 14

Assembly Chart (Cont. ) Assembly Chart for producing Cheese Hamburger 26 November 2020 Lab # 6: Method Study 15

Assembly Chart (Cont. ) 26 November 2020 Lab # 6: Method Study 16

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. 26 November 2020 Lab # 6: Method Study 17

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 26 November 2020 Lab # 6: Method Study 18

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 26 November 2020 Lab # 6: Method Study 19

Operation Process Chart for Refrigerator Support 26 November 2020 Lab # 6: Method Study 20

Operation Process Chart 26 November 2020 Lab # 6: Method Study 21

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. 26 November 2020 Lab # 6: Method Study 22

Flow Diagram (Cont. ) Buyer 75 ft. You 26 November 2020 Lab # 6: Method Study 23

Flow Diagram (Cont. ) 26 November 2020 Lab # 6: Method Study 24

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. 26 November 2020 Lab # 6: Method Study 25

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 26 November 2020 Lab # 6: Method Study 26

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 26 November 2020 Lab # 6: Method Study 27

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. 26 November 2020 Lab # 6: Method Study 28

Flow Process Types: § Product or Material type § Worker (Man) type § Machine type 26 November 2020 Lab # 6: Method Study 29

ASME Standard Symbols 26 November 2020 Lab # 6: Method Study 30

Flow Process Chart Symbols Operation Delay Transportation Storage Inspection 26 November 2020 Lab # 6: Method Study 31

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. 26 November 2020 Lab # 6: Method Study 32

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 26 November 2020 Lab # 6: Method Study 33

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 26 November 2020 Lab # 6: Method Study 34

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 26 November 2020 Lab # 6: Method Study 35

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 26 November 2020 Lab # 6: Method Study 36

Combined Symbols Two symbols may be combined when two activities are performed concurrently. Operation and Inspection 26 November 2020 Lab # 6: Method Study 37

Flow Process Chart-An Example Flow Process Chart Example 26 November 2020 Lab # 6: Method Study 38

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 no. Time (min) 1 2 3 4 5 0. 50 10. 0 0. 75 3. 00 0. 75 15 40 40 6 7 8 9 10 1. 00 4. 00 5. 00 2. 00 60 200 11 12 13 14 15 3. 00 2. 00 1. 00 4. 00 2. 00 4. 00 1. 00 200 60 180 20 16 17 18 19 26 November 2020 Summary Activity Operation Transport Inspect Delay Store Distance Number of steps Time (min) Distance (ft) 5 9 2 3 — 23 11 8 8 — — 815 — — — Step description (ft) X 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 X X X Wait for available bed Go to ER bed Wait for doctor Doctor inspects injury and questions patient Nurse takes patient to radiology X Technician x-rays patient Return to bed in ER Wait for doctor to return Doctor provides diagnosis and advice Return to emergency entrance area X X X Check out Walk to pharmacy Pick up prescription Leave the building Lab # 6: Method Study 39

Material Type - Example 26 November 2020 Lab # 6: Method Study 40

Man Type - Example 26 November 2020 Lab # 6: Method Study 41

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 hand’s activities are broken into work elements and plotted side by side on a time scale. 26 November 2020 Lab # 6: Method Study 42

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. 26 November 2020 Lab # 6: Method Study 43

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 26 November 2020 Lab # 6: Method Study 44

Left-Hand-Right-Hand Chart (An Example) 26 November 2020 Lab # 6: Method Study 45

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 26 November 2020 Lab # 6: Method Study 46

LEFT HAND RIGHT HAND Reach for bolt in bin 1 Grasp bolt Carry bolt to work area Position bolt Reach for nut in bin 2 Grasp nut Carry nut to work area Position nut Hold Bolt Carry assembly to bin 3 Assemble nut 26 November 2020 Release nut Lab # 6: Method Study 47

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. 26 November 2020 Lab # 6: Method Study 48

Worker-Machine Chart for a Gourmet Coffee Store 26 November 2020 Lab # 6: Method Study 49

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. 26 November 2020 Lab # 6: Method Study 50

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 26 November 2020 Lab # 6: Method Study 51

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. 26 November 2020 Lab # 6: Method Study 52

Activity Chart Subject: Time 1 2 3 4 5 6 26 November 2020 Semi-Auto Machine Operator Load machine Present Machine Being loaded Run Idle Unload Lab # 6: Method Study Being Unloaded 53

Activity Chart for Two-Person 26 November 2020 Lab # 6: Method Study 54

Activity Chart of Emergency Tracheotomy 26 November 2020 Lab # 6: Method Study 55

Any Question 26 November 2020 Lab # 6: Method Study 56