Productivity and Quality Management Lecture 14 Last Lecture

Productivity and Quality Management Lecture 14

Last Lecture Summary: Oil & Gas productivity • Productivity improvement has emerged as one of the top issues. • Significant productivity programs launched in many businesses. • In oil and gas industry, challenges to productivity continue to gain significant attention and hopes

Last Lecture Contd.

Summary • Productivity Improvement in Oil and Gas • Factors that improve productivity in Oil and Gas: 1). Integrating Automation 2). Introducing Smart business processes 3). Improving safety 4). Risk Mitigation 5). Innovations 6). The Human element

Motion and Time Study (MTS)

WORK SYSTEMS

HISTORY OF MOTION AND TIME STUDY �Frank B. Gilbreth, Lillian M Gilbreth -1885, he begun to develop motion study. Gilbreth invented motion study designed to determine the best way to complete a job �Frederick W. Taylor -1881, he started to develop time study Taylor designed Time Study; it measures how long it takes a worker to complete a task.

Methodology Outline of MTS • Develop System – Design work methods (sequence of operations and procedures) that make up the preferred solution – Find better methods for work Methods Design • Standardize – Form written standards for operations • Time Standards – Determine a standard time for each operation Develop System Work Meas. mnt Time Standards • Training – Train the operators Training

Defining Work Systems Work • Is our primary means of livelihood • Serves an important economic function in the global world of commerce • Creates opportunities for social interactions and friendships • Provides the products and services that sustain and improve our standard of living

Defining Work Systems • Work consists of tasks – Tasks consist elements of work • Work elements consist of basic motion elements

Defining Work Systems Task • An amount of work that is assigned to a worker or for which a worker is responsible – Repetitive task – as in mass production – Non-repetitive task – performed periodically, infrequently, or only once Work Element • A series of work activities that are logically grouped together because they have a unified function in the task – Example: assembling a component to a base part using several nuts and bolts

Defining Work Systems Basic Motion Elements • Actuations of the limbs and other body parts – Examples: • • • Reaching for an object Grasping the object Moving the object Walking Eye movement – A work element consists of multiple basic motion elements

1. 3 Defining Work Systems • “Time=Money”? How? – New product introduction – Product cost – Delivery time – Overnight delivery – Competitive bidding – Production scheduling • Increase profit using less time!

Defining Work Systems • Importance of Time in Work – Time is the most frequently used measure of work • How many minutes or hours are required to perform a given task? – Most workers are paid by the time they work • Hourly wage rate • Salary – Workers must arrive at work on time – Labor and staffing requirements computed in units of time

Defining Work Systems • A work system is a system consisting of humans, information, and equipment designed to perform useful work – Contributes to the production of a product or delivery of a service – Examples: • Worker operating a machine tool in a factory • Robotic welding line in an automobile plant • A receptionist answering incoming phone calls

Defining Work Systems

Productivity Production as a function in Economics Q=f(K, L) • Q: Output, K: Capital, L: Labor • Is there a way to change function f with a better function g? • Better Function=Higher Productivity

Productivity • The level of output of a given process relative to the level of input • Process can refer to – Individual production or service operations – A national economy • Productivity is an important metric in work systems because – Improving productivity is the means by which worker compensation can be increased without increasing the costs of products and services they produce

Productivity Labor Productivity • The most common productivity measure is labor productivity, defined by the following ratio: LPR = – LPR = labor productivity ratio – WU = work units of output – LH = labor hours of input

Productivity Labor Productivity Index • Measure that compares input/output ratio from one year to the next LPI = – LPI = labor productivity index – LPRt = labor productivity ratio for period t – LPRb = labor productivity ratio for base period

Productivity Example • During the base year in a small steel mill, 326, 000 tons of steel were produced using 203, 000 labor hours. In the next year, the output was 341, 000 tons using 246, 000 labor hours. Determine: (a) the labor productivity ratio for the base year, (b) the labor productivity ratio for the second year, and (c) the productivity index for the second year.

Productivity Solution (a) In the base year, LPR = 326, 000 / 203, 000 = 1. 606 tons per labor hour (b) In the second year, LPR = 341, 000 / 246, 000 = 1. 386 tons per labor hour (c) Productivity index for the second year LPI = 1. 386 / 1. 606 = 0. 863 • Comment: No matter how it’s measured, productivity went down in the second year.

Productivity Labor Factor in Productivity • Labor itself does not contribute much to improving productivity • More important factors: – Capital - substitution of machines for human labor – Technology - fundamental change in the way some activity or function is accomplished

Productivity Horse-drawn carts Railroad trains Steam locomotive Diesel locomotive Telephone operator Dial phone Manually operated milling machine Numerically controlled (NC) milling machine

Productivity Measuring Productivity • Not as easy as it seems because of the following problems: – Nonhomogeneous output units – Multiple input factors • Labor, capital, technology, materials, energy – Price and cost changes due to economic forces – Product mix changes • Relative proportions of products that a company sells change over time

Productivity Productive Work Content • A given task performed by a worker can be considered to consist of – Basic productive work content • Theoretical minimum amount of work required to accomplish the task – Excess nonproductive activities • • Extra physical and mental actions of worker Do not add value to the task Do not facilitate the productive work content Take time

Productivity • Excess Nonproductive Activities can be classified into three categories: – Excess activities due to poor design of product or service – Excess activities caused by inefficient methods, poor workplace layout, and interruptions – Excessive activities cause by the human factor

Productivity Allocation of Total Task Time

Work Systems 1. Manual work system – Worker performing one or more tasks without the aid of powered tools 2. Worker-machine system – Human worker operates powered equipment 3. Automated work system – Process performed without the participation of a human worker direct

Work Systems Manual Work Systems • Human body accomplishing some physical task without an external source of power – With or without hand tools • When hand tools are used, the power to operate them is derived from the strength and stamina of a human worker – Other human faculties are required, such as hand-eye coordination and mental effort

Work Systems Manual Work Systems

Work Systems Pure Manual Work • Material handler moving cartons in a warehouse • Assembly worker snap-fitting two parts together Manual Work with Hand Tools • Material handling worker using a dolly to move furniture • Assembly worker using screwdriver

Work Systems Worker-Machine Systems • Worker operating a piece of powered equipment • Examples: – – – Machinist operating a milling machine Construction worker operating a backhoe Truck driver driving an 18 -wheeler Worker crew operating a rolling mill Clerical worker entering data into a PC

Work Systems Worker-Machine Systems

Work Systems Automated Work Systems • Automation is the technology by which a process or procedure is accomplished without human assistance – Implemented using a program of instructions combined with a control system that executes the instructions – Power is required to drive the process and operate the control system

Work Systems Automated Work System

METHODS DESIGN

Methods Design Develop System Standardize Time Standards Methods Design Training • Motion study - analysis of the basic hand, arm, and body movements of workers as they perform work • Work design - design of the methods and motions used to perform a task • Includes: – Workplace layout and environment – Tooling and equipment used in the task

MOTION STUDY

WHAT IS MOTION AND TIME STUDY? • Motion Study is designed to determine the best way to complete a repetitive job

Motion Study Basic Motion Elements • Therbligs – 17 basic motion elements – Basic building blocks of virtually all manual work performed at a single location – With modification, used today in several work measurement systems

Motion Study 17 Therbligs 1. Transport empty (TE) – reach for an object 2. Grasp (G) – grasp an object 3. Transport loaded (TL) – move an object with hand arm 4. Hold (H) – hold an object 5. Release load (RL) – release control of an object 6. Use (U) – manipulate a tool

Motion Study 7. Pre-position (PP) – position object for next operation 8. Position (P) – position object in defined location 9. Assemble (A) – join two parts 10. Disassemble (DA) – separate multiple parts that were previously joined 11. Search (Sh) – attempt to find an object using eyes or hand

Motion Study 12. Select (St) – choose among several objects in a group 13. Plan (Pn) – decide on an action 14. Inspect (I) – determine quality of object 15. Unavoidable delay (UD) – waiting due to factors beyond worker control 16. Avoidable delay (AD) – worker waiting 17. Rest (R) – resting to overcome fatigue

Motion Study Classification of Therbligs Effective therbligs: • Transport empty • Grasp • Transport loaded • Release load • Use • Assemble • Disassemble • Inspect • Rest Ineffective therbligs: • Hold • Pre-position • Position • Search • Select • Plan • Unavoidable delay • Avoidable delay

Motion Study Micromotion Analysis • Objectives: – Eliminate ineffective therbligs if possible – Avoid holding objects with hand – Use workholder – Combine therbligs – Perform right-hand left-hand motions simultaneously – Simplify overall method – Reduce time for a motion, e. g. , shorten distance

Example: A repetitive Manual Task • Current method: An assembly worker performs a repetitive task consisting of inserting 8 pegs into 8 holes in a board. A sightly interference fit is involved in each insertion. The worker holds the board in one hand picks up the pegs from a tray with other hand inserts them into the holes, one peg at a time.

Example: A repetitive Manual Task • Current method and current layout:

Example A repetitive Manual Task • Improved method and improved layout: – Use a work-holding device to hold and position the board while the worker uses both hands simultaneously to insert pegs. – Instead of picking one peg at a time, each hand will grab four pegs to minimize the number of times the worker’s hands must reach the trays.

Motion Study Principles of Motion Economy • Developed over many years of practical experience in work design • Guidelines to help determine – Work method – Workplace layout – Tools, and equipment • Objective: to maximize efficiency and minimize worker fatigue

Work Methods Design To select preferred work method: 1. 2. 3. 4. Eliminate all unnecessary work Combine operations or elements Change the sequence of operations Simplify the necessary operations

Summary • • • History of Motion and Time Study Defining Work Systems and Productivity Methods Design Motion Study Work Methods Design

References • Groover, Mikell P. , Work Systems: The Methods, Measurement & Management of Work, 2007, Prentice Hall • Barnes, Ralph M. , Motion and Time Study: Design and Measurement of Work, 1990, John Wiley & Sons Inc.

Improving Productivity