3P5 Industrial Engineering Lecture 1-2: Method of Study

Course Intro

Bio

• Digital Built Britain at Cambridge
• Type of operations for making on technologies to make profit
• Based on the layout to make profits
• Technology is not the problem
  • How to make the technology to generate the real values for the customers
• Production process
  • to make the customers happy
• Research projects
  • emerging technologies in sustainable systems
  • wearable health care

Industrial Engineering

• design

• improvement

• installation

  • of intergated systems

• components

  • men
  • materials
  • equipments

• Knowledge and skills

  • math
  • physical
  • social

Outline

• Method study
  • how a process can be studied and improved
• Ergonomics
  • how to make a process human friendly
• Lean manufacturing
  • how to identify and reduce wastes
• Supervision 1
• Work measurement 1
  • how to measure time and effort in operations
• work measurement 2
  • Ditto
• factory layout planning
  • how to measure how good a layout is
• supervision 2
• Reliability engineering
  • how to measure equipment failures
• maintenance planning
  • how to improve reliability of operations

Course Information

• 3 supervisions ? to be confirmed
  • 1 Jan 24- Feb 7
  • 2 Feb 02- Feb 21
  • 3 Feb 28- Mar 14
• supervisor
  • Frans
  • Dequn
• exam
  • paper 3 (joint paper with 3p4)
  • 2 questions from 3p4 and 3p5
• coursework
  • production game (with 3p4)
• Core text
  • Groove, mp “work systems: the methods, measurement and management of work”, pearson, 2014

Supporting sources

• Emma
• Charlottoe

Method of study introduction

Questions to ponder

• systematically study the way
  • factors
    • manufacuring operations
  • Questions
    • what should we study?
    • how can we record the operations?
    • what questions should we ask?
• Improve?
  • Fundamental principles of motion economy?
    • Motion economy is the process of minimizing the physical and perceptual loads imposed on people engaged in any type of work, whether it be in the office, the shop floor, the kitchen, or at the driving wheel.
    • 运动经济是**将从事任何类型工作的人的身体和感知负荷降到最低的过程，无论是在办公室、车间、厨房，还是在驾驶室。
    • how they are working
    • what are their pattern
    • what is the level of the music
    • Symbol of everybody’s working

Objectives

• procedure for doing method study
• techniques used for recording industrial operations
• the principles of motion economy for working plance design

The nature of work

• work’s define
  • activity
    • person
      • Uses physical
      • mental efforst
        • accomplish
          • a given task
        • perform a
          • Duty
• the pyramidal structure of work
  • task
  • work element
  • basic motion elements
• macro vision of the working domain
• economics
• Employee working for you
• making them comfortable on working domain
• put them in the domain about their basic motions

Work study

• work study
  • Method study
    • methods analysis
    • methods design
  • work measurement
    • time study
    • PMTS
      • A predetermined motion time system is frequently used to perform Labor Minute Costing in order to set piece-rates, wage-rates and/or incentives in labor oriented industries by quantifying the amount of time required to perform specific tasks under defined conditions. Wikipedia
      • 预先确定的运动时间系统经常被用来进行劳动分钟成本计算，以便通过量化在规定条件下执行特定任务所需的时间来确定计件工资、工资率和/或劳动力导向型行业的奖励。维基百科
    • Working sampling
    • MTM
      • ?

Method study

• systematic recording and critical examination of existing and proposed way of doing work
  • means of
    • designing
    • developing
    • applying
      • easier and more effective methods
      • reducing costs
• other terms
  • methods engineering
  • work simplification
  • Process re-engineering
  • business process re-engineering

Typical Objectives of method study

• increase productivity and efficiency

• reduce cycle time

• reduce product cost

• reduce labour content

• improve customer satisfaction

• improve product and service quality

• reduce lead times and improve work flow

• Increase flexibility of work system

• apply more ergonomic work methods

  • 人机工程学
  • Human factors and ergonomics (commonly referred to as human factors) is the application of psychological and physiological principles to the engineering and design of products, processes, and systems. The goal of human factors is to reduce human error, increase productivity, and enhance safety, system availability and comfort with a specific focus on the interaction between the human and the engineering system.[1]

• improve worker safety

• enhance the environment

  • inside
  • Outside the factory

Method study procedure

• SELECT
  • the work to be studied
• RECORD
  • all the relevant facts about the present method by direct observation

---

• EXAMINE
  • those facts critically and in ordered sequence
• DEVELOP
  • the most practical economic and effective method
• DEFINE
  • the new method so that it can always be identified

---

• INSTALL
  • that method as standard practice
• MAINTAIN
  • stadard practice by regular checks
• What is the abstractions for the three layers
  • prepare
  • design
  • Implement

SELECT

• selections main criterias (main 3)
  • bottlenecks
    • whole
  • Labour intensive operations
  • operations with high scrap or wastage
    • where there is more scraps
    • there will be a room for improvement
• Other criterias
  • movement over long distances
  • repectitive operations
  • Prior to automatition
    • when you have an automation
    • try to see whether the automation machines can come into play
  • work with health and safety concerns

Record

• Record
  • sequence
    • operation chart
    • process charts
  • times
    • multiple activity charts
  • position and movement
    • layouts
    • string diagrams
• Diagrams, charts and pictorial methods are widely used

Operation charts

• Processing and assembly operations
  • changing the shape
  • joining two or more parts to form an assembly
• Inspection operations
  • checking the materials

Operation chart for subassembly

• Bracket
• frame motor
• power cord

Process maps (better for Veronica)

• detailed picture of process or system
• symbols
  • beginning
  • Task or activity step
  • decision point
• [外链图片转存失败,源站可能有防盗链机制,建议将图片保存下来直接上传(img-FAHLu99h-1646153113883)(/Users/top1/Library/Application%20Support/typora-user-images/image-20220124114335440.png)]

Cross-functional process Map (difference between sequence diagram: similiar)

• High level view
• 

Recording sequence- process charts

• graphical and symbolic representation

  • of the processing activities performed
    • on something or by some one

• Types

  • materials
    • material analysis
  • worker process chart
  • form process chart

Flow process chart

• Operation
  • processing of a material
• Inspections
  • check for quality or quantity
• Move
  • transport of material to new location
  • time factors should be in
• Delay
  • material are waiting to be processed or moved
• Storage
  • keep materials in a protected location

Process chart for consisting of several machining operations

a flow process chart one handed

• 

Two handed process chart

• operator at a work station
• movement of both hands are charted individually and to a greater level of detail
• normal process chart
• MTM
  • method time measure
• Operation factors
  • operation
  • trasnport
  • delay
  • Storage
• Micro-motion study

Activity charts

• how much time is spent on each activity
• type of charts
  • activity chart
    • right hand / left-hand activity chart
      • Workplace activity chart
  • Worker-machine activity chart
  • Worker-multimachine activity chart
  • gang activiy chart
    • Aka multiworker activity chart

Shading formats for activity chart

• Shading
  • black
  • grey
  • white
  • Diagonal lines
  • horizontal lines
• colour
  • blue
  • yellow
  • white
  • green
  • Red
• Activity
  • operation
  • insepction
  • idle
  • moving
  • Holding

Example of activity chart

• Activity description
  • Pick up plate tote pan
  • carry plate to drill press and load
  • activate press

• chart

• activity time (min)
• Cumulative time

Right hand-left hand activity chart

• left hand
  • pick up board
  • hold board
  • hold board
  • put assembly in tote pan
• time (min)
  • 0.08
  • 0.06
• right hand
  • pick up peg
• cummulative time (min)
  • 0.08

Multiple activity chart

• activities of more than one subject
  • worker
  • machine
  • Item of equipment
• each subject are recorded on a seperate bar or column
• useful for analyzing and improving operations
  • number of interrelated activities
• Short-cycle operations where an operator is interfacing with one or more mechanical devices

Example of multiple activity chart

• Chart
  • One worker operating more than one machines
  • Worker
  • time
  • machine 1
  • time
  • machine 2
  • time
  • cumulative time (min)
• No two machines should be idle at the same time

Layout chart, String diagrams

• showing movements plotted on a scale drawing
• excellent of getting to grips with a complex layout
• transportation of the materials for visualizing the layout

String diagrams example

• before
  • Rivet
  • Cut
  • Fold
  • Sheet metal
  • Stack
  • Drill
  • Check
  • Mark
• After
  • fold

Examine, develop and define

Examine

• two categories

  • happening to material
    • make ready
      • Prepare the materials
      • work and set it in position ready to be worked on
    • do
      • operations where transformation is made to the materials
    • put away
  • Materials is not being touched

• eXAMINE TOOLS

  • Eliminating
  • Combining
  • Rearranging
  • Simplifying

• Systematic questioning techniques

  • purpose
    • undertaken activity
  • place
    • undertaken activity
  • sequence
    • undertaken activity
  • person
    • undertaken activity
  • Means
    • undertaken activity

Examine: systematic questioning

• purpose
  • what is actually done?
  • what is achieved>?
  • Why is the activity necessary at all?
• Place, sequence and person
  • were is it being done?
  • when is it done?
  • who is doing it?
• Means
  • why is it being done in that approach

Second stage of questionsing

• What should be done?
• When should it be done?
• …

Develop

• Most practical, economic and effective method

• Principles of Motion Economy

  • Maximise efficiency and minimize fatique
    • use of human body
    • design of the workplace
    • design of tools and equipment

use of human body (12 basic principles)

• basic five

  • both hands should be fully utilised
  • two hands should begin and complete their movements at the same time
  • motions of the arms should be symmetrical and in opposite directions and should be made simultaneously
  • the work should be designed to emphasise the worker’s preferred hand
  • two hands should not be idle at the same time except during the period of rest

• laws of physics to assist in the use of hands and arms while working

  • continuous curved movements are better than straight-line motions
  • Momentum should be employed to help the worker, but should be reduced to the minimum whenever it has to be overcome by muscular effort
  • advantage of gravity instead of opposing it
  • Rhythm is essential to Smooth and automatic performance of a repetitive operation
    • the work should be arranged to permit esay and natural rhythm whenever possible
  • hand and body motions should be made at the lowest classification at which it is possible to do the work satisfactorily

• Recommendations for using body members other than the hands and arms

  • method should be designed to utilise the worker’s feet and legs when appropriate
  • work should be arranged so that eye movements are confined to a comfortable area, without the need of others

Classifications of hand and arm motions

• 1
  • finger motions only
• 2
  • finger and wrist motions
• 3
  • Finger, wrist and forearm motions
• 4
  • Finger, wrist , forearm, and upper arm motions
• 5
  • finger, wrist, forearm, upper arm, and shoulder motions

Arrangement of workplace

• habit formation
• pre-positioned
• Gravity feed
• normal work area
• maximum work area
• adaquate seat position

Design of tools and equipment

• Hands should be relieved of all work
• Two or more tools should be combined whenever possible
• hands should be relieved of work
  • can be performed by feet
• Multiple tools together

Define

• new method so that it can always be identified
• having developed the improved method it is then necessary to define it
• Standard Operating procedure (SOP)
• Procedure
• Tools
• Layout
• Checks
• Set-up information

Standard Operating procedure

• ensure the tasks are always performed in the same way
  • reduce variations in operation time
  • reduce variations in quality
  • provide a basis for training new operators
  • allow variations to be easily identified
  • form a fixed basis for further improvement
  • important for auditing, ISO, British Standard

Standard operating procedure

• Purpose
• required PPE
• Potential Hazards
• Reference documents
• APS
• Steps
• Key points
• Page
• Version number
• Document Number

How is it reviewed and why is it revised?

• revisement report

Install and maintain

Install

• As standard practice

Maintain

• Standard practice by regular basic

Conclusion

• Know the life cycle of the opeartion
• improve

Q

• Where can we get the slides?
• Where can I have the supervision papers?
  • Questions 1-3 from examples Paper 1

• Where three categories?

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