PPT ON Method Study &

PPT ON Method Study & Flowcharting BY Prof.D.K.PARVE ASSISTANT PROFESSOR MECHANICAL ENGG. DEPT.

Outline 1. Work Study 2. Method Study 3. Various Charts 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). Lab # 6: Method Study

Work Study (Cont.) Work Study Work Measurements Method Study 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. 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 Lab # 6: Method Study

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. Lab # 6: Method Study

Method study - Methodology • Procedure to accomplish method study, called "SREDIM" shall be as follow: • Select: the job or operation that needs improvement, • Record: all facts, how work is done by chart methods, • Examine: every aspect of the job by asking; what, why, where, when, who and how • Develop: review ideas, eliminate, simplify, combine, re-arrange, make new method which more safe, chart new method, submit for approval, • Install: the new method, consider best time to introduce, convince all, train users, • Maintain: check frequently, match results, correct deviations. Lab # 6: Method Study

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

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 Lab # 6: Method Study

Method Study Applications • The need for methods analysis can come 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) Lab # 6: Method Study

Recording Techniques • Charts • Outline process chart. • 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. • Two hands process charts. • 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. Lab # 6: Method Study

Recording Techniques(Cont.) • Diagrams and models (2-D and/or 3-D) • Flow diagrams, which is the use of symbols for flow process charts, superimposed on drawings and the "descriptions" are not necessary. • String diagrams, which is used for solving movement problems since it shows congestions and excessive distances. • Cut-out templates (2-D models). • 3-D models. • Photography • Photographs, • Films, • Video. Lab # 6: Method Study

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. Lab # 6: Method Study

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

Assembly Chart (Cont.) Lab # 6: Method Study

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. Lab # 6: Method Study

Pieces / Hr Operation Number Hours / 1000 Tape Carton Operation Process Chart (Cont.) • Operations charts show the introduction of raw materials at the top of the chart on a horizontal line. • Some parts require no fabrication steps. These parts are called buyouts. Buyouts are introduced above the operation Lab # 6: Method Study

Operations Chart Steps • Step by Step Procedures For Preparing an Operations Chart: • 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 Lab # 6: Method Study

Operation Process Chart Operation Process Chart for Refrigerator Support Lab # 6: Method Study

Operation Process Chart Lab # 6: Method Study

Flow Diagrams • A flow diagram is essentially a flow process chart drawn to: • Show the layout of a facility. • Show the flow of work through that area • Show overcrowding areas, crossing worker paths, total travel. • Identify how layout can be redesigned to reduce travel, motion, collisions, etc. • Store materials near where they are used. • 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. Lab # 6: Method Study

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

Flow Diagram (Cont.) Lab # 6: Method Study

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. Lab # 6: Method Study

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 Lab # 6: Method Study

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 Lab # 6: Method Study

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. Lab # 6: Method Study

Flow Process Types: • Product or Material type • Worker (Man) type • Machine type Lab # 6: Method Study

ASME Standard Symbols Lab # 6: Method Study

Operation Delay Storage Transportation Inspection Flow Process Chart Symbols Lab # 6: Method Study

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. Lab # 6: Method Study

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 Lab # 6: Method Study

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 Lab # 6: Method Study

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 Lab # 6: Method Study

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 Lab # 6: Method Study

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

Flow Process Chart-An Example Flow Process Chart Example Lab # 6: Method Study

Summary Process: Emergency room admission Subject: Ankle injury patient Beginning: Enter emergency room Ending: Leave hospital Number Time Distance Activity of steps (min) (ft) Operation 5 23 — Transport 9 11 815 Insert Step Inspect 2 8 — Append Step Delay 3 8 — Store — — — Remove Step Step Time Distance Step description no. (min) (ft) 0.50 15 10.0 - 0.75 40 3.00 - 0.75 40 1.00 - 1.00 60 4.00 - 5.00 - 2.00 200 3.00 - 2.00 200 3.00 - 2.00 - 1.00 60 4.00 - 2.00 180 4.00 - 1.00 20 1 X Enter emergency room, approach patient window 2 X Sit down and fill out patient history 3 X Nurse escorts patient to ER triage room 4 X Nurse inspects injury 5 X Return to waiting room 6 X Wait for available bed 7 X Go to ER bed 8 X Wait for doctor 9 X Doctor inspects injury and questions patient 10 X Nurse takes patient to radiology 11 X Technician x-rays patient 12 X Return to bed in ER 13 X Wait for doctor to return 14 X Doctor provides diagnosis and advice 15 X Return to emergency entrance area 16 X Check out 17 X Walk to pharmacy 18 X Pick up prescription 19 X Leave the building Flow Process Chart-An Example Lab # 6: Method Study

Material Type - Example Lab # 6: Method Study

Man Type - Example Lab # 6: Method Study

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. Lab # 6: Method Study

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. Lab # 6: Method Study

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 Lab # 6: Method Study

Left-Hand-Right-Hand Chart (An Example) Lab # 6: Method Study

L-R Hand Chart of Signing a Letter Lab # 6: Method Study

Lab # 6: Method Study

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. Lab # 6: Method Study

Worker-Machine Chart for a Gourmet Coffee Store Lab # 6: Method Study

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. Lab # 6: Method Study

PPT ON Method Study &