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Questions and Answers
What is another name for a cause and effect diagram?
What is another name for a cause and effect diagram?
What is NOT one of the 6 general categories of causes often used in a cause and effect diagram?
What is NOT one of the 6 general categories of causes often used in a cause and effect diagram?
Which of the following is NOT an example of a factor that could be considered under "Materials" in a cause and effect diagram?
Which of the following is NOT an example of a factor that could be considered under "Materials" in a cause and effect diagram?
Which of the following is the BEST example of a factor that could be considered under "Measurement" in a cause and effect diagram?
Which of the following is the BEST example of a factor that could be considered under "Measurement" in a cause and effect diagram?
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What is the main purpose of a Cause & Effect Diagram?
What is the main purpose of a Cause & Effect Diagram?
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Which of the following is NOT a benefit of using a worker-machine chart?
Which of the following is NOT a benefit of using a worker-machine chart?
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What is the primary purpose of a Flow Process Chart?
What is the primary purpose of a Flow Process Chart?
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A "TAKT" time refers to:
A "TAKT" time refers to:
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What is the purpose of a Gang Process Chart?
What is the purpose of a Gang Process Chart?
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What is the primary function of a Travel Chart?
What is the primary function of a Travel Chart?
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Which of these charts is best for analyzing the efficiency of a single worker's actions?
Which of these charts is best for analyzing the efficiency of a single worker's actions?
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What does the 'Examine- The Question' section refer to?
What does the 'Examine- The Question' section refer to?
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Which of the following methods is used to analyze specific actions a worker takes?
Which of the following methods is used to analyze specific actions a worker takes?
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Which of the following is NOT a step in the USA principle for automation projects?
Which of the following is NOT a step in the USA principle for automation projects?
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Which of the following strategies focuses on reducing the time needed to complete tasks by performing multiple operations simultaneously?
Which of the following strategies focuses on reducing the time needed to complete tasks by performing multiple operations simultaneously?
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How can the 'Simplify the Process' step in the USA principle be implemented?
How can the 'Simplify the Process' step in the USA principle be implemented?
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Which of the following strategies focuses on combining multiple operations into a single, unified operation?
Which of the following strategies focuses on combining multiple operations into a single, unified operation?
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What is the overarching goal of the 'Ten Strategies for Automation'?
What is the overarching goal of the 'Ten Strategies for Automation'?
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According to the provided text, the question "Why is it done?" applies to which of the following steps?
According to the provided text, the question "Why is it done?" applies to which of the following steps?
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What is the primary purpose of asking "What is done?" within the "Examine-Secondary Questions" section?
What is the primary purpose of asking "What is done?" within the "Examine-Secondary Questions" section?
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Which of the following is NOT a direct secondary question related to "Place" within the "Examine-Secondary Questions" framework?
Which of the following is NOT a direct secondary question related to "Place" within the "Examine-Secondary Questions" framework?
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The secondary question "When is it done?" is relevant to which of the primary steps in the "Examine" framework?
The secondary question "When is it done?" is relevant to which of the primary steps in the "Examine" framework?
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In the context of the "Examine" framework, which primary question directly focuses on the individual responsible for the action?
In the context of the "Examine" framework, which primary question directly focuses on the individual responsible for the action?
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Which of the following is the correct order of secondary questions related to "Means" in the "Examine-Secondary Questions" framework?
Which of the following is the correct order of secondary questions related to "Means" in the "Examine-Secondary Questions" framework?
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The text emphasizes understanding the reason behind an action in which of the following primary question categories?
The text emphasizes understanding the reason behind an action in which of the following primary question categories?
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The "Examine-Secondary Questions" section focuses primarily on:
The "Examine-Secondary Questions" section focuses primarily on:
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What is the primary purpose of a "written standard practice"?
What is the primary purpose of a "written standard practice"?
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Which of the following is NOT a purpose of a "written standard practice"?
Which of the following is NOT a purpose of a "written standard practice"?
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What is the most crucial factor in determining the level of detail required for a "description of the method" in a written standard practice?
What is the most crucial factor in determining the level of detail required for a "description of the method" in a written standard practice?
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Which of the following is a benefit of using a "written standard practice"?
Which of the following is a benefit of using a "written standard practice"?
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What is the role of "the works engineers" in relation to a "written standard practice"?
What is the role of "the works engineers" in relation to a "written standard practice"?
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Which of the following is NOT a type of information typically included in a "written standard practice"?
Which of the following is NOT a type of information typically included in a "written standard practice"?
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Which section of the "written standard practice" would address the "general operating conditions"?
Which section of the "written standard practice" would address the "general operating conditions"?
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How does a "written standard practice" contribute to "worker involvement"?
How does a "written standard practice" contribute to "worker involvement"?
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Which of the following is NOT a type of chart or diagram used in record-keeping, according to the content provided?
Which of the following is NOT a type of chart or diagram used in record-keeping, according to the content provided?
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What specific information does an Operation Process Chart aim to provide?
What specific information does an Operation Process Chart aim to provide?
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The "Muda" mentioned in the context of the Flow Process Chart refers to:
The "Muda" mentioned in the context of the Flow Process Chart refers to:
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Which of the following symbols is NOT included in the 'Record Symbols' section provided?
Which of the following symbols is NOT included in the 'Record Symbols' section provided?
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What is the primary goal of using a Flow Process Chart?
What is the primary goal of using a Flow Process Chart?
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What is the primary difference between an Outline Process Chart and a Flow Process Chart?
What is the primary difference between an Outline Process Chart and a Flow Process Chart?
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Why is it important to use record-keeping symbols in manufacturing processes?
Why is it important to use record-keeping symbols in manufacturing processes?
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Which of the following charts helps analyze the sequence of activities within a production cycle?
Which of the following charts helps analyze the sequence of activities within a production cycle?
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What is the main purpose of using symbols for 'Record', 'Select', and 'Examine' in record-keeping?
What is the main purpose of using symbols for 'Record', 'Select', and 'Examine' in record-keeping?
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What is the key function of a Travel Chart in record-keeping?
What is the key function of a Travel Chart in record-keeping?
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What is the main advantage of using a Cyclegraph in record-keeping?
What is the main advantage of using a Cyclegraph in record-keeping?
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Which of the following situations would likely benefit from using a Procedure Chart?
Which of the following situations would likely benefit from using a Procedure Chart?
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What is the primary objective of a Simultaneous Motion Cycle Chart?
What is the primary objective of a Simultaneous Motion Cycle Chart?
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Why is it essential to conduct a final check after each operation in a production process?
Why is it essential to conduct a final check after each operation in a production process?
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What is a key advantage of using Flow Diagrams in record-keeping?
What is a key advantage of using Flow Diagrams in record-keeping?
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Flashcards
Pie Chart
Pie Chart
A circular chart divided into sectors showing proportions of a whole.
Cause and Effect Diagram
Cause and Effect Diagram
A chart used to identify and analyze potential causes of a problem.
5Ms and 1P
5Ms and 1P
Categories (Machines, Materials, Methods, Mother Nature, Measurement, People) for analyzing causes.
Machines
Machines
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Measurement
Measurement
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Petty Cash Process
Petty Cash Process
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Worker-Machine Process Chart
Worker-Machine Process Chart
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TAKT Time
TAKT Time
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Idle Time
Idle Time
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Flow Diagram
Flow Diagram
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Gang Process Chart
Gang Process Chart
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Two-Handed Process Chart
Two-Handed Process Chart
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Travel Chart
Travel Chart
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Examine
Examine
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Purpose Questions
Purpose Questions
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Place Questions
Place Questions
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Sequence Questions
Sequence Questions
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Person Questions
Person Questions
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Means Questions
Means Questions
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With a View To
With a View To
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Evaluate
Evaluate
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Operation Symbols
Operation Symbols
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Inspection Symbols
Inspection Symbols
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Transport Symbols
Transport Symbols
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Delay Symbols
Delay Symbols
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Storage Symbols
Storage Symbols
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Flow Chart
Flow Chart
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Outline Process Chart
Outline Process Chart
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Flow Process Chart
Flow Process Chart
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Simultaneous Motion Cycle Chart
Simultaneous Motion Cycle Chart
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Procedure Chart
Procedure Chart
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Chronocyclegraph
Chronocyclegraph
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Cyclegraph
Cyclegraph
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Muda Reduction
Muda Reduction
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Written Standard Practice
Written Standard Practice
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Operative Instruction Sheet
Operative Instruction Sheet
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Quality Circles
Quality Circles
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Spring Loaded Table
Spring Loaded Table
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Time Studies
Time Studies
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Multiple Improvement Ideas
Multiple Improvement Ideas
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Training and Retraining
Training and Retraining
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Report (ABC)
Report (ABC)
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USA Principle
USA Principle
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Understand the Existing Process
Understand the Existing Process
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Simplify the Process
Simplify the Process
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Ten Strategies for Automation
Ten Strategies for Automation
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Computer Integrated Manufacturing (CIM)
Computer Integrated Manufacturing (CIM)
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Study Notes
Methods Engineering and Operations Analysis
- Methods engineering is the analysis and design of work methods and systems, including tooling, equipment, technologies, workplace layout, plant layout, and work environment.
- Other names include work study, work simplification, methods study, process re-engineering, and business process re-engineering.
Objectives in Methods Engineering
- Increase productivity and efficiency
- Reduce cycle time
- Reduce product cost
- Reduce labor content
- Improve customer satisfaction
- Improve product/service quality
- Reduce lead times and improve workflow
- Increase flexibility of work system
- Improve worker safety
- Apply more ergonomic work methods
- Enhance the environment (both inside and outside the facility)
Operations Analysis
- Study of an operation or group of related operations to analyze efficiency and effectiveness for improvements relative to specified objectives.
- Objectives include increasing productivity, reducing time and cost, and improving safety and quality.
- Methods engineering and operations analysis are similar; methods engineering focuses more on design.
Methods Engineering - Areas
- Methods analysis: study of an existing method or process.
- Objectives include eliminating unnecessary and non-value-adding work elements, combining elements and operations, rearranging elements into a logical sequence, and simplifying remaining elements and operations.
- Methods design: design of a new method or process:
- Required for new products/services, or when no existing standard exists.
- Designed from scratch, using best practices for similar operations.
- Redesign of existing methods based on prior analyses.
How to Apply Methods Engineering
- Systematic Approach: based on the scientific method (in science, research, development, engineering design, and other problem areas).
- Step 1: Define the Problem and Objectives: The problem may be low productivity, high cost, inefficient methods, or the need for a new method or operation. Possible objectives are to increase productivity, reduce labor content and cost, improve safety, or develop a new method or new operation.
- Step 2: Analyze the Problem: Data collection and analysis activities. Activities include identifying the basic function of the operation, gathering background information, observing the existing process or similar processes, collecting operation data, conducting experiments, developing a mathematical model, performing a computer simulation, and using charting techniques.
- Step 3: Formulate Alternatives: Identify multiple ways to perform a task or accomplish processes, aiming to formulate all feasible alternatives.
- Step 4: Evaluate Alternatives and Select the Best: Systematically assess alternatives and select the best solution based on the original problem definition and objectives.
- Step 5: Implement the Best Method: Installing the selected solution to introduce the changes. This may involve pilot studies or trials; ensure documentation of the new method and replace the previous documentation.
- Step 6: Audit the Study: Perform an audit/follow-up on the methods engineering project to determine how successful the project was in terms of the original problem definition and objectives, finding implementation issues, and determining what should be done differently in the next study.
Method Study
- To simplify the job and develop more economical methods (of doing it) consisting of several steps. -Select the job to be studied. -Record the activities by collecting data or observation. -Examine the processes to challenge purpose, place, sequence, method of work. -Develop new methods. -Evaluate multiple solutions. -Define the new method. -Install the method through training and establish control procedures. -Maintain new methods.
Select - Where to Look
- Poor use of resources
- Bad layout
- Bottlenecks, lengthy operations, and poor use of time (holding up other operations)
- Inconsistent quality
- High fatiguing work
- Excessive overtime
- Employee complaints
Select - Economic Considerations
- Key profit-generating operations
- Key costly operations
- Repetitive work
- Long travel times
- Excessive overtime
Select - Technical Considerations
- Extensive paperwork
- Repetitive work (automation)
- Hazardous work
- Inconsistent quality
Select - Human Considerations
- Satisfaction level
- Start with non-controversial jobs
- HSE (Health, Safety, and Environment)
Select - Limiting the Scope
- One operation or a sequence
- The whole operation or part
- Which aspect (worker, materials, equipment, etc.)
Select - Possible Results
- Increased production rate
- Reduced cost
- Less labor, materials, or equipment
- Improved quality
- Improved safety
- Reduced scrap
- Improved standards of cleanliness
Basic Data Collection & Analysis Tools
- Histograms
- Pareto charts
- Pie charts
- Check sheets
- Defect concentration diagrams
- Scatter diagrams
- Cause-and-effect diagrams
Histogram
- A statistical graph consisting of bars representing discrete values or ranges of values, in which the length of each bar is proportional to the frequency or relative frequency of the value. This allows quick visualization of data distribution, central trends, and data scatter/spread.
Pareto Chart
- A special form of histogram in which attribute data are arranged according to a criterion such as cost or value. Uses Pareto's Law ("the few vital and the many trivial") and often described as the 80/20 rule where 80% of effects come from 20% of causes.
Cause and Effect Diagram
- A graphical, tabular chart used for analyzing the potential causes of a given problem.
- Often developed by worker teams examining operational problems.
- Provides a graphical way to discuss and analyze a problem, listing possible causes in an organized way.
- General categories of causes are the 5Ms and 1P (Machines, Materials, Methods, Mother Nature, and People)
Record - Symbols
- Operation (Make ready, Do, Put away): large circle
- Inspection: box
- Transport: arrow
- Delay: letter D
- Storage: triangle
Record - Charts and Diagrams
- Outline Process Chart
- Flow Process Chart (Worker, Material, Equipment)
- Two-Handed Process Chart
- Procedure Chart
- Simultaneous Motion Cycle Chart
- Multiple Activity Chart
- Flow Diagram
- String Diagram
- Cyclegraph
- Chronocyclegraph
- Travel Chart
Operation Process Chart
- Chronological sequence of all operations, inspections, time allowances, and materials.
- Depicts entrance and exit of all components and sub-assemblies.
- Provides information on the number of employees required and time for jobs/inspections.
Record - Example Outline Chart
- Illustrates a detailed diagram of activities and their specific times.
Record - Example Flow Chart
- Illustrates a detailed diagram of activities in a specific sequence.
Flow Process Chart
- Shows a more detailed representation of activities, including transportation and delays.
- Aims to list every detail and question the necessity/improvement of each step.
- Questions include whether steps can be combined or sequenced to be changed and if the correct person is conducting the activity.
Worker and Machine Process Charts
- Used to study, analyze, and improve one workstation.
- Shows the time relationship between the person's and machine's cycle.
- Reveals idle time for both machines and workers.
- Establishes "takt" time.
Flow Diagram
- A pictorial representation of the layout of a plant, supplementing a flowchart.
Gang Process Chart
- A process chart used to show the time each worker spends on an activity, and the time the machine spends on an activity.
Multiple Activity Chart
- A chart used to visualize the simultaneous activities of different people/groups.
String Diagram
- A diagram that maps the movement paths and activities of different elements involved in a process.
Travel Chart
- A chart used for tracking the movement of a person or item between different steps in a process.
Two-Handed Process Chart
- Shows the sequence of a process that involves the two hands of an operator.
Examine - The Questions
- Purpose: What is actually done, Why is it necessary?
- Place: Where? Why?
- Sequence: When? Why?
- Person: Who? Why?
- Means: How? Why?
- With a view to: Eliminate, Combine or Rearrange, Simplify
Examine - Secondary Questions
- What is done? Why is it done? What else might be done? What should be done?
- Where is it done? Why is it done there? Where else might be done? Where should it be done?
- When is it done? Why is it done then? When might it be done? When should it be done?
- Who does it? Why does that person do it? Who else might do it? Who should do it?
- How is it done? Why is it done that way? How else might be done? How should it be done?
Develop
- New Designs, Multidisciplinary Teams, Worker Involvement, Quality Circles, Simple Ideas
Evaluate
- Multiple Improvement Ideas: consider costs, benefits, and drawbacks.
- Report (ABC, Accurate, Brief, and Clear): example.
Define
- The written standard practice, also known as an operative instruction sheet, records the improved method for future reference, explains the new method to management and operatives, aids training/retraining, and forms the basis for time studies.
- Description of the method, amount of detail dependent on the nature of the job and production volume.
- Diagram of the workplace layout; possibly sketches of special tools, fixtures.
Install
- Five installation stages: gaining acceptance by management, gaining acceptance by departmental supervision, gaining acceptance by the workers and their representatives, preparing to make changes, controlling the changeover.
- Training: use films to demonstrate old and new methods; develop the habit of doing the job correctly; training should follow a numbered sequence; learning curves (periods of rest between practice periods longer than practice periods).
Maintain
- Workers shouldn't revert to old methods unless necessary.
- Maintain a clearly defined and specified method; assign a specialist permanently; and conduct a formal review to maintain the new improved method.
Method Study in the Office
- Offices use resources efficiently, with an increasing percentage of workers, needing controls of administrative costs, and machinery's introduction.
- Look for significant proportions of office labor costs, errors, high dissatisfaction, and changes in response to external influences (quality circles).
- A hierarchy of systems, procedures, activities, and methods; columnar charts display departments/sections.
- Form design should be compatible with intended use, and easy to complete and use; paper weight, shape, color, and house style must be considered.
- Control of forms: ensure each form serves a specific function; questions the validity of the form in the current work environment/technology; check the appropriate use of forms.
Office Layout
- Record major systems, supporting procedures, basic method studies for each procedure, capacity assessments.
- Analyze volumes of output, communicate with managers/senior team members to see potential future trends, and identify communication paths and frequencies.
- Design individual work stations to ensure ergonomics.
- Calculate total work station requirements using volume and capacity data.
Motion Study and Work Design
- Concerned with the basic motions of a human worker while performing a given task.
- Examples of basic motion elements: Reach, Grasp, Move, Release. Guidelines for work design (motion economy) focus on human body use, workplace layout, and tooling design.
Facility Layout Planning
- Refers to the size, shape, and arrangement of functions/departments in a facility for efficient workflow and operational efficiency.
- Objectives: customer satisfaction, utilization, efficient workflow, employee morale & safety.
- Problem areas: designing new facilities, expanding/contracting existing ones, installing equipment, and retiring old equipment.
Work Measurement Techniques
- Basic techniques include direct time study, predetermined motion time systems (PMTS), standard data systems, and work sampling.
- PMTS (a database of basic motion elements) analyses manual tasks, establishing standard times for tasks.
- Work sampling determines the proportion of time spent by workers/machines in various activities, useful for methods engineering in identifying areas needing attention.
Ten Strategies for Automation
-
- Specialization of operations. 2. Combined operations. 3. Simultaneous operations. 4. Integration of operations. 5. Increased flexibility. 6. Improved material handling and storage. 7. On-line inspection. 8. Process control and optimization. 9. Plant operations control. 10. Computer integrated manufacturing (CIM).
Understand the Existing Process
- What are the inputs and outputs.
- What happens to the work unit between inputs and outputs?
- What is the process function and use value?
Simplify the Process
- Purpose of the operation/transport?
- Can this step be eliminated?
- Appropriate technology being used, if so how can the step be simplified?
- Can steps be combined or performed simultaneously?
- Integrate steps into a production line.
Automate the Process
- Is automation feasible for quality, productivity enhancements?
- Strategies can involve the following improvement options:
- specialization of operations
- Combining operations
- Simultaneous operations
- Integration of operations
- Increased flexibility
- Improved material handling
- On-line inspection
- Process control and optimization
- Plant operations control
- Computer integrated manufacturing (CIM)
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Description
Test your knowledge on various quality control tools including cause and effect diagrams, flow process charts, and worker-machine charts. This quiz will cover definitions, purposes, and benefits associated with these tools in a quality management context.