2024.07.23 INGB122_SU2.2_Flow Charts_A_Students(3).pdf

INGB 122 SU2: Capturing, Measuring and Managing Processes SU2.2: Flow Charts Lecture A 23 July 2024 1 Module Outcomes 2 School of Industrial Engineering Module Purpose q...

INGB 122 SU2: Capturing, Measuring and Managing Processes SU2.2: Flow Charts Lecture A 23 July 2024 1 Module Outcomes 2 School of Industrial Engineering Module Purpose qThe purpose of this module is to introduce students to industrial engineering. This includes an introduction to: the field of Industrial Engineering fundamental concepts of industrial engineering industrial engineering studies at the NWU qSU2 outcomes Define basic operations management concepts and terminology; Construct and communicate processes through process drawings; Etc… 3 School of Industrial Engineering Textbook 4 School of Industrial Engineering McGraw-Hill: E-textbook qChapter 4 qE-textbook: Page 233-284 q Niebel’s Methods, Standards and Work Design, 13th Edition § Chapter 2 5 School of Industrial Engineering Flow Charts 6 School of Industrial Engineering  Process Drawings Process Drawings: Flow Charts Basic PD Flow Charts Capture process steps Communicate process to reader Introduce reader to environment Ensure analyst Capture process understands the steps and data process to analyse concerning process and improve Capture present method Capturing and Each chart has its communicating own specific purpose processes 7 School of Industrial Engineering Operation Process Chart 8 School of Industrial Engineering  Operation p rocess cha rt Operation Process Chart qCaptures chronological sequence of all activities (start to finish) § From arrival of raw material § To packaging of final product Operation: when part is transformed or studied / planned prior to productive work being performed on it Inspection: when part is examined to determine its conformity to standard (quality) 9 School of Industrial Engineering Operation Process Chart qCaptures chronological sequence of all activities (start to finish) § From arrival of raw material § To packaging of final product When only operations are included (outlined) it is called an outline process chart Operation: when part is transformed or studied/planned prior to productive work being performed on it Inspection: when part is examined to determine its conformity to standard (quality) 10 School of Industrial Engineering Operation Process Chart qCaptures chronological sequence of all activities (start to finish) § From arrival of raw material § To packaging of final product Operation: when part is transformed or studied/planned prior to productive work being performed on it Inspection: when part is examined to determine its conformity to standard (quality) qInformation on chart: § Title, part number, drawing number, process description, present or proposed method, date, analyst name 11 School of Industrial Engineering  Operation Process Chart Vertical line: general flow of process (work) Horizontal line: flow of material/parts into process (either raw or worked on) Flowchart Parts/WIP either conventions enter line for assembly (left) Or leave vertical line for disassembly (right) 12 School of Industrial Engineering Operation Process Chart No Junction: minimize line crossing Junction: when parts/material joins the current process Flowchart conventions Alternate Paths: Split in the process flow line Rework: when steps need to be repeated for quality. 13 School of Industrial Engineering Example 1 qLabel steps sequentially 1 qBrief description of each 1 operation/inspection qDoesn’t have to include times (but preferrable) Separate Process Separate Process Main Workflow 14 School of Industrial Engineering Example 1 qMain purpose: 1 qIt helps understand 1 the sequence of process steps and how a certain change in the process will impact the rest of the process. 15 School of Industrial Engineering Flow Process Chart 16 School of Industrial Engineering  Flow pro Flow Process Chart cess char t qContains more detail than operation process chart qNot always used for entire assembly process (only part of process/component) § Depending on complexity of process qChart aids in recording non-production hidden costs § Excessive distance travelled § Unnecessary delays § Unnecessary temporary storages qSame information on chart as previous charts: title, etc. 17 School of Industrial Engineering ASME symbols 18 School of Industrial Engineering Example Any recommendations you can think of while Event/activity constructing the chart description you jot down Select/cross/shade the ASME symbol Summary of all the different activities Time activity takes to be completed (min/sec) Connect the various ASME symbols to indicate the process Distance travelled (only flow for transport symbol) 19 School of Industrial Engineering Example 2 Method Type 20 School of Industrial Engineering Flow Diagram 21 School of Industrial Engineering  Flow diag Flow Diagram ram qVisual flow of work qShows the layout of an environment (how the process flows) qAssists analyst in understanding process before suggesting changes qUse existing layout diagram and add flow lines. 22 School of Industrial Engineering Example qShaded area indicated space required for revised layout (in next slide) 23 School of Industrial Engineering Example Revised Layout (Shaded Area) 24 School of Industrial Engineering Travel Chart Flow of Worker (not Process) 25 School of Industrial Engineering  Travel chart Travel Chart qIntroduction to facilities design (INGB 417): determines how an activity’s tangible fixed assets best support achieving the activity’s objective. qIs the working environment contributing towards productive work? Employees movements within their environment when performing process steps: qHow often employees travel from one workstation to another qIs current layout efficient? What should the layout be? qTravel chart must be accompanied by high level facility layout (Flow Diagram) § Block layout § Scale/distances § Neat/visually user friendly 26 School of Industrial Engineering  Travel chart Travel Chart (To/From or From/To Chart) qCapture movement of workers between station over certain period of time qMake a mark for each movement from one workstation to another qSummarise movements qDetermine whether current layout is optimal in supporting the activity 27 School of Industrial Engineering  Travel Chart Example To Work- WS 1 WS 2 WS 3 station 1 || ||| 5 WS 1 WS 1 Summary of Work- From |||| ||| 7 moves from WS 2 station workstation WS 2 2 || ||| 5 WS 3 WS 3 Work- station 6 5 6 Summary of moves into 3 workstation WS 1 WS 2 WS 3 28 School of Industrial Engineering  Travel chart Travel Chart (To/From or From/To Chart) qCapture movement of workers between station over certain period of time qMake a mark for each movement from one workstation to another qSummarise movements qDetermine whether current layout is optimal in supporting the activity 29 School of Industrial Engineering (Complimenting Tool – Spaghetti Diagram) qA tool that is almost a visual representation of the travel chart qAlso like a combination between travel chart and flow diagram qBrief introductory video available at: § https://www.youtube.com/watch?v=5QEHS5tieiU 30 School of Industrial Engineering Worker and Machine Process Chart ONE employee (ONE/MORE machines) 31 School of Industrial Engineering Worker and Machine Process Chart qStudy, analyse and improve one workstation at a time (ONE employee and ONE/MORE machines) qShows time and relationship between: § Working cycle of person § Operating cycle of machine(s) qAim: § Better utilisation of man and machine (optimally used) § Better balance of work cycle § Optimal number of machines per operator at a workstation? 32 School of Industrial Engineering Worker and Machine Process Chart qOften machine are § Automatic (little to no assistance required from operator) § Semi-automatic (little assistance required from operator) Operator idle time Machine coupling: one employee operate more than one machine 33 School of Industrial Engineering Worker and Machine Process Chart qChart details: Chart details: § Title Title § Additional information: dditional information: § Part number § Present method or proposed method § Drawing number § Date § Operation description § Name of analyst School of Industrial Engineering Include: element description, operator, machine operator operates One Cycle Drawn to scale: Certain distance = certain time unit 1 cm = 10 minutes Vertical solid line = employee working time or machine operating time Vertical dotted line = machine loading and unloading (thus machine is not idle, but also not productive) Break in vertical line = idle time (machine/employee is idle) School of Industrial Engineering Worker and Machine Process Chart qDetermine total idle time and working time for operator qDetermine total idle time and productive time for each machine Total time (cycle time) must be the same School of Industrial Engineering  Worker and Machine Process Chart qIdle times = place to start improving (non- productive time) qLoading/unloading machines = necessary, but should be minimized qDetermine: can operator handle another machine OR is operator assigned too many machines? § Machine idle: operator assigned too many machines or require training. § Operator idle: handle more machines qCompare costs of idle machine vs idle operator: reduce idle time of most expensive one qWhat is most economical number of machines one employee can operate? School of Industrial Engineering Gang Process Chart ONE machine (ONE/MORE Operators) 38 School of Industrial Engineering Gang Process Chart qSometimes one machines requires several operators Gang chart 39 School of Industrial Engineering Gang Process Chart: Present Method 40 School of Industrial Engineering Gang Process Chart: Proposed Method From 6 to 4 employees From 2.3 man-minutes idle time to 0.32 man-minutes idles time Or from 18.4 idle man- hours per 8 hour working day to 2.6 idle man-hours per 8 hour working day. 41 School of Industrial Engineering  Worker and machine Time Units process chart qMan-minutes: time “man” did some activity in terms of Gang chart minutes § Note – all “man” (operators) involved in activity qMan-hours: time “man” did some activity in terms of hours § Note – all “man” (operators) involved in activity qAlways clearly state whether busy with one operator or one machine or all operators or all machines etc. and time unit. 42 School of Industrial Engineering  Time Units Continued For every 1 minute cycle all For every 1 minute cycle all For every 1 hour of cycle all For every 8-hour day all the the operators (added the operators (added the operators (added operators (added together) together) are idle for together) are idle for together) are idle for are idle for 18.4 hours 2.3 minutes 0.038333 hours 2.29998 hours 2.3min/60 0.038333 hours x 60 2.29998 hours x 8 = 0.038333 hours = 2.29998 hours =18.39984 43 School of Industrial Engineering Time units continued Express in a useful time-unit that supports the objective of why you do it. 44 School of Industrial Engineering Thank you! 45