Methods Engineering & Layout Planning
Chapters:
8. Introduction to Methods Engineering and
Part II Operations Analysis
9. Charting Techniques
10. Motion Study and Work Design
11. Facility Layout Planning and Design
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Introduction to Methods Engineering
and Operations Analysis
Sections:
Chapter 8
1. Evolution and Scope of Methods
Engineering
2. How to Apply Methods Engineering
3. Basic Data Collection and Analysis
Techniques
4. Automation and Methods Engineering
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods Engineering
Analysis and design of work methods and
systems, including the tooling, equipment,
technologies, workplace layout, plant layout,
and work environment
Other names for methods engineering:
Work study
Work simplification
Methods study
Process re-engineering
Business process re-engineering
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Objectives in Methods Engineering
Increase productivity and efficiency
Reduce cycle time
Reduce product cost
Reduce labor content
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Other Objectives
Improve customer satisfaction
Improve product and/or service quality
Reduce lead times and improve work flow
Increase flexibility of work system
Improve worker safety
Apply more ergonomic work methods
Enhance the environment (both inside and
outside the facility)
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Operations Analysis
Study of an operation or group of related
operations for the purpose of analyzing their
efficiency and effectiveness so that
improvements can be developed
Objectives in operations analysis
Increase productivity
Reduce time and cost
Improve safety and quality
Same basic objectives as methods engineering
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods Engineering
Can be divided into two areas:
1. Methods analysis
2. Methods design
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods Analysis
Concerned with the study of an existing
method or process
Objectives:
Eliminate unnecessary and non-value-
adding work elements
Combine elements and operations
Rearrange elements into more logical
sequence
Simplify remaining elements and operations
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods Design
Concerned with either of the following situations:
1. Design of a new method or process
Required for new product or service and
there is no existing precedent
Method must be designed from scratch,
using best existing practice for similar
operations
2. Redesign of an existing method or process
based on a preceding methods analysis
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Systematic Approach
1. Define the problem and objectives
2. Analyze the problem
3. Formulate alternatives
4. Evaluate alternatives and select the best
solution
5. Implement the best method
6. Audit the study
A systematic approach is more likely to yield
operational improvements than an
undisciplined approach
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Techniques of Methods Engineering
Data gathering and statistical tools
Charting and diagramming techniques
Motion study and work design
Facility layout planning
Work measurement techniques
New approaches
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Charting & Diagramming Techniques
Network diagrams
Traditional industrial engineering charting
techniques
Operation charts
Process charts
Flow diagrams
Block diagrams
Process maps
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Motion Study and Work Design
Concerned with basic motions of a human
worker while performing a given task
Examples of basic motion elements:
Reach
Grasp
Move
Release
Guidelines for work design include “principles
of motion economy”
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Facility Layout Planning
Facility layout refers to:
Size and shape of a facility
Arrangement of the different departments
and equipment within the facility
Problem area includes:
Design of a new facility
Installing new equipment, retiring old
equipment
Expanding (or contracting) an existing
facility
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Work Measurement Techniques
Four basic work measurement techniques:
1. Direct time study
2. Predetermined motion time systems
(PMTS)
3. Standard data systems
4. Work sampling
PMTS and work sampling can be used in
methods engineering to make improvements
in the work methods
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
New Approaches
Lean production
Based on the Toyota production system
Embraced by U.S. companies due to its
success at Toyota
Six Sigma and other quality-focused programs
Widely adopted in industry for improving
quality of work processes
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Selecting Among Alternative Proposals
Need for a systematic procedure to decide
among alternative proposals
To begin, list the technical features and
functional specifications for the application
Must features
Desirable features
Criteria matrix to evaluate alternatives
Drop candidates that do not satisfy “must
features”
Develop scores for desirable features
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Evaluation of Robots for Welding
Industrial Robot Candidates
Model A Model B Model C Model D
Must features:
Continuous path control OK OK OK OK
Six-axis robot arm OK OK Not OK OK
Walkthrough programming OK OK OK OK
Desirable features:
Ease of programming (0-9) 6 4 6
Capability to edit program (0- 4 2 5
5)
Multi-pass features (0-4) 2 2 2
Work volume (0-9) 5 8 6
Repeatability (0-5) 5 2 4
Lowest price (0-5) 4 5 3
Delivery (0-3) 1 1 3
Evaluation of vendor (0-9) 6 5 8
Totals: 33 29 37
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Basic Data Collection & Analysis Tools
1. Histograms
2. Pareto charts
3. Pie charts
4. Check sheets
5. Defect concentration diagrams
6. Scatter diagrams
7. Cause and effect diagrams
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Histogram
A statistical graph consisting of bars representing
different members of a population, in which the
length of each bar indicates the frequency or
relative frequency of each member
A useful tool because the analyst can quickly
visualize the features of the data, such as:
Shape of the distribution
Any central tendency in the distribution
Approximations of the mean and mode
Amount of scatter in the data
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Histogram for Data Display
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Pareto Chart
Special form of histogram in which attribute data
are arranged according to some criterion such
as cost or value
Based on Pareto’s Law: “the vital few and the
trivial many”
Often identified as the 80%-20% rule
80% of a nation’s wealth is owned by 20%
of the population
80% of sales are accounted for by 20% of
the SKUs
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Pareto Distribution
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Pie Charts
Example: Annual sales revenues and customer
distributions for two years
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Check Sheet
Data collection tool generally used in the
preliminary stages of a study of a quality problem
Data often entered by worker as check marks in
a given category
Examples:
Process distribution check sheet - data on
process variability
Defective item check sheet – types and
frequencies of defects on the product
Defect location check sheet - where defects
occur on the product
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Defect Concentration Diagram
A drawing of the product (all relevant views), onto
which the locations and frequencies of various
defect types are added
Useful for analyzing the causes of product or
part defects
By analyzing the defect types and
corresponding locations, the underlying causes
of the defects can possibly be identified
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Defect Concentration Diagram
Four views of refrigerator showing locations of
surface defects
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Scatter Diagrams
An x-y plot of data collected on two variables,
where a correlation between the variables is
suspected
The data are plotted as pairs; for each xi value,
there is a corresponding yi value
The shape of the collection of data points often
reveals a pattern or relationship between the
two variables
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Scatter Diagram
Effect of cobalt
content on wear
resistance for a
cemented carbide
cutting tool
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cause and Effect Diagram
A graphical-tabular chart used to list and analyze
the potential causes of a given problem
Can be used to identify which causes are most
consequential and how to take corrective
action against them
Also known as a “fishbone diagram”
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cause and Effect Diagram
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Methods Engineering and Automation
USA Principle
Ten Strategies for Automation
Automation Migration Strategy.
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
USA Principle
1. Understand the existing process
2. Simplify the process
3. Automate the process
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Understand the Existing Process
What are the inputs?
What are the outputs?
Number and placement of inspections
Number of moves and delays experienced by
the work unit
Time spent in storage
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Mathematical Models
What are the important output variables?
How are these output variables affected by
inputs to the process?
Develop mathematical model of the process
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Simplify the Process
What is the purpose of this operation or this
transport?
Can this step be eliminated?
Is the most appropriate technology being
used?
How can this step be simplified?
Can steps be combined?
Can steps be performed simultaneously?
Can steps be integrated into a manually
operated production line?
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automate the Process
If simplification is successful, automation may
not be necessary
Ten strategies for automation
Automation migration strategy
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Ten Strategies for Automation
1. 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)
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automation Migration Strategy
Phase 1: Manual production using single
station manned cells operating independently
Phase 2: Automated production using single
station automated cells operating
independently.
Phase 3: Automated integrated production
using a multi-station automated system with
serial operations and automated transfer of
work units between stations.
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automation Migration Strategy
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
