Unit 3 Charting and Diagramming Techniques For Operations Analysis
Unit 3 Charting and Diagramming Techniques For Operations Analysis
OPERATIONS ANALYSIS
OVERVIEW
Charting and diagramming techniques are useful for analyzing a work process because
they graphically illustrate and summarize the activities in that process. Pertinent factual
information—such as the production quantity, delivery schedules, operational times, facilities,
machine capacities, special materials, and special tools—may have an important bearing on the
solution of the problem, and such information needs to be recorded. Once the facts are presented
clearly and accurately, they are examined critically, so that the most practical, economical, and
effective method can be defined and installed. This unit discusses the important charting and
diagramming techniques used in methods engineering and operations analysis.
LEARNING OBJECTIVES
At the end of this unit, students are expected to
1. Define methods study
2. Discuss the steps in methods study
3. Understand diagrams and charts used in recording the present method
4. Understand how IE charts and diagrams are used for process improvement
DISCUSSION
Methods Study
A systematic recording of existing and proposed ways of doing in order to simplify the
job. Method study enables the industrial engineer to subject each operation to systematic
analysis. The main purpose of method study is to eliminate the unnecessary operations and to
achieve the best method of performing the operation. Method study is also called methods
engineering or work design. Method study is essentially concerned with finding better ways of
doing things. It adds value and increases the efficiency by eliminating unnecessary operations,
avoidable delays and other forms of waste. The improvement in efficiency is achieved through:
1) improvement of procedures
2) improvement of layout
3) reduction of human fatigue
4) improvement in the use of materials,
machines, and labor
5) improvement in physical workplace
Steps in Methods Study
The basic approach to method
study consists of the following eight steps.
The detailed procedure for conducting the
method study is shown in the following figure.
Charting and Diagramming Techniques for Operations Analysis
1. SELECT the work to be studied and define its boundaries. Select the project to be studied –
consider
a) economic considerations –“bottleneck” operations, medical costs, long distances
b) technical considerations –rework, quality issues
c) human factors –medical injuries, repetitive work, worker experiences
d) using exploratory tools –Pareto Analysis, Fishbone Diagram, Gantt Chart
e) using general Job/Worksite Analysis Guide
2. RECORD the relevant facts about the job by direct observation and collect such additional
data as may be needed from appropriate sources.
3. EXAMINE the way the job is being performed and challenge its purpose, place sequence and
method of performance.
4. DEVELOP the most practical, economic and effective method, drawing on the contributions
of those concerned.
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assembly or leaving a vertical line for disassembly. Materials that are disassembled or
extracted are represented by horizontal material lines drawn to the right of the vertical
flow line, while assembly materials are shown as horizontal lines drawn to the left of the
vertical flow line. A typical completed operation process chart illustrating the
manufacture of telephone stands is shown in Figure 3.1.
Two types of flowcharts are currently in general use: product or material (see
Figure 3.4, preparation of direct mail advertising) and operative or person (see Figure 3.5,
service personnel inspecting LUX field units). The product chart provides the details of
the events involving a product or a material, and the operative flowchart details how a
person performs an operational sequence.
This tool facilitates the elimination or reduction of the hidden costs of a component.
Since the flowchart clearly shows all transportations, delays, and storages, the information it
provides can lead to a reduction of both the quantity and duration of these elements. Also,
since distances are recorded on the flow process chart, the chart is exceptionally valuable in
showing how the layout of a plant can be improved.
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Figure 3.4: Flow process chart (material) for preparation of direct mail advertising.
of the plant areas involved and then sketch in the flow lines, indicating the movement of
the material from one activity to the next. A pictorial representation of the layout of
floors and buildings, showing the locations of all activities on the flow process chart, is a
flow diagram. When constructing a flow diagram, analysts identify each activity by
symbols and numbers corresponding to those appearing on the flow process chart. The
direction of flow is indicated by placing small arrows periodically along the flow lines.
The flow diagram is a helpful supplement to the flow process chart because it indicates
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Figure 3.5: Flow process chart (worker) for field inspection of LUX.
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backtracking and possible traffic congestion areas, and it facilitates developing an ideal
plant layout. Figure 3.6 illustrates a flow diagram made in conjunction with a flow process
chart to improve the production of the Garand (M1) rifle at Springfield Armory.
Figure 3.6: Flow diagram of the old layout of a group of operations on the
Garand rifle.
(Shaded section of plant represents the total floor space needed for the revised layout. This
represented a 40 percent savings in floor space.)
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Charting and Diagramming Techniques for Operations Analysis
Activity charts usually have more than one time scale e.g., activity time and cumulative
time (see figure below).
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Figure 3.9: Right/left hand Activity chart for placing pegs on a pegboard
(Note that left hand is used as a work holder)
effectively. The gang process chart shows the exact relationship between the idle
and operating cycles of the machine and the idle and operating times per cycle of
the workers who service that machine. This chart reveals the possibilities for
improvement by reducing both idle operator time and idle machine time.
Figure 3.11 illustrates a gang process chart for a process in which a large
number of idle work-hours exist, up to 18.4 h per 8-h shift. The chart also shows
that the company is employing two more operators than are needed. By relocating
some of the controls of the process, the company was able to reassign the
elements of work so that four, rather than six, workers could effectively operate
the extrusion press. A better operation of the same process is shown on the gang
process chart in Figure 3.12. The savings of 16 h per shift was easily developed
through the use of this chart.
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Figure 3.11: Gang process chart of the present method of operation of a hydraulic extrusion process.
Charting and Diagramming Techniques for Operations Analysis
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Charting and Diagramming Techniques for Operations Analysis
Figure 3.12: Gang process chart of the proposed method of operation of a hydraulic
extrusion process.
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Charting and Diagramming Techniques for Operations Analysis
Process Maps
A process is a sequence of tasks that add value to inputs to produce outputs.
Basic process map is a block diagram showing the steps in a process (see figure 3.14).
Process maps are widely applied to business processes. Also applicable to production,
logistics, and service operations
Levels of detail:
High-level process map – macroscopic view of process and includes
only the most important steps
Low-level process map – used to map each of the steps in a high-level
process map
Process map symbols:
(a) beginning/ending point of the process,
(b) task or activity step,
(c) decision point
Symbols are connected by arrows to indicate sequence
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or indirect costs, such as delay time, storage costs, and material handling costs. The flow
diagram is a useful supplement to the flow process chart in developing plant layouts. The
worker/machine and gang process charts show machines or facilities in conjunction with the
operator or operators, and are used to analyze idle operator time and idle machine time.
REVIEW QUESTIONS
1. What is methods study?
2. Enumerate and explain the procedure for conducting the method study.
3. How does the operation process chart show materials introduced into the general flow?
4. How does the flow process chart differ from the operation process chart?
5. What is the principal purpose of the flow process chart?
6. What symbols are used in constructing the flow process chart?
7. How does the gang process chart differ from the worker and machine process chart?
8. What is a flow diagram?
9. What are some of the problem areas that can be identified using flow diagram?
10. What are the three block symbols for used in a basic process map?
PROBLEMS
1. A study reveals the following steps in the assembly of a truss (small triangle of three
small pieces within a large triangle of three larger pieces):
Forklift delivers 2 _ 4 pieces of pine from outside storage area (20 min).
Bandsaw operator cuts six pieces to appropriate length (10 min).
Assembler #1 gets three short pieces, bolts small triangle (5 min).
Assembler #2 gets three long pieces, bolts large triangle (10 min).
Assembler #3 gets one of each triangle and fastens into truss (20 min).
Supervisor inspects complete truss and prepares for delivery (5 min).
Complete a flow process chart of the operation.
3. An activity that almost everybody has done at some time on their life is to pound a nail
into a piece of wood with a hammer. Using the workplace sketched below, construct a
left and right hand activity chart.
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4. Before being named chef at a local restaurant, Gregory was responsible for work-study at
some manufacturing companies. He viewed being chef for a restaurant as a process
manufacturing, consistently, the same meals in the same way. As part of his strategy to
assure consistency in meal preparation, Gregory wants you to draw an operation process
chart for his salad making operation.
As prepared at Gregory’s restaurant, the typical salad contains: lettuce, pepper,
mushrooms. Cucumbers, croutons, magic ingredient and dressing. The ingredients are
processed as follows,
REFERENCES
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