DISCUSSION

Categories of Charts and Diagrams

2. Traditional IE Charts and Diagrams
Flow Diagram
Although the flow process chart gives most of the pertinent
information related to a manufacturing process, it does not show a
pictorial plan of the flow of work. Sometimes this information is
helpful in developing a new method. For example, before a
transportation can be shortened, the analyst needs to see or
visualize where room can be made to add a facility so that the
transportation distance can be shortened.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Flow Diagram
Likewise, it is helpful to visualize potential temporary and
permanent storage areas, inspection stations, and work points.
The best way to provide this information is to take an existing
drawing 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.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
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 backtracking and possible traffic congestion areas, and it
facilitates developing an ideal plant layout.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and
Diagrams
Flow Diagram
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
FIGURE 3.6: Flow diagram of the old layout of Springfield Armory.
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.)
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
Activity charts are listing of activities of one or more subjects (e.g.,
workers, machines) plotted against a time scale to indicate
graphically how much time is spent on each activity. These
activities are generally repetitive.
Types of activity charts:
1. Right-hand/left-hand activity chart (a.k.a. workplace activity chart)
2. Worker-machine activity chart
3. Gang activity chart (a.k.a. multi worker activity chart)
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
Instead of using symbols for
the work activities, as in the
other charts, the activities
are indicated by vertical
lines or bars. When bars are
used, they are shaded or
colored to indicate the kind
of the activity being
performed.
FIGURE 3.7: Shading formats for activity charts
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
Activity charts usually have more
than one time scale e.g., activity
time and cumulative time

FIGURE 3.8: Activity chart for a worker

performing a repetitive task
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
Right-hand/left-hand activity chart.
The Left and Right Hand Chart is a process chart in which the
activities of a worker’s hands (or limbs) are recorded in their
relationship to one another. It is a specialized form of process
chart because it shows the two hands (and sometimes the feet)
of the operative moving or static in relation to one another,
usually in relation to a time scale.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
One advantage of incorporating a time scale in the chart form is
that the symbols for what the two hands are doing at any given
moment are brought opposite each other. The two-handed
process chart is generally used for repetitive operations, when
one complete cycle of the work is to be recorded.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
Right-hand/left-hand activity
chart Shows contributions of
the right and left hands balance
of the workload between the
right and left hands

Figure 3.9: Right/left hand Activity chart for

placing pegs on a pegboard
(Note that left hand is used as a work holder)
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
Worker-machine activity chart.
The worker and machine activity 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
the operating cycle of the machine. These facts can lead to a
fuller utilization of both worker and machine time, and a better
balance of the work cycle.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
The completed worker and machine process chart clearly shows
the areas in which both idle machine time and idle worker time
occur (see figure 3.10). These areas are generally a good place
to start in effecting improvements. However, the analyst must
also compare the cost of the idle machine with that of the idle
worker. It is only when total cost is considered that the analyst
can safely recommend one method over another.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts

The savings of 16 h per shift

was easily developed
through the use of this
chart.

FIGURE 3.10: Worker- machine activity chart

for servicing a machine
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts

The savings of 16hr per shift

was easily developed
through the use of this
chart.

FIGURE 3.10: Worker- machine activity chart

for servicing a machine
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
Gang activity chart.
The gang process chart is, in a sense, an adaptation of the
worker and machine chart. A worker and machine process chart
helps determine the most economical number of machines one
worker can operate.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
However, several processes and facilities are of such magnitude
that instead of one worker operating several machines, several
workers are needed to operate one machine 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.
 DISCUSSION
Categories of Charts and Diagrams
2. Traditional IE Charts and Diagrams
Activity Charts
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.
FIGURE 3.11: Gang process chart of the present method of operation
of a hydraulic extrusion process.
FIGURE 3.12: Gang process chart of the proposed method
of operation of a hydraulic extrusion process.
 DISCUSSION
Categories of Charts and Diagrams
3. Block diagrams and process maps
Block Diagram is a graphic consisting mostly of blocks and arrows to
portray the relationships among components of a physical system. It is a
graphical representation of a system – it provides a functional view of a
system. Block diagrams give us a better understanding of a system’s
functions and help create interconnections within it.
 DISCUSSION
Categories of Charts and Diagrams
3. Block diagrams and process maps
Block diagrams derive their name from the rectangular elements found in
this type of diagram. They are used to describe hardware and software
systems as well as to represent processes. Block diagrams are described
and defined according to their function and structure as well as their
relationship with other blocks.
 DISCUSSION
Categories of Charts and Diagrams
3. Block diagrams and process maps
Block diagrams are generally used when the visualization of
information or control flows is important – or when processes are
involved. In this way we can represent complex algorithms or flows of
information or communication among individual components within
a large system as with, for example, in a facility designed for mass
production. A graphical representation is often easier to understand
than a textual representation. An example of a block diagram is
shown in figure 3.13.
Figure 3.13: Block Diagram
 DISCUSSION
Categories of Charts and Diagrams
3. Block diagrams and process maps
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).
Figure 3.14: Basic 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
 DISCUSSION
Categories of Charts and Diagrams
3. Block diagrams and process maps
Process Maps
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
 Figure 3.15: Relationship map for
a Custom Workshop

Alternative Forms of Process Maps

• Relationship process map – block diagram that
shows the input-output connections among
departments (or other functional components)
of an organization (see figure 3. 15)
• Cross-functional process map – block diagram
showing how the steps of a process are
accomplished by various departments (see FIGURE 3.16: Cross Functional process map for
a Custom Workshop
figure 3. 16)
• Departments listed as rows separated by
dashed lines
• Also called a swim-lane chart
 SUMMARY
The various charts presented in this module are valuable tools
for presenting and solving problems. Just as several types of
tools are available for a particular job so several chart designs
can help solve an engineering problem. Analysts should
understand the specific functions of each process chart and
choose the appropriate one for solving a specific problem and
improving operations.
 SUMMARY

The flow process chart provides more details for the analysis
of manufacturing operations, to find hidden or indirect costs,
such as delay time, storage costs, and material handling costs.
 SUMMARY

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
• What is methods study?
• Enumerate and explain the procedure for conducting the
method study.
• How do the operation process chart show materials
introduce into the general flow?
• How does the flow process chart differ from the operation
process chart?
• What is the principal purpose of the flow process chart?
 REVIEW QUESTIONS
• What symbols are used in constructing the flow process chart?
• How does the gang process chart differ from the worker and
machine process chart?
• What is a flow diagram?
• What are some of the problem areas that can be identified using
flow diagram?
• 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.
 PROBLEMS
2. The current operation consists of the following elements:
Operator removes pressed unit (0.2 min).
Operator walks to inspection area, checks for defects (0.1 min).
Operator files rough edges (0.2 min).
Operator places unit on conveyor for further processing and returns to
press (0.1 min).
Operator cleans press die element with compressed air (0.3 min).
Operator sprays lubricant into die (0.1 min).
Operator places sheet metal into press, pushes START (0.2 min).
Press cycles automatically for 1.2 min.
Draw the worker-machine chart.
 PROBLEMS
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.
 PROBLEMS
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
• Aft, L. S. (2000). Work Measurement and Methods Study.
Wiley.
• Groover, M. P. (2007). Work Systems and the Methods,
Measurement and Management of Work. Pearson
Education International.
• Niebel, A. F. (2009). Niebel's Methods, Standards, & Work
Design (12 ed.). McGraw Hill.
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