2 method study

Method Study

Method StudySelect

Record

Examine

Develop

Evaluate

Define

Install

Maintain

To Simplify the job and develop more economical methods of doing it

the job to be studied

by collecting data or by direct observation

by Challenging purpose, place, sequence, and method of work

new methods drawing on contributions of those concerned

results of different alternative solutions

new method and present it

new method and train persons in applying it

and establish control procedures

Select – Where to Look

• Poor use of resources

• Bad layout

• Bottlenecks

• Inconsistent quality

• High fatiguing work

• Excessive overtime

• Employee’s complaints

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Select – Economic Considerations

• Key profit- generating operations

• Key costly operations

• Repetitive work

• Long travels

• Excessive overtime

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Will it pay to begin, or continue, a method study of this job?

Select – Technical Considerations

• Extensive paperwork

• Repetitive work (automation)

• Hazardous work

• Inconsistent quality

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Desire to acquire more advanced technology

Select – Human Considerations

• Satisfaction level

• Start with non-controversial jobs

• HSE

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Workers satisfaction/resentment

Select – Limiting the Scope

• One operation or a sequence

• The whole operation or part

• Which aspect: worker, materials, equipment, … etc.

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Setting boundaries and determining content

Select – Possible Results

• Increased production rate

• Reduced cost

• Less labor, materials, or equipment

• Improved quality

• Improved safety

• Reduced scrap

• Improved standards of cleanliness

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Select – Pareto Analysis

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

A job on which there is much CHASING AROUNDCHASING AROUND usually has great improvement possibilities.

Pick a job that involves HARD WORKHARD WORK and make it easy to do

If your materials are expensive - then a job on which much MATERIAL IS USEDMATERIAL IS USED or SCRAPPED is a good one to study.

Select a job on which the INSPECTIONINSPECTION of the product can be improved or eliminated.

Tips

Work on SIMPLE JOBSSIMPLE JOBS until you learn the technique.

Pick a job that work in a PARTICULAR WAY for a LONG TIME

Record- Charts and DiagramsOutline Process Chart

Flow Process Chart (Worker, Material, Equipment)

Flow diagram

Two-Handed Process Chart

Procedure Chart

Simultaneous motion Cycle Chart

Multiple Activity Chart

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Flow Diagram

String Diagram

Cyclegraph

Chronocyclegraph

Travel Chart

Record- Symbols

Operation (Make ready, Do, Put away)

Inspection

Transport

Delay

Storage

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Record- Symbols

Operation (Make ready, Do, Put away)Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Record- Symbols

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Outline Process Chart

• An outline process chart is a process chart giving an overall picture by recording in sequence only the main operations and inspections.

• Only symbols for ‘Operation’ and ‘Inspection’ are used.

Symbols• (Operation): A part is changed in one or more of

its characteristics.

• (Inspection): A part is examined for identification or compared with its corresponding standard without any transformation of its characteristics.

• Vertical line: show the sequential steps or process flow.

• Horizontal line: Assembly/disassembly of raw or subassembly materials.– Drawn to the left of the vertical line: Assembly– Drawn to the right of the vertical line: Disassembly

Procedure

• Record the chart identification information: process name; present or proposed method; part #; drawing #; analyst; and date.

• Identify all operations, inspections, and materials involved in the manufacturing process.

• Arrange all events related to each material in manufacturing sequence and connect them with vertical lines.– The main assembly process is placed to the right.– Do not cross vertical flow lines and horizontal lines. If

unavoidable, draw a small semi-circle at the junction.• Record the time allowance and name of each operation

and inspection.• Summarize the process in tabular format.

ProcedurePart 1

O-1

O-2

O-3

Part 2

O-4

O-5

O-6

Assembly part 2 to part 1

O-7Comp 1

Comp 2

I-1

Record- Example

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

Outline Chart

Face, turn, cut

Face opposite end

Dimension and finish

Straddle mill four flats

Remove burr

Final inspection of machining

Degreasing

Cadmium plating

Final check

Face both sides

Drill hole

Final check

Assemble and drill

Turn shank

Remove chip

Dimensions

Degreasing

Cadmium plating

Final check

Fit stop pin

Final check

Switch Rotor

Flow Process Chart

• A graphic, symbolic representation of the work performed or to be performed on a product as it passes through some or all the stages of a process (ANSI Z94)

• 3 Types:– Worker type: A flow process chart which records what

the operator does– Material type: A flow process chart which records how

material is handled or treated– Equipment type: A flow process chart which records

how the equipment is used

Flow Process Chart

This chart uses circles for operations,

arrows for transports, squares for

inspections, triangles for storage, and

the letter D for delays. Vertical lines

connect these symbols in the

sequence they are performed.

Procedures

• Record chart identification information• Identify all operations, inspections, transportations,

delays, storages, and materials involved in the manufacturing process.

• Classify each activity and circle the appropriate chart symbol.

• Record the times for activities and distances for transportations.

• Include comments or recommendations for potential changes.

• Summarize the process in tabular form.

OPC VS FPC

FPC OPC

Contain all activities Limited to operation and inspection

Detail process Bird’s – eye

Usually a single line Cover the whole process

Flow Diagram

• A flow diagram is a representation of the

location of activities or operations and the

flow of materials between activities on a

pictorial layout of a process (ANSI Z94)

Procedures

(1) Record chart identification information.

(2) Sketch the layout.

(3) Identify each activity by an appropriate symbol and a number.

(4) Use different colors to indicate flow lines for more than one part.

Point out problems

1. Cross traffic

2. Backtracking

3. Distance traveled

4. Procedure

Examine- The QuestionsPurpose: What is actually done?

Why is it necessary?

Place: Where? Why?

Sequence: When? Why?

Person: Who? Why?

Means: How? Why?

Select

Record

Examine

Develop

Evaluate

Define

Install

Maintain

With a view to:

Eliminate

Combine or Rearrange

Simplify

is being done?is being done?

is it being done?is it being done?

is it done?is it done?

does it?does it?

is it done?is it done?

WHATWHATWHATWHAT

WHEREWHEREWHEREWHERE

WHENWHENWHENWHEN

WHOWHOWHOWHO

HOWHOWHOWHOW

1.1. Can any operation be eliminated?Can any operation be eliminated?1.1. Can any operation be eliminated?Can any operation be eliminated?

As unnecessary?

By changing the order of the work?

By new or different equipment?

By changes in the layout?

2.2. Can any movement be eliminated?Can any movement be eliminated?2.2. Can any movement be eliminated?Can any movement be eliminated?

By leaving out operations?

By changing the equipment?

By changing the layout?


By conveyors? (Make sure they are economical).

By shifting some operations to another job into which they fit more conveniently?

3.3. Can any delays be eliminated?Can any delays be eliminated?3.3. Can any delays be eliminated?Can any delays be eliminated?

4.4. Can inspection or counting be eliminated?Can inspection or counting be eliminated?4.4. Can inspection or counting be eliminated?Can inspection or counting be eliminated?




Do they give unnecessary duplication?

Are they done at the best point in the sequence?

Are they really necessary? What happens after they are done and the information obtained?

Can they be performed more conveniently by another person?






By changing the quantity handled at one time?

5.5. Can operations be combined?Can operations be combined?5.5. Can operations be combined?Can operations be combined?

6.6. Can movements be combined?Can movements be combined?6.6. Can movements be combined?Can movements be combined?



If they provide rest, can they be grouped better?



7.7. Can delays be reduced?Can delays be reduced?7.7. Can delays be reduced?Can delays be reduced?

8.8. Can the inspection or counting be combined?Can the inspection or counting be combined?8.8. Can the inspection or counting be combined?Can the inspection or counting be combined?




9.9. Can steps be made safer?Can steps be made safer?9.9. Can steps be made safer?Can steps be made safer?

By a better tool?

By changing position of control or tools?

By using better material, containers, racks, bins or trucks?

By lessening visual requirements?

By better workplace heights?

10.10. Can any operation be made easier?Can any operation be made easier?10.10. Can any operation be made easier?Can any operation be made easier?

By using inertia where possible and avoiding it where work must overcome it?

THATTHAT it’s done

KNOWINGKNOWINGKNOWINGKNOWING YOU ASKYOU ASKYOU ASKYOU ASK

WHYWHY is it done at all? What else could be done to accomplish the same result

WHEREWHERE it is done? WHYWHY it is done there? Where else could it be done?

WHENWHEN it is done? WHYWHY it is done then? At what other time could it be done?

WHOWHO does it? WHYWHY does this person do it? Who else could do it?

HOW HOW it is done? WHYWHY is it done this way? In what way could it be done?

Now Let’s Consider these Actions in DetailNow Let’s Consider these Actions in DetailNow Let’s Consider these Actions in DetailNow Let’s Consider these Actions in Detail

ELIMINATEELIMINATEELIMINATEELIMINATE

Consequently, that operation can be ELIMINATEDELIMINATED. Entirely too many operations that are studied for improvement, should instead be eliminated.

asking the question WHYWHY of the prompter WHATWHAT, often results in the answer that there is no good reason for doing the operation at all.

COMBINECOMBINECOMBINECOMBINE

If two operations can be combined, the labor cost after combining is often no more than the cost of one of the operations before. Also, the combining of two operations automatically eliminates the transports and storage between the operations.

the answer to WHEREWHERE, WHENWHEN and WHOWHO may lead to improvements by COMBININGCOMBINING OPERATIONSOPERATIONS.

This possibility comes up quite often when improving group operations.

CHANGE SEQUENCECHANGE SEQUENCECHANGE SEQUENCECHANGE SEQUENCE sometimes the answers to WHYWHY or WHEREWHERE, WHENWHEN and WHOWHO lead to possibilities of changing the sequence or the order in which operations are done.

SIMPLIFYSIMPLIFYSIMPLIFYSIMPLIFY

This should not be done until all the other steps are completed.

after every possibility for ELIMINATIONELIMINATION, , COMBINATIONCOMBINATION, and CHANGE IN SEQUENCECHANGE IN SEQUENCE has been noted, the development of HOWHOW should be made.

Contoh:

Studi kasus di perakitan TV

Lug

Shrinkage Band

Funnel Glass

Inner Shield

Panel Glass

Shadow Mask

Frame

Mask Spring

Frit Glass

Out side Graphite

Base

Getter

Shrinkage Band

Contact Spring

Inside Graphite

Shield Cup

G4

G3

G2

G1

Bead Glass

Exhaust tube

Cathode

Flare

Outer pin

Getter

Spring

BSC

Mount Assy

O-1 Weld

O-2

I-1

Mount Tilt

Check G/NG

(83,0)

(75,7)

(84,5)

Shield Cup

G4

G3

G2

G1

Bead Glass

Exhaust tube

Cathode

Flare

Outer pin

Getter

Spring

BSC

PETA ALIRAN PROSES

RINGKASAN

KEGIATANSEKARANG USULAN BEDA

JML WKT JML WKT JML WKT

OPERASI

PEMERIKSAAN

TRANSPORTASI

MENUNGGU

PENYIMPANAN

JAR

AK

(m

)

JUM

LAH

WA

KT

U (

detik

) ANALISA LAMBANG

URAIAN KEGIATAN

AP

A

DIM

AN

A

KA

PA

N

SIA

PA

BA

GA

IMA

NA

CATATAN

TINDAKAN

RU

AN

G

GA

BU

NG

UR

UT

AN

TE

MP

AT

OR

AN

G

PE

RB

AIK

I

Merakit E/G dengankomponen tambahan yaitu

BSC, spring dan getter(welding)

Mengambil holder yangberisi 25 mount yang telah

selesai dirakit di stasiunwelding (material handling)

Mengukur ketegaklurusanmount dengan bantuan

alat ukur (mount tilt)

Memberikan holder yangberisi 25 mount yang telah

selesai diukurketegaklurusannya

Memeriksa mount untukmelihat apakah mount

bagus atau NG

25

25

1

25

1

83

15.3

75.7

1.4

84.5

1,5

2

1

2

84,5

158,7

16.7

Pekerjaan : proses mount assy

No peta : 04

Orang bahan

Sekarang usulan

Dipetakan oleh : Nina Agustin

Tanggal dipetakan : 2 Agustus 2004

*LAYOUT RUANG MOUNT ASSY

Line 1 (14”)

Line 2 (20”/21”

MountTilt

FinalInspect

FinalInspect

FinalInspect

MountTilt

FinalInspect

WeldingMachine

WeldingMachine

Blower

Sub Mount Tables

Stock room

SterilizerRoom

1,5 m

MaterialTable

MaterialTable

7,1 m

5 m

7 m

4,9 m

17,5

m8,5 m

BlowerBlower

Ket:= Pergerakan operator mount tilt

PETA ALIRAN PROSES

RINGKASAN

KEGIATANSEKARANG USULAN BEDA

JML WKT JML WKT JML WKT

OPERASI

PEMERIKSAAN

TRANSPORTASI

MENUNGGU

PENYIMPANAN

JAR

AK

(m

)

JUM

LAH

WA

KT

U (

detik

) ANALISA LAMBANG

URAIAN KEGIATAN

AP

A

DIM

AN

A

KA

PA

N

SIA

PA

BA

GA

IMA

NA

CATATAN

TINDAKAN

RU

AN

G

GA

BU

NG

UR

UT

AN

TE

MP

AT

OR

AN

G

PE

RB

AIK

I

Merakit E/G dengankomponen tambahan yaitu

BSC, spring dan getter(welding)

Mengambil holder yangberisi 25 mount yang telah

selesai dirakit di stasiunwelding (material handling)

Mengukur ketegaklurusanmount dengan bantuan

alat ukur (mount tilt)

Memberikan holder yangberisi 25 mount yang telah

selesai diukurketegaklurusannya

Memeriksa mount untukmelihat apakah mount

bagus atau NG

25

25

1

25

1

83

15.3

75.7

1.4

84.5

1,5

2

1

2

84,5

158,7

16.7

Pekerjaan : proses mount assy

No peta : 04

Orang bahan

Sekarang usulan

Dipetakan oleh : Nina Agustin

Tanggal dipetakan : 2 Agustus 2004

2 158,7

1 84,5

2 9,03

0 0

0 0

0 7,67

*LAYOUT RUANG MOUNT ASSY SETELAH PERUBAHAN MATERIAL HANDLING

MountTilt

FinalInspect

FinalInspect

FinalInspect

MountTilt

FinalInspect

WeldingMachine

WeldingMachine

Blower

Sub Mount Tables

Stock room

SterilizerRoom

1,5 m

1,3 m

MaterialTable

Material

Table

7,1 m

5 m

7 m

4,9

m

17,5

m

8,5 m

BlowerBlower

Line 1 (14”)

Line 2 (20”/21”

Ket:= Pergerakan operator mount tilt

2 method study

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