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INDUSTRIAL ENGINEERING - Coggle Diagram

- - - - Execution of work by an operator using the standard instruction (OMS). Reduces: NVA; Variation; Mistake proofing; Training time.
  - - - Improve the method
        
        Implementation of 5S
        
        7 Deadly wastes: Overproduction; Movement; Motion; Waiting; Overprocessing; Inventory; Defects.
        
        VA x NVA
        
        Work simplification: Eliminating; Combining; Simplifying
      - Method analysis
        
        Analyze the operation.
        
        It is the Layout; Method; Safe/Ergonomic; Quality acceptable?
        
        Are there wasted motions?
        
        Develop several methods.
        
        Listen the operators from the process
        
        Use motions of both hands/arms.
        
        Motions should be short and simple.
        
        Parts should be handled in multiples
        
        Feet activate devices.
        
        Place tools/materials close to work.
        
        Reduces mental concentration and movement.
        
        Select the best.
        
        Based on data.
        
        Best = Safety, Quality, Cost (labor/material/equipment), Delivery (right qty at the right time), Customer satisfaction,
        
        Install the best.
      - It needs to
        
        Be capable and repeatable.
        
        Guarantee quality.
        
        Never included repair, rework setps.
- - - - b) Living document.
      - a) Detailed step (activity) by step (activity) process documentation.
    - - Simple, descriptive, detailed, measurable
      - Should have a good starting point (gain control of an item) and end (completion of a move/body travel)
      - It needs to clarify:
        
        Tool to be used.
        
        How to position/assembly the part.
        
        Items stocked.
        
        How many revolutions to tight.
      - Bad vs Good
        
        Bad: Tape the box shut.
        
        Good: Reach the tape dispense with one hand and remove 10cm piece of tape while the other hand holds down flaps. Apply tape to end of cartoon with both hands. Turn carton 180 degrees.
    - - Small part of an activity. A group of elements forms an activity.
        
        Activity: Remove cap plug from hitch fram. Procure plug and install to the LHS of the hitch frame....
        
        Elements:
        (i) Cap plug - Plain - Remove 1st (0.071s);
        (ii) Fitting - First (0.204s).
      - All elements described in an activity must be time accounted.
        
        Time of the activity = Time of all elements of the activity
    - - a) Standard data.
        Priority
        
        JD Data base for elements presents in several worldwide methods.
        
        Total Allowed SM = Average observed time x Performance rating x P&F x Job Delay
      - b) Time study (measuring work)
        
        Only for unique elements that does not exist in the data base.
        
        Should only be performed on average operators.
        
        Average operator = trained, experienced, competent.
        
        Use a stopwatch that reads in decimal minutes.
        
        Record the activity performed by an average operator.
        
        Focus on the element that does not exist in the data base.
        
        Creates a data collection plan that guarantees reliability, repeatability, free from bias.
        
        Follow the table that relate takt time vs number of observations.
        
        Element time = average time of the observations.
        
        Proration
        
        Work that does not occur every cycle (calibrate or opening a bag). Rateio
        
        Performance rating
        
        Effort of the operator.
        
        Skill.
        
        Normal minutes = Time to perfor a work at 100% work pace
        
        Ranges from 70 to 140%
        
        a) Constant controlled pace (Press and hold buttom, move and hold..)
        
        Element time = Average observed time *115%
        
        b) Process limited (manual arc welding, spray painting..)
        
        Element time = Minimum observed time*130%
        
        Arc welding time
        Adjusted time = (Spec weld size/Average weld size observed) x observed time
        does not consider observations with weld size less than the spec weld size
        
        Spray paint time
        Adjusted time = (Spec paint thickness/Average thickness) x observed time
        
        Standard minutes = Normal minutes * Personal and Fatigue
        
        P&F = Drink water, bathroom, fatigue increasing along the day.
        See the table to match the work and the P&F
        in average is 114%
        
        Job Delay Factor
        
        Immeasurable, miscellaneous work, or interruptions (turn lights on and off, contact supervisor...).
        1.03 to 1.06
- - - - Man-Machine
        
        Total Standar Minutes = D + R + IDA
        
        IDA = [ (MT x 1,08) - (R/1,3) ] x 1,1
        
        Incentive Opportunity = (D+R+IDA) / (D/1,3) + (R/1,3) + (IDA/1,1)
        
        Output Standard = (TSM/Pieces per cycle) x JD x 1.667
        
        Actual Cycle Time Minutes = (D/1,3) + (R/1,3) + (IDA/1,1)
        
        Actual Cycle Time Standard = (Actual Cycle Time Minutes/Pìeces per cycle) x JD x 1,667
- - - - Measurable.
        
        Repetitive.
        
        Predictable.
        
        Verifable.