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DEXTERITY TRAINING

OVERVIEW
Often we come across the action plan which calls for training or retraining
of the operator whenever there is some quality concern or a concern
related to safety. Whether the operators are new or experienced, there is
always a need of training on some of the very fundamental things and
basic systems of an organization.
Dexterity training to all the workmen and shop floor officers is the way out
to impart the basic training to operators and ensure consistency in quality
and output.

There are 4 Major objectives of Dexterity


1. Awareness of shop floor quality system and Tools being used in
system.
2. Enhancement of the Basic Skill.
3. To inculcate the observation Skill and to develop the Learning skill by
using 3 step Learning Method.
4. To identify and eliminate Ineffective, Irrational and Irregular
Movements to improve body movements through 4 motion economy
principles.
- It helps you to correctly perform, from the outset, simple
gestures such as tightening, riveting, part handling.
- It allows you to acquire, master and perfect these basic
operations in a manner that ensures quality, safety and
fluid movements.

Advantages of mastery of basic skills:


1. Allows movements to be rendered repeatable, limiting variation
in execution, and thus the risk of non-quality.
2. Favors the optimization of operations by improving the fluidity
of movements.
3. Provides enhanced ergonomy and safety by developing the
most favorable movements.
4. Facilitates on-the-job (workstation) training, as the basic
skills/movements are already mastered

Benefits:Dexterity will lead to a culture that will ensure:1. Obedience to an operating standard, this is the guarantee of better
mastery of dispersion and obedience to the key points. It thus adds to an
improved quality.
2. The profound knowledge of workstations, for which the dexterity
Instructor has compiled the standards, will enable him to train his
operators, while making sure that the operators obeys to the operating
procedures and diagnose quality problems much more rapidly,
particularly if they are due to non-adherence to the operating procedure.
3.The conditions in which workstation operations are carried out to be
standardised by optimizing the movements and rendering them more
fluid, while minimizing moves and non value added
activities/operations.
4. The horizontal deployment across the shops/plants and daily updation
of standards on account of QCD progress achieved.
Indeed, correct mastery of use of the standards demands that the
dexterity Instructors are thoroughly trained in their use and in the
workstation optimization method, and that the operators themselves are
trained to use their workstation and have been sensitized to the
standardization principles.

The target of Dexterity: The target of Dexterity is to teach, practice and improve body movements
of workers through 4 motion economy principles.
By implementation of these principles we can achieve the fluidity in coordination between quality, delivery and safety, which are our target. One
must not forget to use these four principles to analyze and improve the

The four motion economy principles: 1) Reduce the number of movements Eliminate movements (e.g.
movements between two individual operations, irrational and unnecessary

movements) Reduce the number of movements (e.g. subsidiary


movements, the number of parts)
2) Execute movements simultaneously Simultaneous operation with
both hands (e.g. it is easier to perform symmetrical movements with both
hands) Reduce the "dead" time of each hand (e.g. balance left - right
hand activity)
3) Shorten movement distance Move, stand, shoulder, arm, forearm,
hand, and finger Change a curvilinear movement into a rectilinear
movement (e.g. parts at the bottom of a box)
4) Make movements easier Eliminate the factors hampering movement
(e.g. a screwdriver machine hose in front of a parts bin) Reduce the
weight to be handled (e.g. by using a gravity or guide device)
By implementation of these principles we can achieve the fluidity in coordination between quality, delivery and safety.
One must not forget to use these four principles to analyze and improve
the following three areas:A)Use of the human body
Where possible: - Both hands should start and finish the operation at the
same time. - Reduce idle time for either or both hands, except at times of
rest.
- Arm motions should be symmetrical, in opposite/similar directions and
performed simultaneously.
- Facilitate easy and curved movements during the operation, rather than
straight line motions involving sharp changes in direction.
- Employ rhythmical standard operation, so one assignment naturally
follows on to the next (position of parts). - Ensure a similar focal point for
tools, materials, etc. to reduce head movements and eye strain.
B) Arrangement of the work place.
Where possible - Use fixed positions for tooling and parts to allow habits to
form easily. - Use gravity feeding to ensure a common pickup point. Position parts, materials and tools to enable sequential use and single
touch pick up. - Use ejector systems or drop deliveries, so the operator
has minimal effort to pass on parts to the next operation.
All part stored should be within the reach area or workstation area.

C) Design of tools and equipment.


Where possible
- Eliminate the need to use one hand purely to hold a part by using jigs.
- Use combination tools (back to back benches).
- Use counterbalances on heavy tooling.
- Ensure handles on tools are designed to use maximum hand contact.
- Place tooling in the most convenient positions, to eliminate excessive
body movements.
- Where two operators are fitting the same part to their respective sides of
a large product, (e.g. wheels on a car assembly line), separate part
supplies should be used
- Tools should be placed to enable immediate use, without having to turn,
lift or alter their position beforehand.

If the standard Operation Sheets are designed by considering these above


stated principles, the Rhythm & Fluidity in operators movements will
definitely be observed which will lead to improved speed together with
quality & safety.

After understanding the basics of motion economy principles Basic skill


development is accelerated by:1.3 Step Learning.
2. Observation.
3. Standardization and 4 Principles of motion economy.
4. Evaluation.
5. Rhythmic practice.

How training is imparted?


During Dexterity training, certain basic principles are to be applied so
that learning is smooth, quick and everlasting. These principles are:A. Dexterity School has to be PLAYFUL
B STANDARDIZED workbench implementation
C. Dexterity training is a MANAGEMENT ACT. Cell leader has to be
present /visiting during or at least at the end of the training session.
D. Dexterity (Dexterity school) is not a line work station. Trainees are
working to improve BASIC GENERIC DEXTERITY, not job allocation.

Dexterity:-

It allows employee to acquire, master and perfect these basic operations


in a manner that ensures quality, safety and fluid movements as well as
helping individuals to solve his specific difficulties while performing an
operations.

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