Ch08-Intro Methods Engrg

Methods Engineering
Part II
Chapters:
8. Introduction to Methods Engineering and
Operations Analysis
9. Charting Techniques
10. Motion Study and Work Design
Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Introduction to Methods Engineering

and Operations Analysis
Sections:
Chapter 8
1. Evolution and Scope of Methods

Engineering
2. How to Apply Methods Engineering
3. Basic Data Collection and Analysis
Techniques
4. Automation and Methods Engineering

Methods Engineering
Analysis and design of work methods
and systems, including the
tooling,
equipment,
technologies,
workplace layout,
plant layout, and
work environment
Other names for methods

engineering:
Work study
Work simplification
Methods study
Process re-engineering
Business process re-engineering
Methods
Engineering
is
often
associated with work measurement.
Objectives in Methods Engineering

Increase productivity and efficiency
Reduce cycle time
Reduce product cost
Reduce labor content
Improve motivation and morale
Other Objectives
Improve customer satisfaction
Improve product and/or service quality
Reduce lead times and improve work flow
Increase flexibility of work system
Improve worker safety
Apply more ergonomic work methods
Enhance the environment (both inside and outside the
facility)
Operations Analysis
Study of an operation or group of related operations for
the purpose of analyzing their efficiency and
effectiveness so that improvements can be developed
Objectives in operations analysis
Increase productivity
Reduce time and cost
Improve safety and quality
Same basic objectives as methods engineering
Methods engineering places more emphasis on design.
It is broader than operations analysis.
Evolution and Scope of Methods

Engineering
Initial research (late 19th century) - Frank
Gilbreth: Motion study
Scientific management (late 19th century-early
20th century)- Frederick W. Taylor: Motion and
time study (first principle of the five principles)
Primary concern: manual physical labor
Today: methods engineering is applied to areas
such as indirect labor, logistics, service
operations, office work, and plant layout.
Methods Engineering
Can be divided into two areas:
1. Methods analysis
2. Methods design

Methods Analysis
Concerned with the study of an existing method or process

break the method (process) down into work elements or
basic operations
examine the details of the elements: a systematic (=
purposefully regular, methodical) search to improve the
process
This involved checklists of questions and suggestions for
improvements
Objectives :
Eliminate unnecessary and non-value-adding work elements
Combine elements and operations
Rearrange elements into more logical sequence
Simplify remaining elements and operations
In your project
Methods Design
Concerned with either of the following situations:
1.Design of a new method or process
Required for new product or service and there
is no existing precedent
Method must be designed from scratch, using
best existing practice for similar operations
2.Redesign of an existing method or process based
on a preceding methods analysis
Systematic Approach in Methods

Engineering
1.
2.
3.
4.
5.
6.
Define the problem and objectives

Analyze the problem
Formulate alternatives
Evaluate alternatives and select the best solution
Implement the best method
Audit the study (follow-ups)
IE 407-IE 408
A systematic approach is more likely to yield operational

improvements than an undisciplined approach
Step 1: Define the problem and objectives

Problem: the reason for needing a systematic approach
to determine its solution
low productivity, high cost, inefficient methods, the
need for a new method/operation
Objective: the desired improvement or new methods
design that would result from the project.
Increase productivity, reduce labor content, improve
safety, develop a new method
The problem definition and the objectives must be
specific to the problem under investigation.
Step 2: Analyze the problem

Data collection and analysis.
Kind of activities involved
Identify the basic function of the operation

Gather background information
Observe existing/similar processes
Collect data
Construct experiments on the process
Develop/utilize a mathematical model of the process
Perform a computer simulation of the process
Use charting techniques
Step 3: Formulate Alternatives

There are multiple ways to perform a task or
accomplish a process.
Some of them are more efficient and effective
than others
Formulate all feasible alternatives

Step 4: Evaluate alternatives and select the

best
Methodical assessment of the alternatives with
respect to the original problem definition and
the objectives.
Selecting the best one with respect to the
objective (but this is not a simple task)

Step 5: Implement the best method

Install the selected solution
Introduce/institute changes proposed in the
existing method
Pilot studies and trials of the new (revised)
method
Documentation of the revised method
Step 6: Audit the study

Continuous improvement (follow-ups)
Fine-tune the organizations problem solving
and decision making skills
How successful was the project in terms of
the original problem definition and the
objectives?
What were the implementation issues?
What should be done differently in the next
study?
The Techniques of Methods Engineering

The following techniques are mostly accociated
with the analysis step in the methods engineering.
Charting and diagramming techniques
Motion Study and Work Design
Facility Layout Planning
Work Measurement Techniques
New approaches
Charting & Diagramming Techniques
They are available mainly for collecting, displaying and

analyzing data
Network diagrams
Traditional industrial engineering charting techniques

Operation charts
Process charts
Flow diagrams
Other (alternative) diagrams

Block diagrams
Process maps
Next week
Motion Study and Work Design

Concerned with basic motions of a human worker while
performing a given task
17 basic motion elements, like reach, grasp, move,
release
Principles of motion economy- guidelines for work
design
Use of human body in developing the standard
method (e.g., design the work so that both hands are
fully utilized)
Workplace layout
Design of tooling used in the task
Motion Study and Work Design -Objective

Unnecessary motions can be eliminated.
Some of the
combined.
motion
elements
The method can be simplified.

In your project
2 weeks later
can
be
Facility Layout Planning

Facility layout refers to:
Size and shape of a facility
Arrangement of the different
equipment within the facility
departments
and
The layout plays an important role in determining the

overall efficiency of the operations
Problem area includes:
Design of a new facility
Installing new equipment, retiring old equipment
Expanding (or contracting) an existing facility
IE 302 and IE 407
Work Measurement Techniques
Four basic work measurement techniques:

1. Direct time study
2. Predetermined motion time systems
(PMTS)
3. Standard data systems
4. Work sampling
They can be used in methods engineering to
make improvements in the work methods
3 weeks later
New Approaches
Lean production
Based on the Toyota production system
Embraced by U.S. companies due to its success at
Toyota
Six Sigma and other quality-focused programs
Widely adopted in industry for improving quality of work
processes
5S: The 5-step work organization:
Seiri (Sort), Seiton (Set in order), Seiso(Shine),
Seiketsu (Standardize), Shitsuke (Sustain)
Most of the tools used are adaptations of the old IE
principles.
Selecting Among Alternative Proposals
Need for a systematic procedure to decide among alternative

proposals
To begin, list the technical

specifications for the application
Must features
features
and
functional
Some features and specifications that should be guaranteed

at the minimum level.
Desirable features
Not must features
Criteria matrix to evaluate alternatives

Proposals are evaluated against the features and
specifications
Eliminate candidates that do not satisfy must features
Develop scores for desirable features
Evaluation of Robots for Welding

Industrial Robot Candidates
Model A
Model B
Model C
Model D
OK
OK
OK
OK
OK
OK
OK
Not OK
OK
OK
OK
OK
6
4
4
2
6
5
2
5
2
8
2
6
5
4
1
6
2
5
1
5
4
3
3
8
33
29
37
Must features:
Continuous path control
Six-axis robot arm
Walkthrough programming
Desirable features:
Ease of programming (0-9)
Capability to edit program (05)
Multi-pass features (0-4)
Work volume (0-9)
Repeatability (0-5)
Lowest price (0-5)
Delivery (0-3)
Evaluation of vendor (0-9)
Totals:

Evaluation of Robots for Welding

Industrial Robot Candidates
Must features:
Continuous path control
Six-axis robot arm
Walkthrough programming
Desirable features:
Ease of programming (0-9)
Capability to edit program (05)
Multi-pass features (0-4)
Work volume (0-9)
Repeatability (0-5)
Lowest price (0-5)
Delivery (0-3)
Evaluation of vendor (0-9)
Totals:
Model A
Model B
Model C
Model D
OK
OK
OK
OK
OK
OK
OK
Not OK
OK
OK
OK
OK
6
4
4
2
6
5
2
5
5
4
1
6
2
8
2
5
1
5
2
6
4
3
3
8
33
29
37
Eliminate C because, it doesnt satisfy one of the must

features
Select D because, it has the highest score among
desirable features.
Basic Data Collection & Analysis Tools

1. Histograms
2. Pareto charts
3. Pie charts
4. Check sheets
5. Defect concentration diagrams
6. Scatter diagrams
7. Cause and effect diagrams
Histogram
A statistical graph consisting of bars representing
different values, in which the length of each bar indicates
the frequency or relative frequency of each member
A useful tool because the analyst can quickly visualize
the features of the data, such as:
Shape of the distribution (theoretical form, Normal,
Gama etc.)
Any central tendency in the distribution (single or
multimodal)
Approximations of the mean and mode (numerical
value of the centre)
Amount of scatter in the data (variance or risk)
Number of individual parts

Histogram for Data Display
Normal distribution

Pareto Chart
Special form of histogram in which attribute
data are arranged according to some criterion
such as cost or value
Based on Paretos (XIXth century economist
who was trying to analyze the distribution of
wealth in Italy) Law: the vital few and the trivial
many also known as 80%-20% rule
80% of a nations wealth is owned by 20% of the
population
80% of sales are accounted for by 20% of the SKUs
(stock keeping unit or items in stock)
Pareto Distribution

Pareto chart as a cumulative frequency

distribution

Pareto cumulative distribution

Can be modeled by
1 A x
y
for 0 y 1 and 0 x 1
A x
where
y=cumulative fraction of the value variable (e.g., wealth,
inventory value, revenue),
x=cumulative fraction of the item variable (e.g., population,
inventory items, customers)
A is a constant determines the shape of the distribution (shape
parameter).
To determine A:
x(1 y )
A
yx

Example: Pareto Cumulative Distribution

Given: 20% of the total inventory items in a
companys warehouse accounts for 80% of the
value of the inventory.
Determine:
(a) The parameter A in the Pareto cumulative
distribution equation.
(b) Given that the relationship is valid for the
remaining inventory, how much of the inventory
value is accounted for by 50% of the items?
Example: Solution
a) x=0.2, y=0.8
A=(0.20(1-0.8))/(0.80-0.20)=0.06667
A
x(1 y )
yx
b) y=(1+0.06667)(0.5)/(0.06667+0.5)=0.941
y
1 A x for 0 y 1 and 0 x 1
A x
50% items in inventory account for 94.1% of the value of

the inventory

Pareto Chart

Pareto Principle in Turkey

80% of the academic publications are affiliated to 20% of
the universities.
78% of the earnings are derived from 96 export items,
which makes the 20% of all export items.
In 2007 elections, three parties (20% of the political
parties) won the 84% of the votes.
Three highest grossing movies in last November, i.e.,
Harry Potter, New Yorkta Be Minare, Saw 3D (only
20% of the movies) makes 80% of the total gross
revenues.
Pie Charts
Example: Annual sales revenues and customer
distributions for two years

Check Sheet
Not check lists
Data collection tool generally used in the preliminary stages of a

study of a quality problem
To recogize the trends
Diagnose the problem
Identify areas of further study
Data often entered by worker as check marks in a given category
Examples:
Process distribution check sheet - data on process variability
Defective item check sheet types and frequencies of defects
on the product
Defect location check sheet - where defects occur on the
product
It is clear from the check sheet that the third shift is reponsible for much
of the variability in the data.
Make an investigation to determine the causes of this variability

The average daily production rate for the third shift is below the daily
rate for the other two shifts.
Defect Concentration Diagram

A drawing of the product (all relevant views),
onto which the locations and frequencies of
various defect types are added
Useful for analyzing the causes of product or
part defects
By analyzing the defect types and
corresponding locations, the underlying causes
of the defects can possibly be identified

Case study
refrigerators
involving
final
assembly
of
Four views of refrigerator showing locations of

surface defects
Defects
here
Defects
here
The defects were clearly shown to be concentrated around

the middle section of the refrigerator.
Upon investigations, it was learned that a belt was wrapped
around each unit for material handling purposes.
The defects were caused by the belt.

The necessary correction action was taken.
Scatter Diagrams
An x-y plot of data collected on two variables, where a
correlation between the variables is suspected
It is useful to identify a possible relationship that exists
between two processes.
The data are plotted as pairs; for each xi value, there is a
corresponding yi value
The shape of the collection of data points often reveals a
pattern or relationship between the two variables

Scatter Diagram
Effect of cobalt content on wear resistance for a
cemented carbide cutting tool
Negative correlation: As cobalt increases wear

resistance decreases.
Cause and Effect Diagram

A graphical-tabular chart used to list and
analyze the potential causes of a given
problem
Can be used to identify which causes are most
consequential (related) and how to take
corrective action against them
Also known as a fishbone diagram or spray
diagram

Six general categories of causes 5M + 1P
Machines
Equipment, tools etc.
Materials
Mother nature
Enviromental factor such as air temperature, humadity etc.
Methods
Procedures, sequence of activities etc.
Measurement
Validity and accuracy of the data collection procedure
People



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Methods Engineering

Work Systems and the Methods, Measurement, and Management of Work

Introduction to Methods Engineering

1. Evolution and Scope of Methods

Work Systems and the Methods, Measurement, and Management of Work

Other names for methods

Objectives in Methods Engineering

Evolution and Scope of Methods

Work Systems and the Methods, Measurement, and Management of Work

Concerned with the study of an existing method or process

Systematic Approach in Methods

Define the problem and objectives

A systematic approach is more likely to yield operational

Step 1: Define the problem and objectives

Step 2: Analyze the problem

Identify the basic function of the operation

Step 3: Formulate Alternatives

Work Systems and the Methods, Measurement, and Management of Work

Step 4: Evaluate alternatives and select the

Work Systems and the Methods, Measurement, and Management of Work

Step 5: Implement the best method

Step 6: Audit the study

The Techniques of Methods Engineering

Charting & Diagramming Techniques

They are available mainly for collecting, displaying and

Traditional industrial engineering charting techniques

Other (alternative) diagrams

Motion Study and Work Design

Motion Study and Work Design -Objective

The method can be simplified.

Facility Layout Planning

The layout plays an important role in determining the

Work Measurement Techniques

Four basic work measurement techniques:

Selecting Among Alternative Proposals

Need for a systematic procedure to decide among alternative

To begin, list the technical

Some features and specifications that should be guaranteed

Criteria matrix to evaluate alternatives

Evaluation of Robots for Welding

Work Systems and the Methods, Measurement, and Management of Work

Evaluation of Robots for Welding

Eliminate C because, it doesnt satisfy one of the must

Basic Data Collection & Analysis Tools

Number of individual parts

Work Systems and the Methods, Measurement, and Management of Work

Histogram for Data Display

Work Systems and the Methods, Measurement, and Management of Work

Work Systems and the Methods, Measurement, and Management of Work

Pareto chart as a cumulative frequency

Work Systems and the Methods, Measurement, and Management of Work

Pareto cumulative distribution

Work Systems and the Methods, Measurement, and Management of Work

Example: Pareto Cumulative Distribution

50% items in inventory account for 94.1% of the value of

Work Systems and the Methods, Measurement, and Management of Work

Work Systems and the Methods, Measurement, and Management of Work

Pareto Principle in Turkey

Work Systems and the Methods, Measurement, and Management of Work

Not check lists

Data collection tool generally used in the preliminary stages of a

Data often entered by worker as check marks in a given category

Make an investigation to determine the causes of this variability

Work Systems and the Methods, Measurement, and Management of Work