ACTIVITY CHARTS

Although the process chart and the flow diagram give a picture of the various steps in the process, it is often desirable to have a breakdown of the process or of a series of operations plotted against a time scale. Such a picture is called an activity chart. The activity chart is of special value for analyzing maintenance work, jobs involving people working in groups, and operations where the work is unbalanced and where there is necessary idle time. Examples: Figures 55, 56, 57 and 58 on pages 87-88. Motion and Time Study Design and Measurement of Work by Ralph M. Barnes (1980)

MAN AND MACHINE PROCESS CHARTS

The man and machine process chart is used to study, analyze, and improve one work station 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 between balance of the work cycle. The operator and machine work intermittently on some types of work. That is, the machine is idle while the operator loads it and while he or she removes the finished work from it, and the worker is idle while the machine is in operation. It is desirable to eliminate idle time for the worker, but it is equally important that the machine be kept operating as near capacity as possible.

The first step in eliminating unnecessary waiting for the operator and for the machine is to record exactly when each works and what each does. Many operations consists of three main steps:

GET READY, such as putting material in the machine DO, such as drilling a hole PUT AWAY or CLEAN UP, such as removing the finished piece from the machine

In charts, the steps performed by the operator are listed on the left-hand side and the operation performed by the machine is listed on the right-hand side.

Synchronous servicing

Assigning more than one machine to operator seldom results in the ideal case where both the worker and the machine are occupied during the whole cycle. Such ideal cases are referred to as synchronous servicing, and the number machines to be assigned can be computed as:

l+m n = ----------------l
where:

n = Number of machines the operator is assigned l = Total operator loading and unloading time per
machine m = Total machine running time

Example : Assume a total cycle time of four minutes to produce a product, as measured from the start of the unloading of the previously completed product to the end of the machine cycle time. Operator servicing, which includes both the unloading of the completed product and the loading of the raw materials, is one minute, while the cycle time of the automatic machine cycle is three minutes

l+m 1+3 n = ----------------- = ------------- = 4 machines l 1

If the number of machines in this example is increased, machine interference takes place. If the number of machines is reduced to some figure less than four, then the operator is idle for a portion of the cycle. In such cases, the minimum total cost per piece usually represents the criterion for optimum operation. To establish the best method, the analyst must consider the cost of each idle machine and the hourly rate of the operator. The procedure is first to estimate the number of machines that the operator should be assigned under realistic conditions by establishing the lowest whole number from the following equation

l+m n1 ----------------l +w

where: n1 = lowest whole number w = Total worker time (not directly interacting with the machine, typically walking time to the next machine).

The cycle time with the operator servicing n1 machines is l + m, since in this case, the operator is not busy the whole cycle, yet the facilities are occupied during the entire cycle Using n1 , we can compute the total expected cost (TEC) as follows: K1(l + m) + n1K2 (l + m) (l + m) (K1 + n1K2) TEC n1 = ---------------------------------- = --------------------------

n1

n1

where: TEC = Total expected cost in dollars per unit of production from one machine. K1 = Operator rate, in dollars per unit of time. K2 = Cost of machine, in dollars per unit of time

After this cost is computed, a cost should be calculated with n1 + 1 machines assigned to the operator. In this case, the cycle time is governed by the working cycle of the operator, since there is some idle machine time. The cycle time now (n1 + 1) (l + w). Let n2 = n1 + 1. The the total expected cost with n2 facilities is: K1n2 (l + w) + K2n2n2 (l + w) TEC n 2 = ------------------------------------- = (l + w) (K1 + n2K2 )

n2

EXAMPLE: It takes an operator 1 minute to service a machine and 0.1 minute to walk to the next machine. Each machine runs automatically for 3 minutes, the operator earns $10.00/hour and the machines cost $20.00/hour to run. How many machines can the operator service?

l+m 1+3 n = ----------------- = ------------- = 3.6 l +w 1 + 0.1

(l + m) (K1 + n1K2) (1 + 3) (10 + 3 x 20) TEC 3 = ----------------------------- = ---------------------------:60 n1 3 TEC 3 = $1.556/unit

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TEC 4 = (l + w) (K1 + n2K2 ) = (1 + .1) (10 + 4x20)/60=$1.65/unit

Based on the lowest cost, the set up with three machines is best.

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GANG PROCESS CHARTS

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. 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 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.

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MOTION STUDY

The overall study of the process should result in a reduction in the amount of travel of the operator, materials, and tools, and should bring about orderly and systematic procedures. The man-machine chart often suggests ways of eliminating idle machine time and promotes a better balancing of the work of the operator and the machine. After such studies have been completed, it becomes time to investigate specific operations in order to improve them. The purpose of motion study is to analyze the motions used by the worker in performing an operation, in order to find the preferred method.

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A systematic attempt is made to eliminate all unnecessary motions and to arrange the remaining necessary motions in the best sequence. It is when we come to the analysis of specific operations that motion study principles and techniques become most useful. Motion study may vary in extent from a cursory analysis followed by a general application of motion economy principles, to a detailed study of individual motions of each hand followed by a careful and extensive application of motion economy principles.

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Motion study is the careful analysis of body motions employed in doing a job. The purpose of the motion study is to eliminate or reduce ineffective movements, and facilitate and speed effective movements. Through motion study, in conjunction with the principles of motion economy, the job is redesigned to be more effective and to produce a higher rate of output. As part of motion analysis, the Gilbreths concluded that all work, whether productive or nonproductive, is done by using combinations of 17 basic motions (therbligs)

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The principles of motion economy

Gilbreth listed certain rules for motion economy and efficiency

The two hands should begin as well as complete their motions at the same time The two hands should not be idle at the same time except during rest periods Motions of the arms should be made in opposite and symmetrical directions and should be made simultaneously Hand and body motions should be confined to the lowest classification with which it is possible to perform the work satisfactorily Momentum should be employed to assist the worker wherever possible, and it should be reduced to a minimum if it must be overcome by muscular effort Smooth continuous curved motions of the hands are preferable to straight line motions involving sudden and sharp changes in direction.

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THE TWO-HAND PROCESS CHART

It sometimes referred to as an operator process chart, is motion study tool. This chart shows all movements and delays made by the right and left hands, and the relationships between the basic divisions of accomplishment as performed by the hands. The purpose of the two-hand process chart is to present a given operation in sufficient detail that the operation can be analyzed and improved. Through the motion analysis of the two-hand process chart, inefficient motion patterns can be identified, and violations of the principles of motion economy can readily be observed. The result is smoother, more rhythmic cycle that keeps both delays and operator fatigue to a minimum.

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In summary, the two-hand process chart is an effective tool to:

Balance the motions of both hands and reduce fatigue Reduce or eliminate nonproductive motions Shorten the duration of productive motions Train new operators in the ideal method Sell the proposed method.

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