Work Study and Plant Layout Optimization Techniques
Work Study: Methods and Measurement
1 The study of methods and work measurement. 2 The systematic recording and critical examination of the ways to implement activities to make improvements. 3 The application of techniques to find the time taken for a skilled worker to perform a task according to a predetermined performance standard.
Total Operation Time and Work Content
4 1 – Total time of operation under the existing conditions. 1.1 – Core content of basic work. 1.1.1 – Work-product and the total operation time. 1.2 Unproductive time. 1.2.A – Additional work contained due to bad product design or misuse of materials. 1.2.B – Additional work contained due to inefficient methods of operation or manufacturing. 1.2.C – Downtime attributable to human resources.
Method Study Procedure
5 1 – Select the job to study. 2 – Register information with data collection or direct observation. 3 – Examine critically the objective, place, order, and method of work. 4 – Create new methods based on input from stakeholders. 5 – Evaluate the results of different solutions. 6 – Identify new methods and present them. 7 – Implement and train people to apply them. 8 – Control procedures to maintain and develop the methods.
Job Selection Considerations
6 1 – Economic considerations or efficiency on the basis of costs. 2 – Technical considerations. 3 – Human considerations.
Process Mapping and Diagrams
7 1 – Diagrams of process operations (material entering the process, work method, process sheet, analysis of the process diagram, process diagram of the operation, flowchart of the process). 2 – Process diagram of the route (route diagram: receipt, inspection, and part numbering—original or improved method; analytical flowchart: receipt, inspection, and part numbering—original or improved method). 3 – Simultaneous activity diagram (diagram of equipment, man-machine chart, diagram of one man with several machines). 4 – Bimanual diagram.
The Critical Examination Technique
8 In each subject, systematic and progressive efforts involve asking questions to understand the purpose, place, person, and related media activities in order to eliminate, combine, reorder, or simplify tasks.
Plant Layout and Efficiency
9 Plant layout is organizing all the elements necessary for production in a factory so as to ensure a continuous flow of work more efficiently. 10 It involves the handling of materials, equipment utilization, inventory levels, and worker productivity.
Benefits of Optimized Layout
11 1 – Increased use of space, equipment, and employees. 2 – Better flow of information, materials, and employees. 3 – Improved morale and working conditions of employees. 4 – Flexibility.
Objectives of Plant Layout
12 1 – Reduce travel distances for materials, tools, and operators. 2 – Proper circulation of personnel, equipment, material moving equipment, etc. 3 – Effective utilization of space as needed. 4 – Safety and reduction of personal accidents. 5 – Location of spaces for inspection to improve the quality of the product. 6 – Decrease in work time. 7 – Improving work conditions. 8 – Increased productivity and lower costs. 9 – Flexibility to provide for future changes or a new plant sort.
Distribution Types
13 Distribution depends on the type of production: process-oriented distribution, product-oriented distribution, or fixed-position distribution.
Process-Oriented Distribution
14 Teams are relaxed and the allocation of tasks allows machines to be used for different products; thus, the breakdown of a machine does not stop work because the process can move to another machine, and operators are more skilled because they will know how to handle any machine. By contrast, the longer distances and separation of operations require more labor, and this set of factors increases costs.
Product-Oriented Distribution
15 1 – Large investments required to mount a high volume. 2 – Work stops at any point if an operation is suspended. 3 – Lacks flexibility. 4 – Rapid production. 5 – Low material handling costs. 6 – Product design varies with difficulty. 7 – Constant demand with large volumes. 8 – Material handling path is shorter. 9 – Balanced line required.
Flow Patterns
16 a – Flow line, b – Flow L, c – Flow U, d – Flow S.
Fixed-Position Distribution
17 Used when the product is bulky and cannot move; machines and teams are taken to the product. This limits the units performed at the same time. This distribution is complicated when space is limited, different materials are needed as the process unfolds, and the volume of material is dynamic.
Productivity Indicators
18 & 19 Productivity is the performance indicator that relates the amount of product used to the amount of output obtained.