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Methods Engineering & Layout Planning

Chapters:

8. Introduction to Methods Engineering and Operations Analysis

9. Charting Techniques

10.Motion Study and Work Design

11. Facility Layout Planning and Design

Part II

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Introduction to Methods Engineering and Operations Analysis

Sections:

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

Chapter 8

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Methods Engineering

Analysis and design of work methods and systems, including the tooling, equipment, technologies, workplace layout, plant layout, and work environment

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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.

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Objectives in Methods Engineering Increase productivity and efficiency Reduce cycle time Reduce product cost Reduce labor content Improve motivation and morale المعنوية الروح Improve product and/or service quality Improve customer satisfaction Reduce lead times and improve work flow Increase flexibility of work system Improve worker safety Enhance the environment (both inside and

outside the facility)

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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.

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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.

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Methods Engineering

Can be divided into two areas:

1. Methods analysis

2. Methods design

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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

(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

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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 سابق Method must be designed from scratch من بدأأفضل using best existing practice ,الصفر

القائمة for similar operations الممارسات

2.Redesign of an existing method or process based on a preceding methods analysis

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Systematic Approach in Methods Engineering

1. Define the problem and objectives

2. Analyze the problem

3. Formulate alternatives

4. Evaluate alternatives and select the best solution

5. Implement the best method

6. Audit the study الدراسة (follow-ups)مراجعة

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The Techniques of Methods Engineering

The following techniques are mostly accociated with the analysis step in the methods engineering.

o Data gathering and statistical toolso Charting and diagramming techniqueso Motion Study and Work Designo Facility Layout Planningo Work Measurement Techniqueso New approaches

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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

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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 designo Use of human body in developing the standard

method (e.g., design the work so that both hands are fully utilized)

o Workplace layouto Design of tooling used in the task

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Motion Study and Work Design -Objective

Unnecessary motions can be eliminated.

Some of the motion elements can be combined.

The method can be simplified.

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Facility Layout Planning

Facility layout refers to:o Size and shape of a facilityo Arrangement of the different departments and

equipment within the facility

The layout plays an important role in determining the overall efficiency of the operations

Problem area includes:o Design of a new facilityo Installing new equipment, retiring old

equipmento Expanding (or contracting) an existing facility

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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

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Basic Data Collection & Analysis Tools

1. Histograms2. Pareto charts3. Pie charts4. Check sheets5. Defect concentration diagrams6. Scatter diagrams7. Cause and effect diagrams