Other Process Analysis/Modeling Tools

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Presentation transcript:

Other Process Analysis/Modeling Tools Flow Process Charts Flow Diagrams Assembly Charts Activity Charts Multi-Activity (Gang) Charts Left-Hand Right-Hand Charts Process Maps Process: A sequence of events leading to some (intended) outcome. For example Manufacture (Freightliner) → finished trucks Assemble dash harness → completed dash wiring harness Fly aircraft → delivered passengers, cargo Climb to assigned altitude → at desired altitude Perform laparoscopic cholecystectomy → gall bladder removed Insert Veress needle → needle in place Purpose is to visually organize and structure a problem rather than to provide a solution.

Process Chart Symbols Operation Move Inspect Storage Delay Operation + Inspection

Flow Process Chart (Single-Object Process Chart) Source: Rago (1963)

Flow Process Chart (Detail) Source: Rago (1963)

Flow Process Chart Source: Groover, M., 2007. Work Systems. Upper Saddle River, NJ: Pearson Prentice Hall.

Flow Process Chart (Detail)

Flow Process Chart Source: Gaither (1986)

Flow Process Chart (Detail)

Flow Diagram Source: Groover (2007)

In-Class Exercise: (Flow) Process Chart, Flow Diagram (handout) Choose a simple activity you do frequently, e.g., Prepare microwave popcorn, Install ski rack on car Do a flow process chart Refer to text, Fig. 6.7 (p. 95) Draw a flow diagram on the back Refer to text, Fig. 6.8 (p. 95) Hand it to the person in front of you to review, make suggestions to improve process Additional copies of the process chart can be downloaded from the Resources section of the IE 366 home page.

Assembly Process Chart (Operation Chart) Source: Groover (2007)

Assembly Process Chart Source: Gaither (1986)

Assembly Process Chart (Details) Source: Gaither (1986)

Activity Chart (one worker) Source: Groover (2007)

Multi-Activity Chart (Gang Chart) Source: Gaither (1986)

Multi-Activity Chart (Detail)

Left-Hand Right-Hand Chart Source: Groover (2007)

Multi-Activity Chart (Worker-multimachine Activity Chart) Source: Groover (2007)

Process Maps (Flow Charts) Symbols In spite of this, there does not seem to be standard formatting or symbology for process maps. The point is simply to map elements of a process to some graphical (typically flow chart) representation.

Process Map Source: Groover (2007) Problems With Flow Process Charts, etc. Reductionist: focus in on the details “Lose the forest for the trees” Lose the “big picture” Focus on small problems/opportunities and miss the big ones. (Assembly process charts can overcome these, to a certain extent.) Source: Groover (2007)

Process Map Source: Overman (2007) Problems With Flow Process Charts, etc. Reductionist: focus in on the details “Lose the forest for the trees” Lose the “big picture” Focus on small problems/opportunities and miss the big ones. (Assembly process charts can overcome these, to a certain extent.) Source: Overman (2007)

Casting Back-End Operations Process Map Scrap? Receive from casting dept Grind & sandblast Perform visual inspection Dispose Yes No Defects? Rework Yes No Perform X-ray inspection Defects? Yes No Pack & ship