Operations Analysis 1: System Analysis Environment Analysis Personnel Analysis Facilities & Equipment Analysis Process Analysis Traditional Industrial Engineering Process Analysis IE 366 Learning Outcome 4: Apply a structured engineering process (analysis/requirements development, design, implementation, operation, evaluation, project management) to work system development. IE 366 Learning Outcome 3: Model work systems using standard techniques, such as flow diagrams, process charts, operation charts, activity charts, block diagrams, and process maps, for purposes of work system documentation, analysis, and design.

System Analysis in The Work Systems Engineering Process Needs, Problems, Opportunities Analysis System Analysis Environment Analysis Personnel Analysis Facilities & Equipment Analysis Process Analysis Task Analysis Failure Modes & Effects Analysis Requirements Engineering Evaluation Checklists Heuristic Evaluation Usability Testing Statistical Analysis Performance Data, Observations Management Planning Scheduling Work Assignment Monitoring Assessment Requirements Operation Role Playing Simulation Full-scale Operation Observation Data Collection Design Workstation Design Equipment Design Procedure Design Job Aid Design Design Specifications Work System Implementation as (Computer) Model Mockup Prototype Operational System

Basic Concepts of System Analysis Model Modeling (Engineered) System: A set of related entities that work together to perform a function (achieve a goal or objective, fill a purpose), e.g., a printed circuit board fab. Subsystem: ..., e.g., a PCB inspector's workstation Supersystem: ... e.g., an electronics manufacturing company. Decomposition and Representation are keys to solutions for complex problems. Analysis: process of breaking a complex problem or system down into smaller parts. Model: a representation Physical Graphical Mathematical Computer Modeling: the process of creating models (usually involves analysis) Understanding Communication Data organization Problem solving Requirements writing

Example For System Analysis: Pre-Reflow Inspection Station (PRIS) Modern SMT process at a electronics manufacturer. Each line consists of 1 solder dispenser 1+ pick & place machine 1 reflow oven Pick & Place Machine 3 Display Circuit Board Keyboard Inspector Cart Reflow Oven Conveyor Document/Tool Tray Magnifier Excerpt from Mike Lee's thesis: The pre-reflow inspection process starts when a populated PCB arrives on the conveyor from the last pick and place machine in the series of pick and place machines. The inspector locates the work order or OPIE (an “interactive” work instruction), identifies the model of the PCB, and loads the diagram of the PCB using a database program called [bView]. [bView] displays a diagram of the PCB on a computer monitor behind the conveyer system. There are also other sources where the inspector can obtain additional information regarding the board or the inspection process, including waivers, instructions, and upstream operators. There are secondary tasks the inspector must perform before inspecting the PCB. An example of such a secondary task is for the inspector to determine and set a temperature profile for the reflow oven based on the board specifications. During the inspection of the PCB, the inspector looks for four types of flaws: Board match: The inspector checks if the populated PCB that arrived at the inspection station is the one planned on the work order. Board population: The inspector checks the populated PCB to see if the components are placed in locations they are designed to be placed, and unpopulated where no components should be placed. Type of component: The inspector checks the components on the PCB to make sure they are the right components. Component orientation: The inspector checks the components on the PCB to see if they are oriented correctly. Components can be positioned slightly rotated or shifted. Another issue with certain components is the risk of the components being rotated 90 or 180 degrees.

PRIS Photo FLOW DIRECTION

Overall SMT Process Solder dispense Pick & place

A Typical PCB

bView Display

Inspection Process Prepare and review documents Program reflow oven Inspect board Check board match Check component placement Check component population Check component rotation/direction Insert manual components

PRIS Preliminary System Analysis PRIS Environment PRIS Personnel PRIS Equipment PRIS Processes PRIS Inspector Prepare & Review Documents Automatic Assembly Equipment Conveyor Inspection Tools Computer Adjustment & Assembly Tools Reflow Oven Furniture Program Reflow Oven Display CPU Keyboard & Trackball Cart Document/Tool Tray Inspect Board Insert Manual Components Solder Dispenser Pick & Place Machine 1 Pick & Place Machine 2 Pick & Place Machine 3 Reflow Oven Displays Reflow Oven Controls Reflow Oven Chamber (handout)

Traditional Industrial Engineering Process Analysis Flow Process Charts Flow Diagrams Assembly Charts Activity Charts Multi-Activity (Gang) Charts Left-Hand Right-Hand Charts Process Maps IDEF0 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)