3. Motion Study & Work Design

Operation Analysis Approach-1 Method analysis Eliminate, simplify, or combine operations Design analysis Reduce the number of parts Design for manufacturability and assembly Manufacture sequence Rearranging operations Mechanizing manual operation

Operation Analysis Approach-2 Set-up and Tools Reduce set-up time: SMED Material Handling Handling equipment Ergonomic principles Lay-out

The Four Principles of Motion Economy 1. Reduce the Number of Motions Eliminate or reduce the number of motions 2. Perform Motions Simultaneously Design improvements in the methods and tools which allow both hands to be used at the same time

The Four Principles (cont’d) 3. Shorten Motion Distances Reduce - walking, reaching, stretching, squatting and turning, etc. 4. Make Motion Easier Work should be smooth and rhythmical, reduce fatigue and promote safety

Use of the Human Body Both hands should start and finish the operation at the same time. Reduce idle time for either or both hands Arm motions should be symmetrical Employ curved movements during the operation Employ rhythmical standard operation Ensure a similar focal point for tools, materials, etc.

Arrangement of the Work Place Use fixed positions for tooling and parts to allow habits to form easily Use gravity feeding to ensure a common pickup point Position parts, materials and tools to enable sequential use Use ejector systems or drop deliveries, so the operator has minimal effort to pass on parts to the next operation Benches and chairs should be at the correct working height to avoid interrupted motions All equipment should be within the maximum work area

Design of Tools and Equipment Eliminate the need to use one hand purely to hold a part Use combination tools Use counterbalances on heavy tooling Ensure handles on tools are designed to use maximum hand contact Place tooling in the most convenient positions Separate part supplies should be used for two operators. Tools should be placed to enable immediate use Provide chutes for access of parts, and components in/out of the workplace

5 S Seiri, Seiton, Seiso, Seiketsu, Shitsuke Sort, Clean, Set in order, Standardize, Progress 5R : Ringkas, Rapih, Resik, Rawat, Rajin

Poka Yoke “Mistake proofing” A manufacturing technique of preventing errors by designing the manufacturing process, equipment, and tools so that an operation literally cannot performed incorrectly

Excuses… I like the way I am doing it now. It's too radical a change. I tried it once and didn't like it. It sounds like a production line. It won't work in our office. I think we should look into it further before we act. It won't pay for itself. I know a fellow who tried it. We've always done it this way.