1. IE 366 1 Operations Analysis 1: ● System Analysis – Environment Analysis – Personnel Analysis – Facilities & Equipment Analysis – Process Analysis ● Traditional Industrial Engineering Process Analysis

2. IE 366 2 The Work Systems Engineering Process Management Planning Scheduling Work Assignment Monitoring Assessment Needs, Problems, Opportunities Design Specifications Requirements Performance Data, Observations Analysis System Analysis Environment Analysis Personnel Analysis Facilities & Equipment Analysis Process Analysis & Modeling Ergonomic Analysis Failure Modes & Effects Analysis Requirements Engineering Design Workstation Design Equipment Design Procedure Design Job Aid Design using Design Principles Design Guidelines Implementation as(Computer) Model Mockup Prototype Operational System Operation Role Playing Simulation Full-scale Operation Observation Data Collection Evaluation Checklists Heuristic Evaluation Usability Testing Statistical Analysis Work System

3. IE 366 3 Basic Concepts of System Analysis ● System ● Analysis ● Model ● Modeling

4. IE 366 4 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 Displa y Circuit Board Keyboard Inspector Cart Reflow Oven Conveyo r Document/Tool Tray Magnifier

5. IE 366 5 PRIS Photo

6. IE 366 6 Overall SMT Process Solder dispense Pick & place

7. IE 366 7 A Typical PCB

8. IE 366 8 bView Display

9. IE 366 9 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

10. IE 366 10 PRIS Preliminary System Analysis PRIS System PRIS Equipment PRIS Perso nnel PRIS Processe s PRIS Inspect or Automatic Assembly Equipment Conveyor Reflow Oven Computer Inspection Tools Adjustment & Assembly Tools Furniture Prepare & Review Document s Program Reflow Oven Inspect Board Insert Manual Componen ts Solder Dispenser Pick & Place Machine 1 Pick & Place Machine 2 Pick & Place Machine 3 PRIS Environment DisplayCPU Keyboard & Trackball Reflow Oven Displays Reflow Oven Controls Reflow Oven Chamber Cart Document/ Tool Tray (handout )

11. IE 366 11 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

12. IE 366 12 Process Chart Symbols Operation Move Inspect Storage Delay Operation + Inspection

13. IE 366 13 Flow Process Chart (Single-Object Process Chart) Source: Rago (1963)

14. IE 366 14 Flow Process Chart (Detail) Source: Rago (1963)

15. IE 366 15 Flow Process Chart Source: Groover, M., 2007. Work Systems. Upper Saddle River, NJ: Pearson Prentice Hall.

16. IE 366 16 Flow Process Chart (Detail)

17. IE 366 17 Flow Process Chart Source: Gaither (1986)

18. IE 366 18 Flow Process Chart (Detail)

19. IE 366 19 Flow Diagram Source: Groover (2007)

20. IE 366 20 In-Class Exercise: ( Flow) Process Chart, Flow Diagram (handout )

21. IE 366 21 Source: Groover (2007) Assembly Process Chart (Operation Chart)

22. IE 366 22 Assembly Process Chart Source: Gaither (1986)

23. IE 366 23 Assembly Process Chart (Details) Source: Gaither (1986)

24. IE 366 24 Source: Groover (2007) Activity Chart (one worker)

25. IE 366 25 Multi-Activity Chart (Gang Chart) Source: Gaither (1986)

26. IE 366 26 Multi-Activity Chart (Detail)

27. IE 366 27 Source: Groover (2007) Left-Hand Right-Hand Chart

28. IE 366 28 Source: Groover (2007) Multi-Activity Chart (Worker- multimachine Activity Chart)

29. IE 366 29 Process Maps (Flow Charts) Symbols

30. IE 366 30 Source: Groover (2007) Process Map

31. IE 366 31 Source: Overman (2007) Process Map