1. 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.

2. 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

3. 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

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
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.

5. PRIS Photo
FLOW DIRECTION

6. Overall SMT Process
Solder dispense
Pick & place

7. A Typical PCB

8. bView Display

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. 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)

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
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.

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

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

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

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

16. Flow Process Chart (Detail)

17. Flow Process Chart
Source: Gaither (1986)

18. Flow Process Chart (Detail)

19. Flow Diagram
Source: Groover (2007)

20. 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.

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

22. Assembly Process Chart
Source: Gaither (1986)

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

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

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

26. Multi-Activity Chart (Detail)

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

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

29. 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.

30. 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)