1. Summer Training Department of Industrial Engineering
Operation Analysis
Summer Training
Department of Industrial Engineering

2. Questioning Attitude Why is this operation necessary?
What can be done to make the job safer?
Who can best perform the operation?
When is the best time to schedule this maintenance?
How can the task be improved?

3. Operation Purpose
Try to eliminate or combine an operation prior to improving it!
Some operations exist because the previous work was unacceptable, necessitating “touch-up” work supposedly accomplished by the first operation.
Can an outside supplier perform the operation more economically?

4. Questioning Attitude

5. Part Design Review every design for possible improvements.
Simplify design to reduce # of parts.
Make joining, machining, and assembly easier.
Design for manufacturing.

6. Tolerances and Specifications
Designers may overcompensate with very tight tolerances (high production cost and time consuming) because they are not aware of the capabilities of the manufacturing dept.

7. Cost vs. Machining Tolerance

8. Materials Find a less expensive material
Find materials that are easier to process
Use materials more economically
Use salvage materials
Use supplies and tools more economically
Standardize materials
Negotiate best prices from vendors

9. Manufacturing Sequence and Process
Rearrange operations
Mechanize manual operations (ergonomically designed tools)
Use of robots
Operate mechanical facilities more effectively
Manufacture near the net shape (eliminates material removal)

10. Setup Reduction and Tools
Tooling amount based on production quantity, recorders, labor, time limits and capital.
Perform setup work while the machine is running
Use efficient clamping devices
Eliminate large adjustments
Use templates or block gages
Maintain records of difficult setups

11. Machine Efficiency Use multiple cutting tools to use available power
Use most efficient tooling
Energy efficient motors

13. Material Handling (MH)
Depending on the part, 30%-50% of the cost is due to MH
Reduce time spent picking up the material
Use mechanized equipment
Make better use of existing handling facilities
Handle material with the greater care
Use bar-coding where applicable

14. Plant Layout
Layout types (product or straight line & process or functional)
Travel charts
Muther’s Systematic Layout Plan (SLP)

15. Travel Chart

20. Work Design Manual work and principles of motion economy
Ergonomic principles of workplace and tool design
Working and environmental conditions

21. Questions & Comments