1. 3. Motion Study & Work Design

2. 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

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

5. 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

6. 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

7. 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.

8. 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

9. 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

10. 5 S Seiri, Seiton, Seiso, Seiketsu, Shitsuke
Sort, Clean, Set in order, Standardize, Progress
5R : Ringkas, Rapih, Resik, Rawat, Rajin

11. 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

12. 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.