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Motion Study & Work Design

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Motion Study & Work Design Evelean William BY Eng . Ahmad Bassiouny

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

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

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

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

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

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

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

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

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

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