Essential Tools for Method Analysis
Translated by
ScribdTranslationsEssential Tools for Method Analysis
Translated by
ScribdTranslationsGraphics for Method Analysis
A good methods engineering program follows a systematic process:
starting with the selection of the project and ending with its implementation.
the same way the operator uses tools such as micrometers and
calibrators to facilitate the work, the methods engineer uses the tools
appropriate for doing a better job in less time. There is a wide variety of
available tools for problem solving and each of them has
specific applications. However, regarding graphic analysis of methods,
there are certain tools that play a fundamental role in the recording and analysis of
information related to a certain production process.
1. Operational Process Diagram
The Operational Process Diagram shows the chronological sequence of all the
operations, inspections, allowed timings, and materials used in a process
of manufacturing or business, from the arrival of the raw material to the packaging
of the finished product. The diagram shows the input of all components and
subassemblies to the main assembly. In the same way that a diagram shows
design details such as parts, tolerances, and specifications, the diagram of the
operational process offers details of manufacturing and business with just a glance
glance.
Two symbols are used to construct the operational process diagram: a small
A circle represents an operation and a small square represents an inspection. A
operation is carried out when a subject under study is intentionally transformed,
or when it is studied or planned before any productive work is carried out
such part. An inspection is conducted when the part is examined to determine its
compliance with a standard (See figure 1).
Operation Inspection
Figure 1. Symbols for Building the Process Diagram
Some analysts prefer to describe only the operations, so the result is
graphic of the description of the [Link] starting the actual construction of
operational process diagram, the analysts identify the diagram by means of the title
Operational Process Chart and additional information such as the part number,
plan number
the person who created the diagram. Additional information may include
data such as the graph number, the floor, the building, and the department.
The vertical lines indicate the general flow of the process as it is carried out.
work, while the horizontal lines that feed the vertical flow lines
they indicate materials, whether purchased or made during the process. The parts are
they show how entering a vertical line for assembly or abandoning one
vertical line for disassembly. The materials that are disassembled or extracted are
they are represented by horizontal lines of materials and are drawn to the right of the
vertical flow line, while the assembly materials are shown by
Horizontal lines drawn to the left of the vertical flow line (See figure 2).
Figure 2. Representation of Lines in the Diagram
In general, the operational process diagram is constructed in such a way that the lines
vertical flows and the horizontal material lines do not cross. If it is strictly
the crossing of a vertical line with a horizontal one is necessary, the convention must be used
to show that no connection is presented; that is, to draw a small
semicircle on the horizontal line at the point where the vertical line crosses it (See figure 3)
Figure 3. Diagram Convention if There is Crossing in the Process.
Other conventions that are important to know are those related to those situations.
within the process, in which it is advisable to mention alternative work routes or
conditions that lead to a reprocessing or rework (See figure 4).
Figure 4. Diagram Convention if Alternative Routes or Rework Exist.
The values of the tempo, based on estimates or real measurements, can
assign to each operation or inspection. The following figure shows a diagram
Complete operational process topic that illustrates the manufacturing of bases for phones.
The completed operational process diagram helps analysts visualize the method in
course, with all its details, in such a way that new and better ones can be identified
procedures.
Figure 5. Diagram Convention if Alternative Routes or Rework Exist.
This diagram shows analysts what effect a change in a certain
operation in the preceding and subsequent operations. It is very common to achieve 30%
reduction of time through the use of operations analysis principles in
together with the operational process diagram, which inevitably suggests
possibilities for improvement.
Likewise, since each stage is displayed in its appropriate chronological order, the
The diagram itself constitutes an ideal layout of the plant. Consequently, the
method analysts consider this tool extremely useful for development
new distributions and improve the existing ones.
2. Flowchart of the Process
In general, the flow diagram of the process has much more detail than the
diagram of the operational process. As a consequence, it is generally not applicable to all
the assemblies, but rather to each component of an assembly. The flow diagram of the
The process is particularly useful for recording non-productive hidden costs such as,
example, the distances traveled, the delays, and the temporary storages. Once
that these non-productive periods are identified, analysts can take measures to
minimize them and, therefore, reduce their costs.
In addition to recording operations and inspections, process flow diagrams
they show all the delays in movements and storage to which one is exposed
article as it goes through the plant. The process flow diagrams, therefore,
they need several symbols in addition to the operational and inspection ones used in the
operational process diagrams.
For example, a circle with a diameter of 1cm denotes an operation, immersed within
a productive process such as drilling, grinding, mixing, among others.
A small arrow means transport, which can be defined as moving an object.
from one place to another except when the movement takes place during the normal course
from an operation or inspection.
A capital D represents a delay, which occurs when a part does not
it can be processed immediately at the next workstation.
An equilateral triangle standing on its vertex signifies storage, which
presents when a part is stored and protected in a certain place so that no one
the removal without authorization.
A square of 1cm x 1cm indicates inspection (of quality, of quantity) as well as
verification tests of parameters or specifications.
In summary, those five symbols constitute the standard set of symbols that
used in process flow diagrams according to ASME Standard 1974 (See figure 6).
Figure 6. Set of Process Diagram Symbols According to the ASME Standard.
Currently, flowchart devices are used; these can be product-based.
or materials and people or operations. The product diagram provides the details
of the events involving a product or a material, while the diagram of
operational flow shows in detail how a person carries out a sequence of
operations.
In the same way as the operational process diagram, the flow diagram of the
The process is identified by a title (Process flow diagram), and the information
additional that accompanies it generally includes the part number, the number of
diagram, the description of the process, the current or proposed method, the date and the name
from the person who created the diagram.
Figure 7. Process Flow Diagram (Material) for Mail Preparation.
Within the additional information that may be useful to fully identify the
the work being done is located in the plant, building or department; the number
of the diagram; the quantity and the cost. The analyst must describe each event of the process,
encircle the appropriate symbol of the process diagram and indicate the times
assigned for processes or delays and transport distances. After you...
connect the symbols of consecutive events with a vertical line.
The column on the right side provides enough space for the analyst.
incorporate comments or make recommendations that lead to changes in the future.
To determine the distance traveled, it is not necessary for the analyst to measure each
movement in a precise manner with a tape or a ruler. A value is obtained
sufficiently correct if the number of columns that the material moves is counted
and then this number, less than 1, is multiplied by the distance between columns.
Movements of 2 meters or less are generally not recorded; however,
they can be registered if the analyst considers that they affect the total cost of the method that is being
is graphing. The diagram should include all delays and times of
storage. As long as a part remains longer in storage or
the longer the delay, the greater the cost that will accumulate as well as the time that the customer will have to
wait for the delivery.
Therefore, it is important to know how much time each delay consumes.
storage. The most economical method to determine the duration of delays and
storage is done by marking several parts with a GIS, which indicates the
exact time during which they were stored or delayed. After that, it is necessary
periodically check the section to see when they resumed production
marked parts. It is checked a number of times, the time consumed is recorded, and then
The results are averaged, and thus, analysts can obtain values over time.
sufficiently accurate.
The flow diagram of the process, in the same way as the process diagram
operational, it is not the end in itself; it is just a means to reach the end. This
This tool facilitates the removal or reduction of hidden costs of a component.
Since the flow diagram clearly shows all the transportations, delays and
storage, the information provided can result in a reduction
in the quantity and duration of these elements. Likewise, since the distances are
are recorded in the flowchart of the process, this diagram is
exceptionally valuable for showing how the distribution of a can be improved
plant.
3. Flow Diagram or Route
Although the flowchart of the process provides most of the information
pertinent related to a manufacturing process, does not show a pictorial plan of the flow of
work. Sometimes this information is useful for developing a new method. For example, before
that transportation can be reduced, the analyst needs to observe or visualize where there is enough
space to build a facility in such a way that the transportation distance can
shorten.
In the same way, it is useful to visualize the potential areas for temporary storage.
the permanent inspection stations and work points. The best way to
providing this information is to obtain a diagram of the areas of the plant involved and
after outlining the flow lines, that is, indicating the movement of the material from an activity
to the other. The flow diagram or route is a graphical representation of the distribution of the
floors and buildings that show the location of all activities in the flow diagram of the
process.
When analysts create a flowchart or journey, they identify each activity.
through symbols and numbers corresponding to those appearing in the flowchart of
process. The direction of the flow is indicated by placing small arrows periodically along
the flow lines. Different colors can be used to indicate flow lines in more than one
part.
The flowchart diagram represents a useful complement to the process flow diagram.
because it indicates the way back and the possible traffic congestion areas and facilitates the
development of an ideal plant configuration.
Figure 8. Flow Diagram or Route.