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3. Motion Study & Work Design

3. Motion Study & Work Design. 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.

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3. Motion Study & Work Design

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  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

  4. 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

  5. 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

  6. 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.

  7. 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

  8. 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

  9. 5 S • Seiri, Seiton, Seiso, Seiketsu, Shitsuke • Sort, Clean, Set in order, Standardize, Progress • 5R : Ringkas, Rapih, Resik, Rawat, Rajin

  10. 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

  11. 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.

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