Methods Engineering & Layout Planning

1. Methods Engineering & Layout Planning Chapters: • Introduction to Methods Engineering and Operations Analysis • Charting Techniques • Motion Study and Work Design • Facility Layout Planning and Design Part II

2. Introduction to Methods Engineering and Operations Analysis Sections: • Evolution and Scope of Methods Engineering • How to Apply Methods Engineering • Basic Data Collection and Analysis Techniques • Automation and Methods Engineering Chapter 8

3. Methods Engineering • Analysis and design of work methods and systems, including the • tooling, • equipment, • technologies, • workplace layout, • plant layout, and • work environment

4. Other names for methods engineering: • Work study • Work simplification • Methods study • Process re-engineering • Business process re-engineering • Methods Engineering is often associated with work measurement.

5. Objectives in Methods Engineering • Increase productivity and efficiency • Reduce cycle time • Reduce product cost • Reduce labor content • Improve motivation and morale الروح المعنوية • Improve product and/or service quality • Improve customer satisfaction • Reduce lead times and improve work flow • Increase flexibility of work system • Improve worker safety • Enhance the environment (both inside and outside the facility)

6. Operations Analysis • Study of an operation or group of related operations for the purpose of analyzing their efficiency and effectiveness so that improvements can be developed • Objectives in operations analysis • Increase productivity • Reduce time and cost • Improve safety and quality • Same basic objectives as methods engineering • Methods engineering places more emphasis on design. It is broader than operations analysis.

7. Evolution and Scope of Methods Engineering • Initial research (late 19th century) - Frank Gilbreth: Motion study • Scientific management (late 19th century-early 20th century)- Frederick W. Taylor: Motion and time study (first principle of the five principles) • Primary concern: manual physical labor • Today: methods engineering is applied toareas such as indirect labor, logistics, service operations, office work, and plant layout.

8. Methods Engineering Can be divided into two areas: • Methods analysis • Methods design

9. Methods Analysis • Concerned with the study of an existing method or process • break the method (process) down into work elements or basic operations • examine the details of the elements: a systematic (methodical) search to improve the process • This involved checklists of questions and suggestions for improvements • Objectives : • Eliminateunnecessary and non-value-adding work elements • Combine elements and operations • Rearrange elements into more logical sequence • Simplify remaining elements and operations

10. Methods Design Concerned with either of the following situations: • Design of a new method or process • Required for new product or service and there is no existing precedent سابق • Method must be designed from scratch بدأ من الصفر, using best existing practice أفضل الممارسات القائمة for similar operations • Redesign of an existing method or process based on a preceding methods analysis

11. Systematic Approach in Methods Engineering • Define the problem and objectives • Analyze the problem • Formulate alternatives • Evaluate alternatives and select the best solution • Implement the best method • Audit the studyمراجعة الدراسة(follow-ups)

12. The Techniques of Methods Engineering • The following techniques are mostly accociated with the analysis step in the methods engineering. • Data gathering and statistical tools • Charting and diagramming techniques • Motion Study and Work Design • Facility Layout Planning • Work Measurement Techniques • New approaches

13. Charting & Diagramming Techniques • They are available mainly for collecting, displaying and analyzing data • Network diagrams • Traditional industrial engineering charting techniques • Operation charts • Process charts • Flow diagrams • Other (alternative) diagrams • Block diagrams • Process maps

14. Motion Study and Work Design • Concerned with basic motions of a human worker while performing a given task • 17 basic motion elements, like reach, grasp, move, release • “Principles of motion economy”- guidelines for work design • Use of human body in developing the standard method(e.g., design the work so that both hands are fully utilized) • Workplace layout • Design of tooling used in the task

15. Motion Study and Work Design -Objective • Unnecessary motions can be eliminated. • Some of the motion elements can be combined. • The method can be simplified.

16. Facility Layout Planning • Facility layout refers to: • Size and shape of a facility • Arrangement of the different departments and equipment within the facility • The layout plays an important role in determining the overall efficiency of the operations • Problem area includes: • Design of a new facility • Installing new equipment, retiring old equipment • Expanding (or contracting) an existing facility

17. Work Measurement Techniques • Four basic work measurement techniques: • Direct time study • Predetermined motion time systems (PMTS) • Standard data systems • Work sampling • They can be used in methods engineering to make improvements in the work methods

18. Basic Data Collection & Analysis Tools • Histograms • Pareto charts • Pie charts • Check sheets • Defect concentration diagrams • Scatter diagrams • Cause and effect diagrams