work measurement and lean applications in the process ...€¦ · process flow and the 5 work...
Post on 24-Jan-2021
2 Views
Preview:
TRANSCRIPT
Work Measurement and Lean
Applications in the Process IndustriesReduce Cost and Improve Flow
Copyright 2009
Luis Armendariz, P.E.,MBA,Six Sigma EngineerLean Physics and Operations Modeling Consultant
Agenda
• Contributors & Origins of Work Measurement
• Global Economy and Work Measurement
• What’s Work ? Lean Principles
• Work Measurement Tools
• Work Measurement Case Studies/Applications • Work Measurement Case Studies/Applications
Traditional and Non-Traditional
• Improvement Challenges & Survey Results
2Copyright 2009
Contributors and Origins of Work
Measurement
The Mayas in Mesoamerican Civilization
ProtimeSystems.com
W= F d F = m a
Issac Newton1643-1727
Long Time CountEstimated Current and Historical Dates
2600 B.C.
Lilian and Frank Gilbreth 1931Lilian 1878-1972
Fredreric Taylor 1856-1915
Henry Ford1863-1947
Greece and EgyptHour Glass
Predetermine Time System (PTS)1910
USA-Sweden-Germany1940
PTS…. And OthersWorkfactor, MOST, Modaps
ProtimeSystems.com
Computer Video-Based Work Measurement
and Video & Pictorial Instruction Systems
1996
Taiichi Ohno1912-1990
3Copyright 2009
Current Economic Issues and WMGDP Global Level
Country Level
Product demand unstable (high variability) creating waste of resources
•State of CA job growth fell 5.0% in July 2009 from a year ago; national job growth fell 4.2%. •State CA unemployment averaged 11.9% in July 2009; the national average was 9.4% •Personal income fell 0.2% to $1.5 trillion in Q1 2009 from a year ago. •Tax revenue fell 16.2% in Q1 2009 from the previous year. •Exports fell 22.4% to $48.8 billion in the first five months of 2009 from a year ago. •Venture capital investment in CA fell 63% to $1.4 billion in Q1 2009 from a year ago.
State Level
4Copyright 2009
What is Work & Lean Principles
Any activity that consumes resources and creates value or non-value added for the customer
What is Work ?
Work Measurement
MPI
5Copyright 2009
What is Work Measurement ?
What is Work Measurement?
Is the application of techniques designed to establish the time for a qualified worker/process
to carry out a task at a defined speed
Work Method
Work
Process
Study
Work Method
To simplify the job and
develop more economical
methods of doing it
(eliminate waste)
Work Measurement
To determine how long it
should take to carry out
Work
Instruction
6Copyright 2009
Work Measurement Methodology
1-Select
2-Record
3-Examine
Work to be studied
Relevant data, work elements
Work element breakdown and effective method
4-Measure
5-Define
7-Install
8-Maintain
Work in each element (time), VA and NVA
6-Compile Work Allowances and determine standard time
Work Method (Why, What, Where, When, Who and How)
Std. work instruction training and visual instructions
Workflow balance and standard work audit
7Copyright 2009
Work Measurement Applications
• Value Stream/Process Flow Mapping • Capacity and Lead Time Analysis • Production Plan/Production Standards• Scheduling• Labor/Staffing Analysis/Labor Standards• Production Incentives• Machine Efficiencies (OEE)
The Work Flows of :• Material• People• Machine• Machine Efficiencies (OEE)
• Costing• Product Design• Layout Planning• Ergonomics• Inventory Planning/ERP• Information Systems• Simulation Modeling• Flow Manufacturing & Service• Learning Curves and Training• Productivity/Efficiency & Effectiveness
TIME
• Machine• Information• Service• Layout• Cash• Environment
8Copyright 2009
Work Measurement Techniques
TimeDirect
Observation
Video
SamplingSampling
Historical
Predetermined
MTM
Most
Stopwatch
/PDA
Sampling
Sampling
Production Records
Computer
Online/LAN
MRP/ERP Transaction
Std. Data
Simulation
Modeling
9Copyright 2009
Work Measurement Approach
Engineer Based Standards Team Video Based Standards
1. Engineer Conducts Work Measurement
1. Engineer /Supv. Facilitates Study2. Cross Functional Team Conducts Work
2. Engineer Compiles Standard3. Engineer Develops Std Work
Instruction4. Management Enforces Standard5. Operators Follow Instructions
Measurement (Including Operators)3. Team Develops Std Work Instruction
(Including Operators)4. Management provides training, removes
barriers and motivate operators5. Operators are accountable to sustain6. Operators are motivated to improve
standards7. Engineer/Mgt. installs the control systems
and operating mechanisms
10Copyright 2009
Work Measurement (7 Workflows)
1-Does the Material flow ?Move from one value adding processing step right to the next value adding step
2-Do the Operators flow ?Is the operator’s work repeatable and consistent within each cycle ?Can the operator perform efficiently from one value adding work element to the next ?
3-Do Machines/Equipment/Tools flow ? Are the machines or equipment adding value to the product/service ?to the product/service ?
4-Does Information flow ?Is there a plan and schedule that maximizes flowDoes everyone know the hourly production target ?How quickly are problems and abnormalities noticed?What happens when there are problems and abnormalities ?
5-Does the Service or Mgt Business Support Function flow ?Are the service functions in the company flowing efficiently and supporting mfg. flow
6-Does the Layout (facility) flow ?Are the material, operators, equipment and information flowing efficiently
7-Does the Cash flow ?What is the material idle time (cash in-idle), WIP, TH, CT and inventory turn over 11Copyright 2009
Beyond 5S/Ergonomics-Human FactorsArrangement and
Storage of Tools
Lighting
Color
Noise & Vibration
PFD Allowances
PersonalFatigue Noise & Vibration
Climate & Ventilation
Toxic Substances
PPE
Work Time and Rests
Facilities
FatigueDelays
12Copyright 2009
The 5 Work Symbols and 7 Waste
7 WasteMotion
Any activity that consumes resources and creates value or non-value added for the customer
What is Work ?
VA
5 Work Symbols
Operation
MotionOverproductionWaitingTransportationInventoryUnnecessary ProcessingDefects
“8” Tap into human potential and creativity
NVA
Storage
Delay
Transport
Inspection
13Copyright 2009
Process Flow and The 5 Work SymbolsProcess Flow AnalysisProcess Description: XXXXXX
Date: XX-XX-XX Material People Machine Information
No. Task Description
Cu
m.
Tim
e (
min
)
Inte
rva
l T
ime
(m
in)
Dis
tan
ce (
Ft)
Op
era
tio
n
Tra
nsp
ort
Sto
rag
e
De
lay
Insp
ect
ion
1 Get tube and place to bender 5 5 6 5
2 Get bent tube & place to assy 10 5 1 5
3 Get connector 15 5 5 5
This tool is used to measure service or manufacturing processes, collecting information using sticky notes to build the VSM
3 Get connector 15 5 5 5
4 Get hose & place 20 4 3 4
5 Start assembly cycle 24 5 0 5
6 Walk and bring finished piece 29 7 6 7
7 Attach to convolute 36 4 0 4
8 Start assembly cycle 40 6 0 6
9 Place to tester fixture 46 6 3 6
10 inspect part 52 5 0 5
11 Attach to Coiler 57 5 0 5
Total 57 24 20 32 0 0 5
Steps Count 12 5 6 1
Work Flow Cycle Efficiency 35%
Total
Steps Count
Work Flow Cycle Efficiency
Cu
rre
nt
Pro
po
sed
14Copyright 2009
Work Measurement (Material)
at VSM Level
A B C
2d 4d 1d1d
Supplier
Customer
Min TAKT
CT= 400 m
C/O= 160 m
TBF = 4 D
TTR = 2 H
Yield = 92%
HCT = 8 FT
EPEI = 4
VA = 300 m VA = 200 m VA = 300 m
Work Cycle Efficiency =(WCE)
VA/(VA+NVA)
= 300+200+300(800+12000)
WCE= 6.3%CT= 213 H
WIP = 20TH = 4
Min
A B C
15Copyright 2009
Work Measurement (Labor Unrestricted)
Assy1
Constant Work Elements Time 1- Pick up part 32- Move to table 23- Assemble housing 104- Inspect assembly 7 5- Move part to bin 2 S/E- Starts and End in container1
23 4
5Assy1
Current State
CT= 30 S
C/O= 0 m
TBF = 0 D
TTR = 0 H
Yield = 92%
HCT = 1 FT
VA = 10 S
IndicatorsWCE= 33%
CT= 30 S TH = 120/hrWIP=110
S E
Observed Time = Constant + Variable Work ElementsObserved Time = (3 + 2+10+7+2 ) + (60/100)Observed Time = 24+ 0.6 = 24.6 Sec
Variable Work Elements Time - Re-fill container f=100 60
Normal Time = Total Observed Time x EfficiencyNormal Time = 24.6 x 1.05 = 25.83 Sec
Standard Time = Total Normal Time x PFDStandard Time = 25.83 x 1.15 = 29.7 Sec, ~30 S
16Copyright 2009
Work Measurement (Labor Unrestricted)
Assy1
Constant Work Elements Time 1- Pick up part 22- Move to table 13- Assemble & test housing 124- Inspect assembly 7 5- Move part to bin 2 S/E- Starts and End in container
12 3
Assy1
Future State
CT= 17.3 S
C/O= 0 m
TBF = 0 D
TTR = 0 H
Yield = 92%
HCT = 1 FT
VA = 12 S
IndicatorsCurrent (Future)
WCE= 33% (70%)CT= 30 S (17 S)TH = 120/hr (208/hr)WIP=110 (3)
Observed Time = Constant + Variable Work ElementsObserved Time = (2+ 1+12 ) + 0Observed Time = 15 Sec
Variable Work Elements Time - Re-fill container f=100 60
Normal Time = Total Observed Time x Eff. RatingNormal Time = 15 x 1.05 = 15.75 Sec
Standard Time = Total Normal Time x PFDStandard Time = 15.75 x 1.10 = 17.3 Sec
17Copyright 2009
Work Measurement (Labor Restricted)
Operator and Machine
A
Restricted WorkIs work in which the output is limited by factors
outside the control of the worker
Operator Working Operator Idle
Current
1.2 min
2.0 min
CT= 1.36 m
C/O= 1 m
TBF = 4 D
TTR = 2 H
Yield = 92%
HCT = 8 FT
VA = 0.8 m
Machine Idle Machine Working
Current
Future
0.8 min
Operator Working Operator Idle
Machine Idle Machine Working
1.12 min
0.8 min
1.36 min
18Copyright 2009
Work Measurement (Labor Restricted)
Operator and Machine «Pump Diagram»
A Machine Process Time 0.8 min
1.36 min
Operator Time
CT= 1.36 m
C/O= 1 m
TBF = 4 D
TTR = 2 H
Yield = 92%
HCT = 8 FT
VA = 0.8 m
Internal Time 0.56 min External 0.56 min Idle 0.24 min
Status
• Idle Time
• Working Time
• Total Cycle
• Utilization
Operator
• 0.24 min
• 1.12 min
• 1.36 min
• 82% (1.12/1.36)
Machine
• 0.56 min
• 0.80 min
• 1.36 min
• 59% (0.8/1.36)
Summary
19Copyright 2009
Work Measurement (Setup Time)
Operators and Machine « Pump Diagram »
ObservedCT = 648 Min
Prep (11min) External
Run TimeSetup
Extract(70min)
Rinse I (50min)
Rinse II (60min)
Remove Gasket (80min)
Install Gasket (145 min)
Clean Gasket (30 min)
MC Breakdown (200 min)
Internal-Reduce
Int-Reduce
Int-ReduceEliminate
Int-Reduce
Int-Reduce
Int-Combine
20Copyright 2009
Work Measurement (Setup Time)
Operators and Machine « Pump Diagram »
Observed = 648 min Reduced = 232 min
Capacity Gain = 416 min
Eliminate
ReduceReduceReduce
ReduceReduceCombine
External
21Copyright 2009
Work Measurement (Single Machine )
« OEE »
Availability (Downtime Loss) = Operating Time / Planned Production Time
Performance (Speed Loss) = Ideal Cycle Time / (Operating Time / Total Pieces)
OEE = Availability x Performance x Quality
Performance (Speed Loss) = Ideal Cycle Time / (Operating Time / Total Pieces)
Quality (Quality Loss) = Good Pieces / Total Pieces
OEE Factor Shift 1 Shift 2
Availability 90% 95%
Performance 95% 95%
Quality 99.5% 96%
OEE 85.1% 86.6%
Note: Availability (TBF and TTR)22Copyright 2009
Work Measurement (Multiple Machine)
« Waterfall Diagram »
A
Multiple Machine and Operator WorkIs work which requires the worker/team to attend two
or more machines/equipment
Machine
A
CTq1
CT= 1.36 m
C/O= 1 m
TBF = 4 D
TTR = 2 H
Yield = 92%
HCT = 8 FT
VA = 0.8 m
A
B
C
CTq2
CT= SetupTime + Process Run Time + Ctq
23Copyright 2009
Work Measurement (People Flow)
« Spaghetti Diagram »Process Layout: 6 People -Crew
3 Op to unload printing frames
30 ft
printing framesand remove gaskets
3 Op to change inksand spray pins
50 ft
24Copyright 2009
Work Measurement (People Flow)
1 9
10
1 2
3Incoming
Outgoing
ProcessSequence
WorkSequence
Operator A1
2
3
4
5
9
8
7
6
1
1
2
1
2
4
3
3
2
Operator B
Operator C
25Copyright 2009
Work Measurement
(Material-Facility Flow)
26Copyright 2009
Work Measurement
(Material-Facility Flow)
27Copyright 2009
Work Measurement PTS
Predetermined Time StandardsPTS
Are pre-established times for basic human motions and are used to build up the time for a job at a
defined level of performance
Studs
Base assembly workplace layout
Studs
18”
12”
8” 8” 8”
12”
28Copyright 2009
Work Measurement
Work SamplingWS
Is a method of finding the % of occurrence of a certain activity by statistical sampling and random observations
n
pqp =∂
Sample SizeObservations
Machine WorkingMachine Idle
Preliminary Study100 observationsP = 25 % machine idleq = 75% working
95% conf level 10% error
1096.1 =∂× p
n
75255
×=
n = 75 observations
Machine Working
Waiting for Repairs Waiting for SuppliesPersonal needs of
workers
Idle
Numb er of Observations: 75 Total %
Machine Running
11111 11111 11111 11111 11111 11111 11111 11111 11111
11111 11111 11111 11 62 82.7%
Machine Idle Repairs 11 2 2.7%
Supplies 111111 6 8.0%
Personal 1 1 1.3%
Idle 1111 4 5.3%
100%
29Copyright 2009
Work Measurement
Service /Business Function
Time To Fill Vacancies(Intellectual Capital Losses)
Lost Hours of Productive Hourly EmployeesLost Hours of Productive Salary EmployeesLost Hours of Productive Executive Employees
A
Lost Hours of Productive Executive Employees
CT= 1.36 m
C/O= 1 m
TBF = 4 D
TTR = 2 H
Yield = 92%
HCT = 8 FT
VA = 0.8 m
Time To Process Purchase Orders
Time To Generate Financial Reports
Time and Resources To Service Machinery and Equipment
Time and Resources To Execute a Project
Time To Train New Employees
30Copyright 2009
Distributing the Work Load
Line Balancing
a. Reduce NVA time to improve work balancea. Reduce NVA time to improve work balance
b. Reduce product cost by removing work time from productb. Reduce product cost by removing work time from product
c. Cycle Time and WIP will be reducedc. Cycle Time and WIP will be reduced
d. Productivity will increase due to more time for VA tasksd. Productivity will increase due to more time for VA tasks
6
8
10
12
14
16
0
2
4
Step 1 Step 2 Step 3 Step 4 Step 5
TaktTaktTimeTime
NVAT
VAT
Set-up
min
d. Productivity will increase due to more time for VA tasksd. Productivity will increase due to more time for VA tasks
31Copyright 2009
Work Measurement (Information Flow)
Does everyone know the target and the method ?
Video Instruction
Text Instruction
WIP
CTInformation Board
TH
Text Instruction
Align plate on table
32Copyright 2009
Achieving Standard WorkRoutine for work to be performed right the first time, every time
Elements of Standard Work
1- Takt (Demand Rate)
Min
A B C
TAKT
WIP = CT x TH
2- Standard WIP
3- Work sequence (Work Instruction,
Documentation & Training)
33Copyright 2009
Sustaining and Improving
Standardization Drives Sustainable Results
KS
TIME
IMP
RO
VE
ME
NT
KK
K
K
K
K
K
KS
S
SS
K-
S-
Kaizen event
Sustained performance
34Copyright 2009
Q&A
Cannot manage if you don’t measure !Contact IIE Membership
Luis Armendariz, P.E.
35Copyright 2009
top related