Chapter 3: Operation Analysis

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Chapter 3 Operation Analysis

• Overview
• Operation Purpose
• Part Design
• Tolerances and Specifications
• Materials
• Manufacturing Sequences and Process
• Setup and Tools
• Material Handling
• Plant Layout
• Work Design

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Questioning Attitude

• Why is this operation necessary?
• What can be done to make the job safer?
• Who can best perform the operation?
• When is the best time to schedule this
  maintenance?
• How can the task be improved?

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Operation Purpose

• Investigate for the operations
• Unnecessary operations result from
• a task operation
• of a previous operation
• Eliminate an unnecessary operation will
• Save and
• Reduce of a method engineer

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Avoid Unnecessary Operation
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Part Design

• Review every design for possible .
• design to reduce number of parts.
• Make joining, machining, and assembly .
• (number of operations, material, relax
  tolerances, etc.).

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Example Design of A Part

• A chair in class
• Origin design four legs and need to be assembled
• New design 2 legs

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Tolerances and Specifications

• Use tolerances and specifications to the
  performance of the process
• The relationship between cost and tolerance
• Designers may with very tight tolerances (high
  production cost and time consuming) because they
  are not aware of the of the manufacturing dept.

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Material

• The knowledge of material engineering is required
• Basic guidelines
• Finding a material
• Finding materials that are
• Using materials more
• Using materials
• Using and more economically
• materials
• Finding the

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Manufacturing Sequence and Process

• Rearranging operations
• manual operations
• Utilize more efficient mechanical facilities
• Operate mechanical facilities more efficiently
• Manufacturing near
• Considering the use of

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Setup and Tools

• Group technology classify parts similar in shape
  and processing sequence in the same family
• Reduce setup time
• Perform setup work while the machine is running
• Use efficient
• Eliminate
• Use or
• Maintain records of
• Utilize the full capacity of the machine
• Share machines capacity
• operations
• Using motors
• Introduce more efficient tooling

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Material Handling (MH)

• Depending on the part, of the cost is due to MH
• Reduce spent picking up the material
• Use
• Make of handling facilities
• Handle material with the
• Use where applicable

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Example of Handling Equipments
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Example of Warehousing Transportations and
Operations
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Plant Layout

• Types of plant layout
• Product layout layout
• This type of layout will
• Lack of workers, need
• Process layout layout (cellular layout)
• A lot of
• Require of the product during the production
• Travel charts Muthers systematic layout
  planning
• Chart relationships
• Space requirements
• Activity relationship diagram
• Space relationship layout
• Alternative arrangements evaluation
• Select layout and installation

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Travel Chart
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Work Design

• Manual work and principles of motion economy
• Ergonomic principles of workplace and tool design
• Working and environmental conditions