英文IE知識(shí).ppt

2002 9 26 SMTTrainingforProductivity 1 IndustrialEngineering WorkDesign PreparedbyKenLeung 2002 9 26 SMTTrainingforProductivity 2 WorkDesign MethodsImprovementErgonomicsAssemblylinebalancingPrinciplesofmotioneconomyVarioustypeofchartsWorkmeasurementTimestudyActivitysampling 2002 9 26 SMTTrainingforProductivity 3 Ergonomics DefinitionApplyinformationabouthumanbehavior abilities limitations andothercharacteristicstothedesignoftools machines system tasks jobs andenvironmentsforproductive safe comfortable andeffectivehumanuse 2002 9 26 SMTTrainingforProductivity 4 Objectives Toenhancetheworkeffectivenessandefficiency IncreasedconvenienceofuseReducederrorsIncreasedproductivityToenhancehumanvalues ImprovedsafetyReducedfatigueandstressIncreasedcomfortGreateruseracceptanceIncreasedjobsatisfactionImprovedqualityoflife 2002 9 26 SMTTrainingforProductivity 5 TwelvePrinciplesofErgonomics 1 Workinneutralpostureseg Wristrestsforkeyboardandmouse 2 Reduceexcessiveforceseg Boxeswithhandholdsforcarrying 2002 9 26 SMTTrainingforProductivity 6 ErgonomicsPrinciples 3 Keepeverythingineasyreacheg Keepmaterialswithinthe reachenvelope ofthearm 2002 9 26 SMTTrainingforProductivity 7 ErgonomicsPrinciples 4 Workatproperheightseg Heavyworkshouldbeperformedlowerthanelbowheight precisionworkshouldbehigher 2002 9 26 SMTTrainingforProductivity 8 ErgonomicsPrinciples 5 Reduceexcessivemotionseg Usepowerscrewdriver 6 Minimizestaticloadeg Useapencilgrip 2002 9 26 SMTTrainingforProductivity 9 ErgonomicsPrinciples 7 Minimizepressurepointseg Providepaddingforhandgrips 8 Provideclearanceeg Providevisualaccess cartondelivery 2002 9 26 SMTTrainingforProductivity 10 ErgonomicsPrinciples 9 Move exercise andstretcheg Changeadjustmentsofthechairforthosesitforalongtime 10 Maintainacomfortableenvironmenteg Considerthequantityandqualityoflightattheworkstation 2002 9 26 SMTTrainingforProductivity 11 ErgonomicsPrinciples 11 Makedisplaysandcontrolsunderstandableeg Clickingiseasierthanmemorizingcommands 12 Reducestresseg Designtasktofitpeople 2002 9 26 SMTTrainingforProductivity 12 Anthropometry DefinitionMeasurementofthehumanbodyanditsbiomechanicalcharacteristics Biomechanicalreferstothemechanical machine like capabilitiesofthehumanskeleton muscularsystems Measuresoursizesandhowwemoveandmoveeasily NeedofAnthropometryWearenotinthesamesize Poordesignformechanicalabilitiesofthehumanbodycanleadtodiscomfortorinjury Eg Heightofkeyboardforacomputer 2002 9 26 SMTTrainingforProductivity 13 AnthropometricData Staticmeasures areusedtodeterminesizeandspacingrequirementsofworkspace eg height weight seattoelbowheight andwingspan Dynamicmeasures areusedtomatchthedynamiccharacteristicsofcontrolstouser eg rangeofmotionforvariousjoints andstrengthoffingers 2002 9 26 SMTTrainingforProductivity 14 AnthropometricData Theanthropometricdataisperformedinnormaldistribution 50thpercentileisthemostofthepopulation 5thand95thpercentilesaretheextremes 2002 9 26 SMTTrainingforProductivity 15 Howtouseanthropometricdata DesignforextremesAstandardistodesigntofit5thor95thpercentilesofthepopulation Designformostofthepopulation50thpercentileofthepopulationshouldbeused MakethedesignadjustableThedesigncanfit5thto95thpercentilesofthepopulation 2002 9 26 SMTTrainingforProductivity 16 Examples 2002 9 26 SMTTrainingforProductivity 17 AssemblyLineBalancing Equalizeworkloadamongtheassemblies Identifythebottleneckoperation Establishthespeedoftheassemblyline Determinethenumberofworkstations Determinethelaborcostofassembly Establishthepercentworkloadofeachoperator Assistinplantlayout Reduceproductioncost 2002 9 26 SMTTrainingforProductivity 18 TableforAssemblyLineBalancing Majoritems operationdescription R value cycletime numberofstations averagecycletime percentload hoursper1000pieces andnumberofpiecesperhour Anexampleisasfollows 1 2 3 4 5 6 7 2002 9 26 SMTTrainingforProductivity 19 ItemsforAssemblyLineBalancingTable R value plantrate Takttimeortimeneededtoproduceaproduct effectiveproductiontime requiredproductionvolume Cycletime Standardtimeforoperation Collectedfromtimestudy stations Cycletime R valueAveragecycletime Cycletime stations 1 2 3 4 2002 9 26 SMTTrainingforProductivity 20 ItemsforAssemblyLineBalancingTable Load Tellhowbusyeachworkstationiscomparedtothebusiestworkstation Load Avg cycletime highestavg cycletime Highestavg cycletime 100 station isthebottleneck 100 stationisreducedby1 thenwewillsave1 forallstations Thelesspercentloaded themoredesirabletobesub assembledorcombined 5 2002 9 26 SMTTrainingforProductivity 21 ItemsforAssemblyLineBalancingTable Hours 1000 Thehoursper1000unitsproduced Choosethebottleneckstation Avg cycletime 60mins x1000Formorethanoneworkersatthestation hrs 1000 workersx hrs 1000 ofbottleneck Becauseeveryoneonanassemblylinemustworkatthesamerate Pcs hr Numberofunitsproducedhourlybyoneworkeratthestation 1 Hrs 1000 X1000 6 7 2002 9 26 SMTTrainingforProductivity 22 ImproveAssemblyLineBalancing CalculatetheLineBalancerateReducingthebottleneckstation Combiningthebottleneckstationwithanoperationinfrontorbehind Combiningotheroperationstoeliminateoneofthem 2002 9 26 SMTTrainingforProductivity 23 Example OriginalLineBalance Producingnewplasticcharger 1200unitsper8 hrsshift with300minseffective 2002 9 26 SMTTrainingforProductivity 24 Example OriginalLineBalance Originallinebalancerate totalcycletime highestcycletimestationxno ofstations 1 354 0 25x7 77 4 Pcs hr 60 0 25 240Improvethebottleneckstationbycombiningwithanoperationinfrontorbehind Combineandeliminateworksteps Re designthejig fixture Operations Bottleneckor100 loadstation 2002 9 26 SMTTrainingforProductivity 25 Example ImprovedLineBalance Improvedlinebalance 2002 9 26 SMTTrainingforProductivity 26 Example ImprovedLineBalance Improvedlinebalancerate totalcycletime highestcycletimestationxno ofstations 0 878 0 229x4 95 9 Pcs hr 60 0 229 262Increaseinoutputwithdecreaseinno ofworkstations Operations Bottleneckor100 loadstation 2002 9 26 SMTTrainingforProductivity 27 PrinciplesofMotionEconomy Guidelinesforefficientandeffectiveworkstationdesign Summarizedto4majorelements EliminationCombinationRearrangementSimplification 2002 9 26 SMTTrainingforProductivity 28 Elimination Eliminateallpossiblejobs steps ormotions Eliminateirregularitiesinjob Eliminatetheuseofhandasholdingdevice Eliminateabnormalmotions Eliminatetheuseofmusclestomaintainafixedposition Eliminatemuscularforcebyusingpowertools Eliminatedanger Eliminateidletime 2002 9 26 SMTTrainingforProductivity 29 Combination Replacewithonecontinuousshortmotion Combinetools controls andmotions RearrangementDistributetheworkevenlybetweentwohands Shiftworkfromthehandstotheeyes Arrangeforastraightforwardorderofwork 2002 9 26 SMTTrainingforProductivity 30 Simplification Reduceeyetravel Keepworkinthenormalworkarea Shortenmotions Adapthandles levers pedals buttons etc tohumandimensionsandmusculatures 2002 9 26 SMTTrainingforProductivity 31 ApplyingthePrinciplesofMotionEconomy 1 Movebotharmsinunisonormovethemsymmetrically butdonotmovejustonearmatatime Eg Takethecapoffaninkbottle 2002 9 26 SMTTrainingforProductivity 32 ApplyingthePrinciplesofMotionEconomy 2 Tominimizebodymovementbylimitingmovementstobodypartswithlowtimerankings Thefollowingillustrationshowsthecorrelationbetweenarmmovementandworkingtime 2002 9 26 SMTTrainingforProductivity 33 ApplyingthePrinciplesofMotionEconomy 3 Minimizefatiguebyrepeatingmotionswithanaturalfeelingofrhythmandbymakingyourcurvedmovementsassmoothaspossible Doaslittleholdingoradjustingofmaterialsasyoucan Usestandsorjigstoholdyourmaterialsortoolsforyou 2002 9 26 SMTTrainingforProductivity 34 ApplyingthePrinciplesofMotionEconomy 4 Keepmaterialsandtoolsinspecifiedplacesinfrontofandaroundyou 5 Trytokeepfromfightinggravitywiththematerialsyouarehandling movethemdown notup Eg Useachutetotransporttheproductsbyitsowngravity 2002 9 26 SMTTrainingforProductivity 35 ApplyingthePrinciplesofMotionEconomy 6 Trytosetyourchairordeskatthemostcomfortablepositionandmakesureyourlightingisbrightenoughandatagoodangle 7 Ifyouutilizeyourlegsandfeet youcanlightentheloadonyourarmsandhands 2002 9 26 SMTTrainingforProductivity 36 ApplyingthePrinciplesofMotionEconomy 8 Side to sideeyemovementsarelesstiringthanup and downones 9 Wheneverpossible combineprocedures usingyourtoolsasextensionsofyourhandsandfeet Trytocombinetwoormoretoolsintoone 2002 9 26 SMTTrainingforProductivity 37 Varioustypesofcharts UsedasrecordtechniquesOutlineprocesscharts Overviewofaprocesswithgraphicalrepresentation Showprincipaloperations andinspections Assistintheplantlayoutdesign designofproduct ormachineryprocesses 2002 9 26 SMTTrainingforProductivity 38 Varioustypesofcharts Flowprocesschart Activitiesofmen materialorequipment Twoormoresubjectscanbepresentedalongsideeachothertoshowtheirinterdependence Activitiesaredividedby5functions operation transport storage delay D inspection Onlytheactivitiesofparticularsubject eitherman material orequipment arerecordedonasinglechart 2002 9 26 SMTTrainingforProductivity 39 Example Flowprocesschart Inspectingandmarkingincomingparts originalmethod 2002 9 26 SMTTrainingforProductivity 40 Example Flowprocesschart Inspectingandmarkingincomingparts improvedmethod 2002 9 26 SMTTrainingforProductivity 41 Varioustypesofcharts Tow handedprocesschart Usefulinshowingidletimebyeitherhand Activitiesofaworker stwohands Simultaneousmovementsbybothhandsappearoppositeeachother Descriptionoftheactivitiesrepresentedbythesymbolsshouldbeinserted 2002 9 26 SMTTrainingforProductivity 42 Example Two handedprocesschart Cuttingglasstubes originalmethod 2002 9 26 SMTTrainingforProductivity 43 Example Two handedprocesschart Cuttingglasstubes improvedmethod 2002 9 26 SMTTrainingforProductivity 44 Varioustypesofcharts Multipleactivitycharts Considerontheactivitiesofasubjectinrelationtooneormoreothers Showupclearlyineffectivetimewithintheprocess Usefulinfindingthebestsequenceofcarryingoutthevariouspartsofthework Operation machinechartshowstheinterrelationshipoftheoperatorandthemachine 2002 9 26 SMTTrainingforProductivity 45 Example Multipleactivitychart workerandmachine Finishmillcasting originalmethod 2002 9 26 SMTTrainingforProductivity 46 Example Multipleactivitychart workerandmachine Finishmillcasting improvedmethod 2002 9 26 SMTTrainingforProductivity 47 TimeStudy Mostcommontechniqueforsettingtimestandards Usefulforrepetitivework Providestandardrateofworking Ameansofassessingtheamountofrestthatshouldbeassociatedwiththejob 2002 9 26 SMTTrainingforProductivity 48 TimeStudy Procedures 1 Selectthejobtostudy 2 Collectinformationaboutthejob 3 Dividethejobintoelements 4 Dotheactualtimestudy 5 Extendthetimestudy 6 Determinethenumberofcyclestobetimed 7 Rate level andnormalizetheoperator sperformance 8 Applyallowances 9 Checklogic 10 Publishthetimestandard 2002 9 26 SMTTrainingforProductivity 49 TimeStudy FocusPoints ExtendthetimestudyCalculateaverageobservedtime Determineperformancerating Calculatenormaltime NormalTime averageobservedtimexperformanceratingFindoutfrequency howmanytimesataskisperformedwithinatimeperiod Calculateunitnormaltime 2002 9 26 SMTTrainingforProductivity 50 TimeStudy FocusPoints DeterminethenumberofcyclesN numberofcyclesR rangeofthesampleofobservations inminutes A requiredprecision 5 or10 d2 statisticalconstant 3 078for95 confidencelevel x averagetime inminutes 2002 9 26 SMTTrainingforProductivity 51 TimeStudy FocusPoints PerformanceratingRatingistheprocessofadjustingthetimetakenbyanindividualoperatortowhatcouldbeexpectedfromanormaloperator Fourmajorfactors skill consistency workingconditions andeffort Effortisthemostimportant Effortistheoperator sspeed andismeasuredbasedonthenormaloperatorworkingat100 2002 9 26 SMTTrainingforProductivity 52 TimeStudy FocusPoints RelaxationallowanceItistheallowancefortheperiodicstopsforpersonalneedsorfatigue Example goingtowashroom gettingadrink ContingencyallowanceItisasmallallowanceoftimewhichmaybeincludedinastandardtimetomeetexpecteditemsofdelays Occursinfrequentlyorirregularly Example interruptionsbysupervisors changingmaterials 2002 9 26 SMTTrainingforProductivity 53 Timestudy Example Example HandsolderingforPWBofMPF82C Identifytheoperations Timefirst10cyclesforeachoperation Calculatetherequiredno ofcyclestobetaken 2002 9 26 SMTTrainingforProductivity 54 DetermineNo ofCycles Takethefollowsasanexample considerfirst10findings ByN 4R2 A2 d2 2 x 2R 140 102 60 0 633Avg x 123 2 60 2 053For95 confidencelevel A 0 05 d2 3 078N 4 0 633 2 0 05 2 3 078 2 2 053 2 166additionalcyclesshouldbetimetaken 2002 9 26 SMTTrainingforProductivity 55 ExtendtheTimeStudy Determineperformanceratingforeachoperation Normaltime avg timeXperformanceratingeg ForM15 normaltime 122 25X0 9 110 03sIdentifyfrequencyandmanpowerforeachoperation Unitnormaltime normaltime frequencyxmanpower eg Unitnormaltime 110 03 8X1 13 75s eg 2002 9 26 SMTTrainingforProductivity 56 EstablishTimeStandard Defineallowances Personal usually5 Fatigue minimum5 Delay usually3 Identifybottleneckstation Standardtime cycletimeofthebottleneck 1 5 5 3 18 68 0 87 21 47sPcs Hr 3600 2