Purpose
How to use a basic understanding of Industrial Engineering to improve the detail of operations and processes to result in reduced costs, a better ROCE and increased profits.
Objective
To equip participants with enough knowledge to enable them to be able to understand the build-up, uses and benefits of Industrial Engineering and related topics (including standards for Cosmos). Deliverables
A series of modules which will enable the above objectives to be met. It is not the aim of these notes to teach participants to become Industrial Engineers but simply to understand the benefits.
Subjects covered
● Introduction and history
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●
●
●
●
●
●
●
● Method study Productivity Work measurement (OMT/IMT) Rating Allowances Time Study Build-up of standard Build-up of standard and Effects of changes to standards Machine Allocations
● Some Real Examples of savings through increased machine efficiency
● Value Chain Analysis (VCA)
Calculation of
labour required and labour efficiencies
labour utilisation
machinery required and machinery efficiencies
machinery capacities
machinery utilisation
Reward Schemes
An existing Scheme
Method Study
It is very important to do the right things
It is also important to do things right
Work smarter not harder
Method Study – Fundamentals
Method study is used when we have an existing situation that requires positive action to bring about a change that will result in some improvement.
Method study helps in the process of finding answers to the questions of change.
Where are we now?
What is the current situation?
Are we trying to solve a problem, take advantage of an opportunity, improve some particular factor or?
How can we get there?
The nature of the area under examination will dictate the shape of the method study
Some Situations are narrow and well defined and will benefit from a simple application of the basic method study procedure
See app. example of load carrier to dye machine
In broader and vaguer (divergent) situations there may be a number of valid courses of action Each will make some improvement to the existing situation from the viewpoint of one individual or group.
These require a wider application of the basic procedure, perhaps using a number of supporting techniques.
The aim is such situations is to develop a wide range of ideas for addressing the basic problem or opportunity situation and then to evaluate each idea against the criteria which have been selected or identified (and agreed) as measuring success.
Traditionally, the benefits that accrue from the practise of method study, have been seen through such things as cost reduction, increased throughput and so on - benefits which are easily and directly measurable.Many method study projects, however, produce benefits which are sometimes note easy to measure - these inclue such things as: increases in job satisfaction and working conditions, more effective decision-making, improved planning and control, etc.
Ergonomics
Operational Research
Systems Analyst
Work Study - this is a combination of method study and work measurement
Method Study Procedure ¨C "SREDIM" ¨C creating a step change in performance
Select the job to be studied / investigated
Record what is happening now
Examine all areas for possible improvements
Develop better ways - involve employees/they can have good ideas
Install revised systems/methods
Maintain the new situation - this is an important part and the one that most people do not carry out
Method Study Procedure ¨C Using a Flow Chart
Operation, Transport, Permanent Storage, Temporary Storage or Delay, Inspection
Indicates main steps in a process, method or prodedure. Usually the item concerned, which may be material, a product, a document, etc., is modified or changed during the operation.
Indicates the movement of workers, materials or equipment from place to place.
Indicates a controlled storage in which material is received into, or issued from, a store or file under some form of authorisation, or an item is retained for reference purposes.
Indicates a delay in the sequence of events, e.g. work or worker waiting between consecutive operations,or any item laid aside temporarily without record until required.
Indicates an inspection for quality and/or a check for quality.
In its broadest sense, productivity is the quantitative relationship between what is produced and all the resources used to produce it
In other words making the best use of the available resources
● land
●
●
●
●
●
buildings material plant and equipment manpower information
Purpose
How to use a basic understanding of Industrial Engineering to improve the detail of operations and processes to result in reduced costs, a better ROCE and increased profits.
Objective
To equip participants with enough knowledge to enable them to be able to understand the build-up, uses and benefits of Industrial Engineering and related topics (including standards for Cosmos). Deliverables
A series of modules which will enable the above objectives to be met. It is not the aim of these notes to teach participants to become Industrial Engineers but simply to understand the benefits.
Subjects covered
● Introduction and history
●
●
●
●
●
●
●
●
● Method study Productivity Work measurement (OMT/IMT) Rating Allowances Time Study Build-up of standard Build-up of standard and Effects of changes to standards Machine Allocations
● Some Real Examples of savings through increased machine efficiency
● Value Chain Analysis (VCA)
Calculation of
labour required and labour efficiencies
labour utilisation
machinery required and machinery efficiencies
machinery capacities
machinery utilisation
Reward Schemes
An existing Scheme
Method Study
It is very important to do the right things
It is also important to do things right
Work smarter not harder
Method Study – Fundamentals
Method study is used when we have an existing situation that requires positive action to bring about a change that will result in some improvement.
Method study helps in the process of finding answers to the questions of change.
Where are we now?
What is the current situation?
Are we trying to solve a problem, take advantage of an opportunity, improve some particular factor or?
How can we get there?
The nature of the area under examination will dictate the shape of the method study
Some Situations are narrow and well defined and will benefit from a simple application of the basic method study procedure
See app. example of load carrier to dye machine
In broader and vaguer (divergent) situations there may be a number of valid courses of action Each will make some improvement to the existing situation from the viewpoint of one individual or group.
These require a wider application of the basic procedure, perhaps using a number of supporting techniques.
The aim is such situations is to develop a wide range of ideas for addressing the basic problem or opportunity situation and then to evaluate each idea against the criteria which have been selected or identified (and agreed) as measuring success.
Traditionally, the benefits that accrue from the practise of method study, have been seen through such things as cost reduction, increased throughput and so on - benefits which are easily and directly measurable.Many method study projects, however, produce benefits which are sometimes note easy to measure - these inclue such things as: increases in job satisfaction and working conditions, more effective decision-making, improved planning and control, etc.
Ergonomics
Operational Research
Systems Analyst
Work Study - this is a combination of method study and work measurement
Method Study Procedure ¨C "SREDIM" ¨C creating a step change in performance
Select the job to be studied / investigated
Record what is happening now
Examine all areas for possible improvements
Develop better ways - involve employees/they can have good ideas
Install revised systems/methods
Maintain the new situation - this is an important part and the one that most people do not carry out
Method Study Procedure ¨C Using a Flow Chart
Operation, Transport, Permanent Storage, Temporary Storage or Delay, Inspection
Indicates main steps in a process, method or prodedure. Usually the item concerned, which may be material, a product, a document, etc., is modified or changed during the operation.
Indicates the movement of workers, materials or equipment from place to place.
Indicates a controlled storage in which material is received into, or issued from, a store or file under some form of authorisation, or an item is retained for reference purposes.
Indicates a delay in the sequence of events, e.g. work or worker waiting between consecutive operations,or any item laid aside temporarily without record until required.
Indicates an inspection for quality and/or a check for quality.
In its broadest sense, productivity is the quantitative relationship between what is produced and all the resources used to produce it
In other words making the best use of the available resources
● land
●
●
●
●
●
buildings material plant and equipment manpower information