Operation Analysis

INSY 3021

Auburn UniversitySpring 2007

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?

Operation Purpose Try to eliminate or combine an operation

prior to improving it! Some operations exist because the

previous work was unacceptable, necessitating “touch-up” work supposedly accomplished by the first operation.

Can an outside supplier perform the operation more economically?

Questioning Attitude

Part Design Review every design for possible

improvements. Simplify design to reduce # of parts. Make joining, machining, and

assembly easier. Design for manufacturing.

Tolerances and Specifications Designers may overcompensate with

very tight tolerances (high production cost and time consuming) because they are not aware of the capabilities of the manufacturing dept.

Cost vs. Machining Tolerance

Find a less expensive material Find materials that are easier to process Use materials more economically Use salvage materials Use supplies and tools more economically Standardize materials Negotiate best prices from vendors

Materials

Manufacturing Sequence and Process Rearrange operations Mechanize manual operations

(ergonomically designed tools) Use of robots Operate mechanical facilities more

effectively Manufacture near the net shape

(eliminates material removal)

Setup Reduction (SMED) and Tools Tooling amount based on production

quantity, recorders, labor, time limits and capital.

Perform setup work while the machine is running

Use efficient clamping devices Eliminate large adjustments Use templates or block gages Maintain records of difficult setups

Machine Efficiency Use multiple cutting tools to use

available power Use most efficient tooling Energy efficient motors

Material Handling (MH) Depending on the part, 30%-50% of the

cost is due to MH Reduce time spent picking up the

material Use mechanized equipment Make better use of existing handling

facilities Handle material with the greater care Use bar-coding where applicable

Plant Layout Layout types (product or straight

line & process or functional) Travel charts Muther’s Systematic Layout Plan

(SLP)

Travel Chart

Work Design Manual work and principles of

motion economy Ergonomic principles of workplace

and tool design Working and environmental

conditions

Questions & Comments