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A I C I F

Copyright 2009

Luis Armendariz, P.E.,MBA,Six Sigma EngineerLean Physics and Operations Modeling Consultant

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A C &

G E ?

C /A

I C &

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C

The Mayas in MesoamericanCivilization

W= F dF = m a

Issac Newton1643-1727

Long Time CountEstimated Current and Historical Dates

2600 B.C.

Lilian and Frank Gilbreth 1931Lilian 1878-1972

Fredreric Taylor1856-1915

Henry Ford1863-1947

Greece and EgyptHour Glass

Predetermine Time System (PTS)1910

USA-Sweden-Germany1940

PTS. And OthersWorkfactor, MOST, Modaps

rot me ystems.com

Computer Video-Based WorkMeasurement

andVideo & Pictorial Instruction Systems

1996

Taiichi Ohno1912-1990

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&

Any activity that consumes resources and creates

value or non-value added for the customer

What is Work ?

Work Measurement

MPI

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1

2

3

Work to be studied

Relevant data, work elements

Work element breakdown and effective method

4

5

7

8

Work in each element (time), VA and NVA

6 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 audit7Copyright 2009

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A

Value Stream/Process Flow Mapping

Capacity and Lead Time Analysis Production Plan/Production Standards Scheduling Labor/Staffing Analysis/Labor Standards Production Incentives

The Work Flows of : Material People

Costing Product Design Layout Planning Ergonomics Inventory Planning/ERP

Information Systems Simulation Modeling Flow Manufacturing & Service Learning Curves and Training Productivity/Efficiency & Effectiveness

TIME

Information Service Layout Cash Environment

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/

/

/

.

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A

Engineer Based Standards Team Video Based Standards

1. Engineer Conducts WorkMeasurement

1. Engineer /Supv. Facilitates Study2. Cross Functional Team Conducts Work

2. Engineer Compiles Standard3. Engineer Develops Std WorkInstruction

4. Management Enforces Standard5. Operators Follow Instructions

Measurement (Including Operators)3. Team Develops Std Work Instruction(Including Operators)

4. Management provides training, removesbarriers and motivate operators

5. Operators are accountable to sustain6. Operators are motivated to improvestandards

7. Engineer/Mgt. installs the control systemsand operating mechanisms

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(7 )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 operators 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 valueo e pro uc serv ce

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

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B 5/EH F

&

PFD Allowances

Personal

&

Delays

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5 7

7 Waste

Any activity that consumes resources and createsvalue or non-value added for the customer

What is Work ?

VA

5 Work Symbols

Operation

OverproductionWaitingTransportationInventoryUnnecessary Processing

Defects

8 Tap into human potential and creativity

NVA

Storage

Delay

Transport

Inspection

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F 5 D:

D: I

.

.

()

()

()

1 G 5 5 6 5

2 G & 10 5 1 5

This tool is used to measure service or manufacturing processes, collectinginformation using sticky notes to build the VSM

4 G & 20 4 3 45 24 5 0 5

6 29 7 6 7

7 A 36 4 0 4

8 40 6 0 6

9 46 6 3 6

10 52 5 0 5

11 A C 57 5 0 5

57 24 20 32 0 0 5 12 5 6 1

35%

C

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( )

Assy1

Constant Work Elements Time1- Pick up part 32- Move to table 23- Assemble housing 104- Inspect assembly 75- Move part to bin 2S/E- Starts and End in container

1

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 STH = 120/hr

WIP=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

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( )

Assy1

Constant Work Elements Time1- Pick up part 22- Move to table 13- Assemble & test housing 124- Inspect assembly 75- Move part to bin 2S/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

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( )

A

Restricted WorkIs work in which the output is limited by factors

outside the control of the worker

I

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

I

Future

0.8 min

I

I

1.12 min

0.8 min

1.36 min

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( )

D

A Machine Process Time 0.8 min

1.36 min

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

I

C

0.24

1.12

1.36

82% (1.12/1.36)

0.56

0.80

1.36

59% (0.8/1.36)

Summary

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( )

D

Observed

CT = 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-ReduceInt-Reduce

Int-Reduce

Eliminate

Int-Reduce

Int-Reduce

Int-Combine

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( )

EE

Availability (Downtime Loss) = Operating Time / Planned Production Time

OEE = Availability x Performance x Quality

Quality (Quality Loss) = Good Pieces / Total Pieces

1 2

A 90% 95%

95% 95%

99.5% 96%

EE 85.1% 86.6%

Note: Availability (TBF and TTR)22Copyright 2009

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( )

D

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

B

C

CTq2

CT= SetupTime + Process Run Time + Ctq

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( F)

103

Operator A

2

3

4

5

8

7

6

1

2

1

4

3

3

2

Operator B

Operator C

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(F F)

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(F F)

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PTS

Are pre-established times for basic human motionsand are used to build up the time for a job at a

defined level of performance

Base assembly workplace layout

18

12

8 8 8

12

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/B F

Time To Fill Vacancies

(Intellectual Capital Losses)

Lost Hours of Productive Hourly EmployeesLost Hours of Productive Salary Employees

A

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

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(I F)

D ?

Video Instruction

Text Instruction

WIP

CTInformation Board

TH

Align plate on table

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A Routine for work to be performed right the first time, every time

E

1 (D )

Min

A B C

TAKT

WIP = CT x TH

2 I3 ( I,

D & )

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I

D

K

TIME

IMPROVEMENT

KK

K

K

K

K

K

KS

S

S

K-

S-

Kaizen event

Sustainedperformance

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&A

Cannot manage if you dont measure !Contact IIE Membership

Luis Armendariz, P.E.

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