INDUSTRIAL ENGINEERING

Ref: Industrial Engineering & Management by Dr.O.P.Khanna; Dhanpat Rai Publications Pvt Ltd.

Definition:
AIIE (Ame ican Institute of Indust ial En!inee s" defines Indust ial En!inee in! as #once ned $ith the desi!n% imp ovement & installation of inte! ated systems of people%mate ials%e'uipment & ene !y.

Production:
P oduction is any p ocess o p ocedu e developed to t ansfo m a set of input elements li(e men% mate ials% capital% info mation and ene !y into a specified set of output li(e finished p oducts & se vices in p ope 'uantity & 'uality% thus achievin! the ob)ectives of an ente p ise.

Productivity:
P oductivity is defined as the atio bet$een *utput & input. *utput means the amount p oduced o the numbe of items p oduced & inputs a e the va ious esou ces employed. i.e+ land & buildin!% e'uipments & machine y% mate ials% labou etc. P oductivity , Actual P oduction - .tanda d P oduction (o " P oductivity , *utput - Input

Difference between Production & Productivity:

P oduction , /00 Pcs i.e+ 1uantity p oduced i espective of inputs P oductivity , /00 Pcs (*utput" fo /0 2achines (Input" , /00Pcs - /0 2c , /0 Pcs pe 2achine

 P oductivity , Rate of Pcs P oduced Pe 2achine (* any othe input facto "

Some Import nt !ormu" # :

/. 2achine Availability 3 ,
Machine Available time x 100 % Total Machine Time

4. 2achine 5tili6ation 3 ,

Actual Running Time x 100 % Machine Available Time

No of M/C's Use ! "o#$ing %ou#s !

Total Available %ou#s ! "o#$ing %ou

7. 2achine Efficiency 3 ,

&tan a# Running Time x 100 % Actual Running Time

8.2achine Effective 5tilis 3 ,

&tan a# Running Time x 100 % Machine Available Time

WORKSTUDY / TIME STUDY / WORK MEASUREMENT:

$or% &e #urement may be defined as the application of diffe ent techni'ues to measu e & establish the time e'ui ed to complete a )ob by a 'ualified $o (e at a desi ed level of pe fo mance. 'per tion n "y#i# is a detailed study of diffe ent ope ations involved in doin! a $o (.*pe ation analysis becomes necessa y in o de to investi!ate the sho t comin!s of the e9istin! method & to develop an imp oved p ocedu e. ANAL(SIS '! &'TI'N: :he pu pose of motion analysis is to desi!n an imp oved method $hich eliminates unnecessa y motion & employs human effo ts mo p oductively. .teps involved in motion analysis a e: /. .elect the ope ation to be studied 4. List & cha t va ious motions pe fo mance the ope ato . 7. Identify the P oductive & Idle motions

8. Eliminate the unnecessa y & non p oductive motions ;. Redesi!n the e9istin! ope atin! p ocedu e by employin! minimum numbe of motions in the most app op iate se'uence & in acco dance $ith the p inciples of motion economy. STANDARD TI&E: .tanda d :ime may be defined as the amount of time e'ui ed to complete a unit of $o ( unde e9istin! conditions% usin! the specified method & machine y% by an ope ato able to do the $o ( in a p ope manne and at a standa d pace. 'T (R) (A R(A &A ('A

No#mal Time

Allo*ances % &tan a# Time

'T+ 'bse#ve Time (R) + (e#fo#mance Rating )acto# (A+ (#ocess Allo*ances &A + &,ecial Allo*nces ('A + (olic- allo*ances .tanda d :ime , (Ave a!e *bse ved :ime < Ratin! 3"=Allo$ances 3 >o mal :ime , (Ave a!e *bse ved :ime < Ratin! 3" .tanda d :ime , >o mal :ime = Allo$ances 3 ,? >.: = (>: < Allo$ 3 /00" E) mp"e: #alculate the .tanda d time $ith the !iven info mation: Ave a!e *bse ved time , 4 min+ Ratin! 3 , ;0 3 % Allo$ances , /; 3 .ol: .td :ime ,>o mal time = Allo$ance 3 >o mal time , Ave a!e *bse ved :ime < Ratin! 3 , 4 < 0.; , / min St nd rd time , / min = /;3 ,/=0./; , *+*, min Time Study Form

(#o uct. ',e#ation. 0esc#i,tion . 'bse#ve Time &to,*atch Rea ing 1Min2 Rating )acto# %

Time &tu - /nginee#. 0ate.

&l No 1 3 4 5 6 7 8 9 : 10

No#mal Time 1min2

Allo*ance %

&tan a# Time 1min2

Ave#age &tan a# Time=

PERFORMANCE RATING:
Ratin! means !au!in! & compa in! the pace o the pe fo mance of $o (e a!ainst the standa d pe fo mance level set by the time study en!inee . Standard Performance is the ate of output $hich 'ualified $o (e $ill natu ally achieve $ithout ove e9e tion as an ave a!e ove the $o (in! day o shift% p ovided% they (no$ and the e to specified method and p ovided they a e motivated to apply themselves to thei $o (. Rating Scale (British Standard) Description 0 60 No Activit;e#- &lo*<clums-<fumbling movements<o,e#ate# a,,ea#s half aslee,< *ith no inte#est in the =ob Comparable Walking Speed (Miles hr) 0 3

86

&tea -< elibe#ate<unhu##ie ,e#fo#mance as of a *o#$e# not on ,iece*o#$ but un e# ,#o,e# su,e#vision< loo$s slo*< but time is not being intentionall- *aste un e# obse#vation< calle as 0A>"'R? &TAN0AR0 @#is$ @usiness li$e ,e#fo#mance< as of an ave#age Aualifie *o#$e# on (B/C/"'R?C necessa#- stan a# of Aualit- D accu#acachieve *ith confi ence ;e#- )astCo,e#ate# exhibits a high eg#ee of assu#ance< exte#it- an coo# ination of movement *ell above that of an ave#age Aualifie t#aine *o#$e# /xce,tionall- fast<#eAui#es intense effo#t an concent#ation<an is unli$el- to be $e,t u, fo# long ,e#io sC as a Evi#tuosoF ,e#fo#mance achieve onl- b- a fe* outstan ing *o#$e#s

1001&tan a# Rating2

136

160

Standard Rating 11002 is a no#mal man of ave#age height an ,h-siAue<unla en<*al$ing on a st#aight line *ithout obst#uctions achieving 5 miles/hou# Reference: Introduction to Work Study, edited by George Kanawaty, International Labour Office ,Geneva As pe the above table + Piece$o ( standa d , 8 miles-h Day$o ( standa d , 7 miles-h :he efo e% 3 of inc ease of day$o ( ove piece$o ( ,8-7 , /.77 (/-0.@;" o 77.773. :he efo e D ywor% St nd rd time, Piece$o ( standa d time = 77.77 3 , Piece$o ( standa d < /.77 (a"Standard Rating: It is the ave a!e ate of pace at $hich a 'ualified $o (e $ill natu ally $o ( if he is motivated to apply himself to $o (. (b"Normal Rating: It is the ave a!e ate o pace at $hich a 'ualified $o (e $ill natu ally $o ( even if he has no specific motivation to apply himself to $o (. VARIOUS TECHNIQUES OF RATING: /. .peed Ratin!% 4. .(ill & Effo t Ratin!%

7. Aestin! Bouse system of Ratin!% 8. .ynthetic Ratin!% ;. *b)ective Ratin! and C. Physiolo!ical evaluation of Pe fo mance level. *+ Speed R tin-: .peed of the movements of a $o (e is the only facto in speed atin!. Ratin! pe sonal obse ves the speed of the movements of the $o (e a!ainst a standa d e9pected pace o speed and note the elationship bet$een as a atin! facto . >o mal :ime , (*bse ved :ime < Ao (e .peed" .peed E9pected f om the $o (e .+ S%i"" & Effort R tin-: :his Ratin! .ystem $as su!!ested by #.E.Deduse in /E/C.:he units of $o ( a e e9p essed as DFs. If a $o (e ac'ui e C0 DFs in one hou % it $ould be the standa d pe fo mance. Ahile timin! the elements the ope ato is ated fo the speed of his movements and his s(ills. An efficient $o (e ea ns points in e9cess of C0 DFs and a poo $o (e $ill be belo$ C0 DFs. DG points fo a )ob can be calculated by addin! the same(i.e+DGpoints" fo each element involved in this )ob. DGpoints fo an element a e e'ual to , (*bse ved :ime < D points Ea ned by the $o (e < Rela9ation facto " - C0 Rela9ation facto depends upon the natu e of $o ( and may va y f om / to 7 fo li!ht to ve y heavy duty $o (s o )obs+ /+ $e#tin- 0ou#e Sy#tem of R tin-: It is based upon facto s $hich a e fu the divided into sub facto and have nume ical values attached $ith them.the Ha ious Iacto s a e (i".(ill : .upe s(ill(=0./;"E9cellent(=0.//"Jood(=0.0K"%Ave a!e(0.00"%Iai (G 0.0;"%Poo (G0./C" (ii"Effo t (iii" #ondition(*f :emp atu e%noise%smo(e%fumes etc.%" and (iv" #onsistency

A $o (e is ated based on the above fou facto s E9ample: Let the obse ved time fo an ope ation be 0.C min and a $o (e $hile bein! obse ved is estimated as follo$s. E9cellent .(ill Jood Effo t Iai #onsistency =0.// =0.04 G0.04

Jood #onditions =0.04 Al!eb ic .um , =0./7 Ahich indicate the $o (e is /7 3 above ave a!e o his pace ate //7 3.If a $o (e !et ne!ative nume ical fi!u e% he is conside ed belo$ ave a!e. :he atin! Iacto in this case is /./7 and thus no mal time fo an ope ation , 0.C < /./7 , 0.C@K min 1+ Synt2etic R tin-: In this system the speed o the pace ate of an ope ato is evaluated $ith the help of p edete mined motion time standa ds LP2:.M.Ha ious elements a e timed in the usual $ay and thei values a e compa ed $ith the time values as e9istin! in p edete mined motion standa ds LP2:.M. P2:. a e compiled as a esult of la !e numbe of obse vations on each movement (and !ene ally" th ou!h mic oscopic motions (i.e% f ame by f ame" analysis..uch studies a e ca ied out fo a $ide va iety of )obs $ith male & female $o (e s unde diffe ent $o (in! conditions. Ratin! Iacto , (:ime Halue E9t acted f om P2:." - (*bse ved :ime". ,+ 'b3ective R tin-: :his system involves %fi st atin! the speed of $o (e a!ainst a standa d pace independent of )ob difficulty and then addin! an allo$ance dependin! upon the )ob difficulty.:he )ob difficulty is decided f om the follo$in!. a" :he amount of body used% b" Ioot movements involved% c" EyeGhand coGo dination% d" Aei!ht moved o lifted% and e" Bandlin! e'ui ements%etc.

4+ P2y#io"o-ic " Ev "u tion of Perform nce Leve": Pe fo mance level of a $o (e can also be estimated physiolo!ically% because hea t beat ate inc eases $ith the muscula activities and amount of o9y!en consumed by a $o (e inc eases $ith the seve ity of physical labou . ALL'$AN5ES:

T0ER6LIGS: :he bli!s $as su!!ested by I.D.Jilbe th. :he bli!s a e used to desc ibe the basic elements of movements o fundamental hand motions of the $o ( cycle. Eve y the bli! is ep esented by a symbol% a definite colou and $ith a $o d o t$o to eco d the same . Io e9ample+the bli! J asp has the symbol 5% Red colou & is denoted by the $o d J Io E9ample.% Macroscopic motion 1G',e#ation of (ic$ing u, a sc#e* #ive# Microscopic Motion(Therbligs) 1GReach hav fo# &c#e* #ive#1T#ans,o#t em,t-2 3GH#as, the same 1H#as,2 4GTa$e a*a- the &c#e* #ive#1T#ans,o#t Ioa e 2

Refer Industrial Engineering &#'( for Sy"bols List!

!anage"ent by O#$#K%anna,$age no

SIMO Chart (Simultan !u" M!ti!n C#$l %:

Definition & 5oncept: It is an e9t emely detailed Left & Ri!ht handed ope ation cha t. It sho$s on a common time scale the simultaneous minute movements(:he bli!s" pe fo med by the t$o hands of the ope ato . Desides hands %the movements of othe limbs of an ope ato may also be eco ded. :he time scale is ep esented in $in%#7* $in% 8*9.:::t2 of minute;+

.I2* #ha t is !ene ally used fo 2ic omotion analysis of (a"..ho t cycle epetitive )obs% (b" Bi!h o de s(ill )obs% And finds applications in )obs li(e component assembly% pac(a!in!% epetitive use of Ni!s and fi9tu es% inspection etc. 5on#truction of SI&' 52 rt: /. 5sin! a /CGmm movie came a a numbe of sho t and epetitive $o (cycles a e filmed ( at /C f ames-second" as the $o (e pe fo ms the )ob. Io eco din! time % a timin! device called Ain( #ounte is placed in the field of vie$. 4. :he Iilm thus obtained is vie$ed and the most efficiently pe fo med one $hole cyle is selected fo analyses. (A cycle involves complete se ies of motions f om be!innin! to the end fo completin! a unit of $o (". 7. A .pecial p o)ecto is employed to study the $o (cycle eco ded on the film .:he $o (study en!inee analyses the film% f ame by f ame% studyin! one f ame at a time and concent atin! fi st on the left hand & then on the i!ht hand movements. 8. :he data noted in stepG7 is eco ded in the fo m of a the bli! cha t .:he du ations of a actual movements a e also ead f om the win% counter. ;. A .I2* #ha t is then d a$n fo fu the study analysis. C. :his .I2* #ha t of e9istin! method is sub)ected to a 'uestionin! p ocedu e based on the p inciples of motion economy+the pu pose is to develop a bette & imp oved p ocedu e fo doin! a )ob. @. A ne$ .I2* cha t is then p epa ed fo the ne$ method. K. :he ne$ method is then chec(ed as e!a ds the advanta!es claimed fo the same.
S!M" C#$RT 0ate. )ilm No. ',e#ation No. &-mbol H TI ( Time1"in$s2 0 10 30 40 50 &-mbol H TI A0 Right %an 0esc#i,tion H#as, hamme# To Job B le

',e#ation. Name of the "o#$e#. Com,onent Name. Ieft %an 0esc#i,tion H#as, Chisel To Job (osition

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60

Use