The entire system or process of doing work should be studied before undertaking a thorough investigation of a specific operation in the

process. Such an over-all study will ordinarily include an analysis of each step in the manufacturing process or system.

Process Analysis Tools

Operation process chart Flow process chart Flow diagram

OPERATION PROCESS CHART

The operation process chart shows the chronological sequence of all operations, inspections, time allowances, and materials used in a manufacturing or business process, from the arrival of raw material to the packaging of the finished product. The chart depicts the entrance of all components and subassemblies to the main assembly. Two symbols are used in constructing the operation process Chart : an operation and an inspection.

FLOW PROCESS CHART

The flow process chart is a device for recording a process in a compact manner, as a means of better understanding it and improving it. The chart represents graphically the separate steps or events that occur during the performance of a task or doing a series of actions. The chart usually begins with the raw material entering the factory and follows it through every step.

The process chart symbols : The American Society of Mechanical Engineers (ASME) has established the five standard symbols are described As follows: Operation An operation occurs when an object is intentionally changed in one or more of its characteristics. An operation represents a major step in the process and usually occurs at a machine or work station.

Transportation A transportation occurs when an object is moved from one place to another, except when the movement is an integral part of an operation or and inspection. Inspection An inspection occurs when an object is examined for identification or is compare with a standard as to quantity or quality.

Delay A delay occurs when the immediate performance of the next planned action does not take place. Storage A storage occurs when an object is kept under control such that its withdrawal requires authorization.

Combined symbols Two symbols may be combined when activities are performed at the same work place or when they are performed concurrently as one activity. Example Represents a combined operation and inspection.

The Process chart symbols

Types of Flow Process Chart:

- Product or Material type - Worker (Man) type - Machine type

Process chart (Material) for preparation of direct mail

Flow process chart (worker) for field inspection of LUX.

FLOW DIAGRAM
A pictorial representation of the layout of floors and buildings, showing the locations of all activities on the flow process chart, is a flow diagram. The flow diagram is a helpful supplement to the flow process chart because it indicates backtracking and possible traffic congestion areas, and it facilitates developing an idea plant layout.

Flow diagram of the old layout of a group of operations on The Garand rifle.

Recoding Buffing Wheels with Emery

In large factories where heavy polishing and buffing operations are required, it is customary to recoat buffing wheels with emery in the plant, thus keeping a supply of fresh wheels always available. The wheels are made of layers of fabric sewed together, and their average weight is 40 pounds. They vary in diameter from 18 to 24 inches, and width of face from 3 to 5 inches. The circumference or face of wheel is coated with glue and emery dust. The first coat of glue is allowed to set approximately one-half hour before the second coat is applied.

The temperature in the room where the wheels are cured is maintained between 80 to 90, and the humidity Is also controlled.

Buffing wheel

Original Method The circumference of the wheel was coated with glue and then roll by hand through a shallow trough filled with emery dust, thus coating the wheel. After the glue had dried, a second coat of glue and emery dust was applied in a similar manner. The wheels were then hauled to a drying oven. And hung on tracks in the oven until the glue was thoroughly dry.

Operator applies glue to circumference of worn wheel by mean of a brush

Old method of recoating wheel. Operator rolls glue-covered wheel back and forth in trough containing emery dust.

Flow Process Chart (original method)

Flow diagram of old method of recoating buffing wheels with emery.

The following questions might be asked about this job: Why coat the wheels by hand? Why handle the wheels so often? Could the wheels be coated on the first floor instead of on the second?

Improved Method
A special coating machine was built, making it possible to apply the glue and emery to the wheel in one operation with much less time and effort than by the old method. Because this machine was located on the first floor between the storage area and the drying oven, it was unnecessary to move the wheels to the second floor. Special truck racks were used instead of regular platform trucks, eliminate much unnecessary handling of wheels.

Improved Method (continue)

The coated wheels remained on the truck racks while in the drying oven.

Special coating machine Special truck rack

Flow Process Chart (improved method)

Flow diagram of improved method of recoating buffing wheels with emery.

Results
The new coating machine, the special truck rack for handling wheels, and the better location of the coating machine reduced the number of: operations from 6 to 4 delays from 4 to 1 Transportation from 12 to 3 length of travel from 240 to 70 feet operators from 4 to 2 average production from 20 to 45 wheels/hour

WORKER AND MACHINE PROCESS CHART

The worker and machine process chart (Man-machine chart) is used to study, analyze, and improve one workstation at a time. The chart shows the exact time relationship between the working cycle of the person and operating cycle of the machine. These facts can lead to utilization of both worker and machine time, and a better balance of the work cycle.

 Many machine tools are either completely automatic or semi automatic. The operator is often idle for a proportion of the cycle. The utilization of this idle time can increase operator earnings and improve production efficiency.

GANG PROCESS CHART

The gang process chart is an adaptation of the worker and machine process chart. The gang process chart shows the exact relationship between the idle and operating cycle of the machine and the idle and operating times per cycle of the workers who service that machine. This chart reveals the possibilities for improvement be reducing both idle operator time and idle machine time.

Gang Process chart