Objectives of Charts and Diagrams

Charting and Diagramming Used in Methods Engineering

Techniques for Operations Analysis 1. To permit work processes to be communicated and

comprehended more readily
Sections:
Chapter 9 1. Overview of Charting and Diagramming Techniques 2. To use algorithms specifically designed for the particular
diagramming technique
2. Network Diagrams
3. To divide a given work process into its elements for
3. Traditional Engineering Charting and Diagramming analysis purposes
Techniques
4. To provide a structure in the search for improvements
4. Block Diagrams and Process Maps

Gantt Charts ? 5. To represent a proposed new work process or method

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

How to Create / Develop the Chart or

Diagram? How to Analyze the Chart or Diagram

Analyst is intimately familiar with the process and
Algorithmic analysis
develops a graphic to represent it
Line balancing, critical path methods

Analyst observes and records information about the
Checklists

process
General questions applied to the particular process to
assess whether they can be applied to the problem of
interest

One-on-one interviews with those familiar with the
process

A graphic model of the process is developed based on
Brainstorming
these interviews
Team activity in which participants contribute
recommendations

Group meetings with personnel familiar with process

The analyst records the discussion of the meeting.
Separating value-added and non-value-added operations

A graphic model of the process is developed based on the
Value added steps:
group meetings 1. Important to customer
2. Physically change the product or service

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Checklist of Questions - Example Categories of Charts and Diagrams

What alternative starting material could be 1. Network diagrams
used?
2. Traditional industrial engineering charts and

Should the part be produced or purchased? diagrams

Operation charts

Can this operation be eliminated, combined, or
Process charts
simplified?
Flow diagrams

Activity charts

Could a different joining method be used? 3. Block diagrams and process maps

Could the inspection task be automated? 4. Gantt charts

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

1
 Network Diagrams Network Diagram - Precedence Constraints

Consist of:

Nodes representing operations, work elements, activities or other

Restrictions on the order in which work
entities elements can be performed

Arrows connecting the nodes indicates relationships among the
nodes

Direction of work flow between nodes

Precedence among nodes

Used to represent

Work elements in assembly line balancing Precedence

Work activities in CPM and PERT
diagram

Two-way flows (movement of materials):
Maximum number of arrows = n(n -1)

One-way arrows (precedence):

n(n − 1)
Maximum number of arrows =
2

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Traditional IE Charts and Diagrams Operation Charts

Graphical and symbolic representation of the operations used
to produce a product

Operation charts

The time to accomplish the operation is sometimes also
included.

Process charts
Two types of operations:

1. Processing and assembly operations

Flow diagrams
Changing the shape, properties or surface of a
material or workpart

Joining two or more parts to form an assembly

Activity charts
2. Inspection operations

Checking the material, workpart, or assembly for
quality or quantity

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Operation Chart

Component

Subassembly

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

2
Checklist of Questions Used to Analyze an
Operation Chart Operation Charts

The focus of the operation chart is on the materials of a product
and the operations on them

Questions related to material

What alternative starting material could be used?

Make or buy decision: should the part be produced in the
factory or purchased?

Questions related to operations

Is this processing operation necessary?

Can this operation be eliminated, combined, or simplified?

Could a different joining method be used?

Questions related to inspection

Is this inspection necessary?

Could the inspection task be automated?
Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Process Charts Flow Process Chart

Graphical and symbolic representation of the processing
activities performed either on something or by somebody.
Uses five symbols to detail the work performed
on a material or workpart as it is processed

The chart consists of a vertical list of activities using symbols through a sequence of operations and activities:
to represent operations, inspections, moves, delays and
storage and other activities.

Principal types of process charts:
Operation – processing of a material

1. Flow process chart – analysis of a material or workpiece being
processed
Inspection – check for quality or quantity
2. Worker process chart – analysis of a worker performing a task
3. Form process chart – analysis of the processing of paperwork
Move – transport of material to new location
forms

Delay – material waiting to be processed or

All these charts are used to examine for possible moved
improvements of operations

Storage – material kept in protected location

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Flow Process Charts

If the processing operation combined with an inspection
at the same workstation: combine symbols - a circle
inside a square

Provides more detail about the steps required to process

a material than in the operation chart:

is used to study a single work part rather than the
multiple components of an assembly

The chart also indicates distances for move activities

and time values for other activities

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

3
 Checklist of Questions Used to Analyze a
Form for Flow Process Chart Flow Process Chart

Questions Related to Material

Make or buy decisions: Should the part be produced in the factory or
purchased from an outside vendor?

Questions Related to Operations and Inspections

Is the operation time too high?

Is the inspection operation necessary?

Questions Related to Moves

How can moves be shortened or eliminated by combining or eliminating
operations?

Can the level of mechanization in material handling be increased?

Questions Related to Delays

Is the delay avoidable?

What is the reason for the delay? Can the reason be eliminated?

Questions Related to Storage

Is the storage necessary?

Why can’t the material be move immediately to the next operation?

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Flow Process Chart Flow Process Chart

Unplanned
vs.
Planned
stoppage
Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Worker Process Charts Form Process Charts

Used to analyze the activities of a human
Used to analyze the flow of paperwork forms
worker as (s)he performs a task that requires and office procedures
movement around a facility.

Also known as process chart- person analysis

The symbols are the same as flow process

chart

Storage activity is omitted since it is difficult to
interpret in the context of human work activity

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

4
 Flow Diagram Flow Diagram

Drawing of the facility layout with the addition of lines
The flow diagram reveals problems in the work flow that
representing movement of materials or workers within may not readily be identified using the process chart
the facility alone.

Arrows on the lines represent direction of movement

Often used in conjunction with a process chart

Operations, inspections, delays, and storages at specific
locations are identified by numbers referenced to the
activity number

For example, if the work flow involves considerable
backtracting, this can be identified in the flow diagram,
whereas it is indicated only as distances in the process
chart.

Thus, it can be used to detect excessive backtracking
(which might be missed in a process chart), excessive
travel, possible traffic congestion, points where delays
typically occur and inefficient layout.

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Flow Diagram Activity Charts

A listing of the activities of one or more subjects (e.g.,
workers, machines) plotted against a time scale to
Flow diagram for worker indicate graphically how much time is spent on each
activity
setting up a milling
machine:

These activities are generally repetitive.

Types of activity charts:

Note the large number of

Right-hand/left-hand activity chart (a.k.a. workplace activity
trips back and forth chart)
between the milling
Worker-machine activity chart
machine and the tool crib
Worker-multimachine activity chart

Gang activity chart (a.k.a. multiworker activity chart)
Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Shading Formats for Activity Charts Activity Chart

Instead of using symbols for the work activities, as in the other Activity charts usually have more than one time scale
charts, the activities are indicated by vertical lines or bars e.g., activity time and cumulative time

When bars are used, they are shaded or colored to indicate

the kind of the activity being performed. Activity chart for a worker performing a repetitive task:

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

5
 Multiple-Activity Charts

Used to track several participants working
together

They consists of multiple columns, one for
each participant.

Objective: to analyze how the workload is
coordinated and shared among the entities.

Right-hand/left-hand activity chart

Worker-machine activity chart

Worker-multimachine activity chart

Gang activity chart (a.k.a. multiworker activity chart)
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Worker-Machine Activity Chart

Shows how work elements are allocated
between a worker and a machine

Help to identify opportunities for cycle time
improvements e.g., replacement of external
work elements by internal work elements
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Gang Activity Chart

This chart indicates activities in which two or
more workers performing together as a team

Also known as multiworker activity chart

Can be used to analyze the operations of
different stations in the the same chart

Objective: To better coordinate the activities
and balance the workload among the workers
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Right-Hand/Left-Hand Activity Chart

Shows

contributions of the right and left hands

balance of the workload between the right and left
hands

Remember the example with pegs

Task involves placing pegs into a peg board

Note that left hand is used as a workholder
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Worker-Multimachine Activity Chart

Can be used to indicate machine interference
(when a machine must wait for service
because worker is currently servicing another
machine)
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Block Diagrams

Graphic consisting mostly of blocks and arrows
to portray the relationships among components
of a physical system

Commonly used in linear control theory, where

Arrows represent the flow of signals or variables in
the system

Blocks contain transfer functions that define how
input signals are mathematically transformed into
output signals
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
6
 Block Diagram Process Maps
•Used to depict flows and interrelationships
A process is a sequence of tasks that add value to inputs
among components in complex systems to produce outputs

Basic process map is a block diagram showing the steps
•Block diagrams are commonly used in linear in a process
control theory, as shown below for a feedback
Widely applied to business processes
control system
Also applicable to production, logistics, and service
operations

Levels of detail:

High-level process map – macroscopic view of
Output y AB process and includes only the most important steps
= =
Input x1 1 + AC
Low-level process map – used to map each of the
x2 = x1 − Cx3 , x3 = Ax2 x3 = Ax1 − ACx3 steps in a high-level process map

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Symbols in the Basic Process Map Basic Process Map

Process map symbols:
(a) beginning/ending point of the process,
(b) task or activity step,
(c) decision point
Symbols are connected by arrows to indicate
sequence

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Alternative Forms of Process Maps Relationship Map

Relationship process map – block diagram that
Block diagram that shows the input- output
shows the input- output connections among connections among departments (or other
departments (or other functional components) functional components) of an organization
of an organization

Cross- functional process map – block diagram
showing how the steps of a process are
accomplished by various departments

Departments listed as rows separated by
dashed lines

Also called a swim
- lane chart

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

7
 Cross-Functional Process Map Gantt Charts

Block diagram showing how the steps of a
A graphical display of schedule project
process are accomplished by departments activities on a time axis

Project activities are listed on a vertical axis

Activity time durations are shown as horizontal

bars with starting and ending times

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Gantt Chart: Planned Activities Gantt Chart: Progress

Shows actual work accomplished at some
Shows planned activities for a construction project point during week 7

Work Systems and the Methods, Measurement, and Management of Work Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7. by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. ©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Gantt Chart Showing Precedence

Arrows can be used to indicate precedence
relationships among activities

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.