PRACTICAL NO 1

STUDY OF THE OUTLINE PROCESS CHART

THE OUTLINE PROCESS CHART:
An outline process chart is process chart giving on overall picture by recording in sequence only the main operation and inspections. Its is design to give a quick understanding of the work which must be done to produce a given product. The greatest adventure of this chart is its simplicity; is enables the Method Engineering to visualize the relationship between processes without showing sometimes confusing materials handling activities. For this reason, the outline process chart is an effective means of illustrating process to person who are uniform liar with the sequence of operation and inspections. In making an outline process chart it is usually convenient to start with a vertical line down to right hand side of the page to show the operation and inspection undergone by the principle unit of component of the assembly. The time allowed per piece in hours is shown to left of each operation no specific time allowed for inspection as the inspectors are on time work.

ASSEMBLING A SWITCH ROTOR

1
`

2
Its consists of: 1. a spindle 2. a plastic molding 3. a stop pin

The operation and inspection carried out on the spindle which made from to mm steel rod are follows: Operation # 1: Operation # 2: Face, turn, undercut and part off on a lathe machine (0.025 hours). Face opposite end on the same machine (0.010 hours). After this operation the work is pent to the inspection department. Inspect for dimension and finish ( no time fixed ) from the Inspect department the work is sent to the milling section. Straddle mill four flats one end on a horizontal miller (0.070 Hours). The work is sent to the burring bench. Remove burrs at burring bench (0.20 hours). The work is returned to the inspection department. Final inspection of machine (no time). De greasing (0.0015 hours). Cadmium plating (0.008 hours). From the plating shop the work goes again to the inspection department. Final check (no time). The plastic molding is supplied with a hole bored concentrate with longitude axis. Face on both sides, bore the cored hole and ream to size on lathe (0.080 hours). Drill Cross-hole (for the stop pin) and burr on spindle drill press (0.022) hours). Form the drilling operations the works goes to the inspection department. Final check dimensions and finish (no time) wait the drawn for Assembly. Assembling the molding to the small end of the spinal and drill the stop pin hole right through (0.02 hours). Once this has been done the assembly is ready for the insertion of stop pin (made from 5 mm diameter steel rod) which has been made as follows. Turn 2 mm diameter shank, chamfer, and part off on a lathe (0.025 hours)

Inspection # 1: Operation # 3: Operation # 4: Inspection # 2: Operation # 5: Operation # 6: Inspection #3:

Operation # 7: Operation # 8:

Inspection # 4: Operation # 9:

Operation # 10

Operation # 11: Inspection # 5: Operation # 12 Operation # 13: Inspection # 5: Operation # 14: Inspection # 7:

Remove the pipe on a finisher ( 0.005 hours). The work now goes back to the inspection department. Inspect for dimensions and finished (no time). Degreasing (0.0015 hours). Cadmium plating (0.006 hours). The work goes now back the inspection depth. Final check (no time) It then passes to the finished part stores and is with drawn for. Stop pin is fitted to assembly and lightly riveted to retain it in position (0.045 hours) The completely assembly is finally inspected ( no time ).

Out line process chart: switch rotor assembly

It is clear from the chart that operations and inspections on the molding are on a vertical line next to that of spindle. This is to because the molding is first component to be assembled to the spindle. The stop-pin line is set farther to the left for the same reason as mentioned above.

PRACTICAL NO 2
STUDY OF THE FLOW PROCESS CHART
FLOW PROCESS CHARTS:
A flow process charts is a process chart setting out the sequence of the flow of a product or a procedure be recording all events under review using the appropriate process chart symbols.

FLOW PROCESS CHART MEN TYPE:

A flow process chart which records what the worker does.

FLOW PROCESS CHART MATERIAL TYPE:

A flow process chart which records what happens to material.

FLOW PROCESS CHART EQUIPMENT TYPE:

A flow process chart which records how the equipment is used. A flow process is proposed by using all the proposed symbols i.e. operation inspection, transport, delay and permanent storage. The aid in discovering operation or inspection, they are particularly valuable because they graphically illustrate materials handling operations which represent a major portion of most product costs. Flow process chats may include information such as the time required to complete an activity on the distance moved. By the systematically questioning need for each activity recorded on the process chart and carefully analyzing the need for better material handling procedures. Its is often possible to reduce substantially the coast of performing a process. Flow process charts have used in factories, office bank stores and hotels, with excellent result.

ENGINE STRIPPING, CLEANING AND DEGREASING:

The flow process chart shows that there are only four operation and the inspection, which there are 21 transports and three delays out of 29 activities excluding the original storage only five can be considered as productive. Detailed examination of the chart leads to a number of question. For example being transported form the old engine stores has to change cranes in the middle of its journey.

QUESTION TECHNIQUES:
Q- what is done? A- the engine is carried part of the way through the stores by one electric crane, is place on the ground and ten pock up by another which transports it to the stripping bag. Q- why is this done? A- because the engine are stored in such a way that they can not be directly picked up by the mono said cream which puns through the stores and degreasing shop. Q- what else might be done? A- the engine could be stored so that they are immediately accessible to the monorail crane which could then pick them up and run directly to the stripping bay. Q- what should be done? A- the above suggestion should be adopted this resulted in the elimination of three transports. Q- what are the engine components cleaned before going to be degreasing since they are again cleaned after the grease is removed? A- the original reason for this practice has been for gotten. Q- why are they inspected at this stage when it must be difficult to make a proper inspection of greasy part and when they will be inspected again in the engine inspection section? A- the original reason for this practice has been for gotten. Q- why is required to transport the part 3 meters in order to put them into the degrease basket. Q- when can the degreaser basket not be kept near at hand? Can the parts not be put straight in to the degreaser basket as the engine is dismantled?

DEVELOP THE IMPROVED METHOD:

There have been considerable reductions in the number of non-productive activities. The number of operations has been reduced form four to three by the elimination o the unnecessary cleaning and the inspection carried out directly after is it has also been eliminated transport have been reduced form from 21 to 15 and the distances involved have also been cut from 237.5 to 150 meters a saving of over 37% in the travel of each engine

PRACTICAL NO 3
STUDY OF FLOW DIAGRAM WITH FLOW PROCESS CHART
FLOW DIAGRAM:
It is sometime desirable to know about the path of movements of men and materials through the factory or working area during the process of manufacture or in the course of other activities. This information can be available with the help of flow diagram developed to indicate movement. The flow diagram is a plan substantially to scale, of the factory or shop, will the location of machines, work places and working area correctly depicted on it. As a result of observation in the shop the path of movements of the materials, components of products under consideration are traced. Sometimes using the process chart symbols to denote the activities carried out at the various stop ping point. Example of the use of a flow diagram with a flow process chart: receiving and inspection aircraft parts:The flow diagram shows the original layout of the receiving department of an aircraft factory. The path of movement of the goods from the point of delivery to the storage bin is shown by the broad line in figure. The symbols for the various activities have been inserted at the proper places. This enables anyone looking at the diagram to imaging more readily the activities the goods are subjected.

RECORDS:The sequence of activities is: 1. unloading from the delivery truck, cases containing aircraft parts. 2. These case are slid down an inclined place. 3. Slid across the floor to the unpacking space and there stacked one on the top of another. 4. await opening 5. cases unstacked 6. Lid removed, delivery note taken out.

7. Cases loaded one at a time on a hand truck 8. Taken to the reception bench.

9. Await dischange from truck 10. Case placed on bench. 11. Unpacked, each piece is taken out of its carton and checked against the delivery note. It is then replaced in its cartons are replaced in the case. 12. Case loaded on hand truck. 13. Delay awaiting transport. 14. Trucked to inspection bench. 15. Await inspection. 16. Parts are unpacked, inspected, measured and replaced. 17. Await transport laborer. 18. Trucked to numbering bench. 19. Awaiting numbering. 20. Parts unpacked, numbered and replacing in the cartons. 21. Await transport laborer. 22. Transport to distribution point. 23. Stored in bins to await issue to the assembly shops.

EXAMINE:
A study of flow diagram shows that the cases take a very long and round about path in journey to the bins.

DEVELOPED THE IMPROVED METHOD:

The case in now slid down the inclined plane from the delivery truck and put straight on a hand truck. the inspection and numbering benches have now been placed beside the reception bench, so that the parts can be passed from hand to hand for inspection measuring and then numbering. It is also decided to open a fresh door into the stores opposite the benches so that the cases could be taken in by the shortest route.

PRACTICAL NO 4
MULTIPLE ACTIVITY CHART- MAN MACHINE TYPE FINISH MILL CASTING
MULTIPLE ACTIVITY CHART:
A multiple activity charts is a chart on which the activities of more than one subject (worker, machine, or equipment) are each recorded on a common time scale to show their inter relation ship. By using separate vertical columns or bass to represent the activities of different operators or machines against a common time scale, the chart show very clearly periods of idleness on the part of any of the subject during the process. The multiple activity chart is extremely useful in organizing terms of operations on mass production work, also on maintenance. Work when expensive plant cannot be allowed to remain idle longer than is absolutely necessary. It can also be used to determine the number of machine which operator should be able to work often. In making a chart the activities of the different operators and machine are recorded In terms of working time and idle time the time are then plotted in their respective columns. The multiple activities chart can also be used to present a picture of the operations performed by a study of the activities. It is possible to determine whiter better use can be made of the operators time or of the machine time in particular. It offer a mean so determining weather a man minding a machine, machine whose time is only partly occupied, can manage to service another machine, or whether the two machine with offset any gain to be obtained from employing the mens time more fully.

RECORDS:
Figure represent a common from of man and machine multiple activity chart occurring the operation of a vertical milling machine finish milling one face of a cast form casting parallel to the opposite face which is used for location it in the fixture. The leading of the chart records the usual standard information. The graduated scale on the edge of the chart can be made to represent any scale of time required in this case one large division equals 0.2 of minute.

EXAMINE CRITICALLY:
Figure represent the method by which the operator was doing the job before the study was made that the machine retains idle while the operator is carrying out all his activities and remains idle while the machine is reeling on an automotive feed. Examination of the chart should that the work carried out by the operator can be divided into the two parts that which must be done with the machine stopped such a removing and locating the work piece and that which can be done while the

machine is renaming, such as gauging. It is an advantage to do as much as possible while the machine is renaming as this will reduce the overall operation cycle time.

DEVELOPE THE NEW METHOD:

Figure shows the improved method of operation. Now gauging debussing the edger of the machine face, placing the casting in the box of finished work picking up an un machined casting and placing it on a work table ready to locate in the fixture are now all done while the machine running. A slight gain in time has been made by placing the boxes with finished work and the work to be done next to one another so that one casting can be out away at the same time as the new one is lifted. The cleaning of the machined casting with compressed air has been debarred until after breaking down the scrape edge, that saving an extra operating. The result of the arrangement which has in would no capital out lay is a saving of 0.64 of a minute on 2 minute, a gain of 32 percent in the productivity of the milling machine an operator.

PRACTICAL 5
STUDY OF A TWO HANDED PROCESS CHART ACTIVITY/PROCESS, CUTTING GLASSTUBE. DEVELOPS THE IMPROVED METHOD WITH THE HELP OF ORIGINAL METHOD:
TWO HANDED PROCESS CHART:
The two handed process chart is process chart in which the activities of a workers hand (or limbs) are recorded in their relationship to one another. Its is specialized form of process chart because it show the two hands (and some time the feet) of the operators moving or static in relation to one another, usually relation to a time scale. One advantage of a time scale on the chart form is that it brings the symbols for what the two hands are doing at any given moments opposite to one another. The two handed process chart is generally used for repetitive operations, When one complete cycle of the work will be recorded. Recording is carried out in more detail than in normally used on follow process charts. The two-handed process charts generally employs the same symbols as the other process chart, but because of the greater detailed covered. The symbols are accorded slightly different meanings.

ORIGINAL METHOD:
In the original method the tube was pressed to the stop at the end of the jig, marked with the file and then ceased back for nothing. It was then taken out of the jig for breaking.

EXAMINE CRITICALLY:
An examination of the detail of the original method using the questioning technique at once raises certain points. 1. why it is necessary to hold the tube in jig? 2. why can not the tube be method while it is being related instead of the right hand having to wait? 3. why does the tube have to be taken out of the jig to break it? 4. why pick up and put down the file at the end of each cycle? Can it not be held?

A study of the sketch will make the answers to the first three questions plan. 1. The tube will always have to be held because the length supported by the jig is short compared with the total length of the tube. 2. There Is no reason why the tube can not be rotated notched at the same time. 3. the tube has to be taken out of the jig to be broken because if the tubes were broken by bending against he face of the jig. The shortened would then have to be picked out an out ware operation if very little were sticking out. If a jig were so designed that the shortened would fall out when broken it would not then be necessary to withdraw the tube. 4. both hand are necessary to break the tube using the old method, this might be necessary if a new jig could be devised.

IMPROVE METHOD:
The solution found by the trainee is to be seen in figure; it will be seen that in redesigning the jig, has been arranged it in such away that the notch is out on the right hand side of the supporting pieces, so that the short end will break away when given a sharp tap, and it will no longer be necessary to withdraw the tube and use both hands to break off the end. The new method is described in the process chart in figure. The number of operation and movement has been reduced from 28 to 6.

PRACTICAL NO 6
STUDY OF VARIOUS RATES OF WORKING ON THE PRINCIPLE RATING SCALES
RATING:
it is assessment of the works rate of working relative to the observers concept of the rate corresponding to standard pace. According to definition, rating is a comparison of the rate of working observed the work study man with a picture of some standard level which he is holding in his mind. This standard level is the average rate at which qualified workers will naturally work at a job. This rate of working corresponds to what is termed the standard rating. If the standard pace is maintained and appropriate relaxation is taken, a worker will achieve standard performance over the working day or shift.

STANDARD PERFORMANCE:
Standard performance is the rate of output which qualified workers will naturally achieve without over exertion as an average over the working day or shift provided they know and achieve to the specified method and provided they are motivated to apply themselves to their work. The rate of working most generally accepted in the United States and Britain as corresponding to the standard rating is equivalent to the speed of motion of the limbs of a man of average physique walking without a load in a straight line on level ground at a speed of 4 miles cm hours (6.4 kilometers per hours). However, the standard pace applied to Europeans and north American working in temperate conditions. It may not be proper pace to consider standard in other parts of the world. In general however given workers of proper physique, adequately nourished, fully trained and suitable activated, there seems little evidence to suggest that different standards for rates of working are needed in different localities, through the periods of time over which workers may be expected to average the standard pace will very widely with the environmental conditions. Anothers accepted example of working at the standard rate is dealing a back of 52 playing cards in 0.375 minutes. Anyone doing manual work will generally carry out the motions directly concerned with his work at risk own natural working rate, which may not be exactly the standard rate, since some men work faster than others. There will of course be different standard pace for different activities, according to the complexity of the element making up the activity, so that the working at the standard rate will not always mean moving the hands or limbs with the same speed. It is not uncommon for workers to work faster at some periods of the day than they do during others, so that the standard performance is rarely achieved as the result of working without any deviation at the standard rate throughout the working periods of the shift, but rather as the cumulative out come of periods of work at varying pace.

COMPARING THE OBSERVED RATE OF WORKING WITH STANDARD:

How is it possible accurately to compare the observed rate of working with the theoretical standard by long practice. The accuracy of one is rating can only be acquired through long experience and practice on may types of operation and confidence is essential to work study man. It may be necessary for him to back his judgment in arguments with management, foremen or workers representatives, unless he can do so with assurance the confidence of all parties in his ability will quickly disappear and he might as well give up practicing time study. This is one of the reasons why trainee may attempt method. Study after a comparatively short training but should on no account try to set time standard, except under expert guidance without long practice, especially if the standards are to be used for incentive payments.

SCALE OF RATING:
In order that a comparison between the observed rate of working and the standard rate may be made effectively, it is necessary to have a numerical scale against which to make the assessment. Examples of various rates of working on the principle rating scale SCALE
60-80 75-100 100-133 0-100 Standard

Description
No Activity. Very slow, clumsy, fumbling movement operator appears half a asleep, with no interest in the job. Steady, deliberate, unhurried performance, as of a worker not on piece work but under proper supervision. Looks slow, but time is not being intentionally wasted while accuracy achieved with confidence. Brisk, business like performance as of an Average qualified worker on piece work; Necessary standard of quality and accuracy achieved with confidence. Very fast: operate operator exhibits a high degree of assurance, dexterity and co-ordination of movement, well above that of an average trained worker. Exceptionally fast; requires intense effort and concentration and is unlikely to be kept up for long periods a virtuoso performance only achieved by a few outstanding workers.

Comparable Working speed (mi/h) (km/h) 2 3 3.2 4.8

0 40 60

0 50 75

0 67 100

0 50 75

80

100

133

100 (standard rating) 125

6.4

100

125

167

8.0

120

150

200

150

9.6

There are several scales of rating in use, the most common of which are those designated the (100-133) scale the (60-80), the (75-100), and the British standard scale [essentially a restatement of the (75-100) ] which is (0-100) scale.

PRACTICAL NO 7
STUDY OF SYSTEM OF REST ALLOWANCES GIVEN AS PERCENTAGE OF BASIC TIME
ALLOWANCE:
Any worker will not able work through the day without any interception the worker requires some time for his personal needs, rest and other seasons the detail for these allowance is given below.

CONTINGENCY ALLOWANCES:
A contingency allowance is a small allowance of time which may be included in a standard time to meet legitimate and expected items of work or delay the precise measurement of which is uneconomical because of their in frequent irregular occurrence provides for small unavoidable delays as well as for accessional and miner extra work. It should be greater then 5 present. The duties for which the contingency allowance is given should be specified. It may however, in fairness, be necessary to give contingency allowances in enterprises where the shop work in not organized.

RELAXING ALLOWANCE:
It is own addition to the basic time untended to provide the worker with the opportunity to recover form the physic logical and physiological effects of carrying out. Specified work under specified condition. The relaxation allowance has two occupants 1. personal need allowance. 2. Fatigue allowance.

PERSONAL NEED ALLOWANCE:

The personal needs allowance provides for the necessity to give away form the work place to attend the personal meats such as washing going longer personal need allowance them man the allowance is made as a constant percentage. Common figures being 5 percent men and 7 percent for would.

FATIGUE ALLOWANCE:
Fatigue may be defined as a physical and or mental weariness exiting in a person and adversely affecting his ability to perform work the effect of figure can be lessened by rest because during which the body recover exertion on by slowing the down the rate of working and thus reducing the consumption of energy. The figure allowance always contain a constant basic allowance and may be in addition a variable component of a size depending on how fatiguing the element are assessed to be the constant pertain of the fatigue allowance is that considered to be educated for a worker. A common figure is 4 percent for both men and woman for purpose of calculation the relax eating allowance many be seem be made up of a constant allowance, always given as a basic min.

A variable addition, sometime depending on the circumstance of the job In 100-133, 60-80 and 75-100 scales, the lower figure in each instance was defined as the rate of working of an operative on time rates of pay, and higher, in each case one-third higher, corresponded to the rate of working called the standard rate, that of a qualified worker who is suitable motivated to apply himself to his work, as for instance by an incentive scheme. The underlying assumption was that workers on incentive perform, on average, about one-third more effectively than those who are not. In the (0-100) scale, 0 represents zero activity and 100 the normal rate of working of the motivated qualified workers, that is the standard rate. How the rating factor is use. The figure 100 represents standard performance. If the study man decides that the operation is being performed with less effective speed than his concept of standard he will use a factor of less than 100, say 90 or 75 or whatever he considered represents a proper assessment. If on the other hand, he decides that the effective rate of working is above standard, he gives it a factor greater than 100, say 110, 115 or 120. It is usual practice to round off rating to the nearest multiple of five on the scale that is to say. If the rate is judged to be 13 percent above standard it would be put down at 115.

VARIABLE ADDITIONS TO THE MINIMUM FATIGUE ALLOWANCE:

1. 2. 3. 4. 5. Standing Abnormal position Weight lifting or use of force Light conditions Air conditions 6. Visual 7. Aural strain 8. Mental strain 9. Monotony 10. Monotony physical

1. STANDING:
An additional allowance is given when an operative has to perform a job standing extra effort is involved when a job is perform standing a provides for seats to be made available for relaxation provides for reacts to be made available for relaxation periods at or means the work place the suggested allowance is 2 percent for men and 4 percent for woman.

2. ABNORMAL POSTION:
Body Weight not evening disrobed on both feet 2% max Body held inclined away form the vertical 5% max Arms geld above chest (every timing) 10% max Body band stooping or lying 5% max Confirmed position (mince at cool seam) 6-8% max The natural position is standing or sitting with the work approx waist high other position may be considered abnormal.

3. WEIGHT LIFTING OR USE OF FORCE:

The allowance in table are for lifting or classifying weight in the most confer able meaner the figure 1 table show that for weight above 30 kg the additional figure allowance increase rapidly reacting about 58 % at t of 50 kg

4. LIGHT CONDITION:
It the light provided in below and it is impossible to improve it an allowance should be given adding to amount of strain imposed body tight condition may be due to glare oar great a constant between the background and the working plane as well as to lack of light.

5. AIR CONDITIONS:
The allowance in table is to take account of endorsable are condition with in the workshop which are die to features of the working process and which can not be wholly eleven lineated when an operative has to work in close proximity to can planet fame an alliance of us to 15 percent may be called for according to the revert of the condition of maxis fore are percent so that a resistor 10 per sent often given.

6. VISUAL STRAIN:
Eye strain may be caused by having to give very close attention to the work pike or kinsmen begin used as in watch making or in watching a satiny frame for yarn break.

7. AURAL STRAIN:
Perceptible strain occurs when a load noise in made at irregular interval as riveting or when operatives are required to listen for change in pitch toner level as in testing certain type. EXAMPLE: Normal testing of automobile engines 9 percent Over speed testing of automobile cycle 4 percent Press Shop or plate assembly shoe noise 2.3 percent Pneumatic hammer, 5 second on, 5 off 4 percent

8. MENTAL STRAIN:
It may be caused by prolonged concentration or instance trying to remember along and complicated process sequence. It may also be caused by the having to attend to a number of machines simultaneously in which case it appears to be the result of anxiety.

9. MENTAL MONOTONY:
Generally the result of the repeated use mental faculties as in mental arithmetic. It is more likely to occur in routine office activities than in the work shop.

10. PHYSICAL MONOTONY:

The strain caused by the repeated use of certain member of the body such as fingers, hands, arm and legs method study tends to make work more tedious for skilled operatives but often enables the simplified work to be done by Len skilled workers tenderness may be alleviated by placing workers in position where they can talk to their neighbors while working. EXAMPLE: Very short cycle work cycle time about 5 second 3.5 percent Short cycle work, cycle of 5-10 sec 1-2 percent The relaxation allowance givens as percentage of basic time will normally be added element by element to each element of work.