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Assignment 1solution - Work Analysis and Design

The document outlines an assignment focused on the analysis and design of a production process in a factory that manufactures machined components. It includes the development of a flow process chart, recommendations for process improvements, and an evaluation of two workstations using Therbligs and Motion Economy Principles. Additionally, it provides feedback on effective and ineffective motions, as well as recommendations for ergonomic improvements in the workstations.

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12 views6 pages

Assignment 1solution - Work Analysis and Design

The document outlines an assignment focused on the analysis and design of a production process in a factory that manufactures machined components. It includes the development of a flow process chart, recommendations for process improvements, and an evaluation of two workstations using Therbligs and Motion Economy Principles. Additionally, it provides feedback on effective and ineffective motions, as well as recommendations for ergonomic improvements in the workstations.

Uploaded by

khloud.egemy
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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MENG 4444: Work Analysis and Design

ASSIGNMENT # 4 Solution

Fall 2024
Question 1

A supplier of machined components for industrial machinery (e.g., power tools, pumps, motors,
compressors) operates a factory that includes a forge shop, machine shop, and finishing department.
Many of the parts produced by the company are fabricated through these three departments. Because
of this, the factory is laid out as three large square rooms, arranged in-line to form a rectangle with an
aspect ratio of three-to-one. Each room is 200 ft by 200 ft. The rectangle runs from north to south,
with the forge shop on the south end and the finishing department on the north end. Large doors are
located on the south wall for work entering the factory and on the north wall for finished products
exiting the factory. For one part of particular interest here, the raw material is a steel billet that is
purchased from a steel wholesale supplier. The billets arrive in pallet loads of 100 billets at the
shipping and receiving department, which is a building that is 35 ft by 50 ft located 25 ft from the
south wall door of the factory. The shipping/receiving department inspects the parts and sends them
by forklift truck to be stored in the company’s warehouse that is located in another building 500 ft
away from the factory in a southerly direction. The warehouse is 200 ft by 200 ft with its entrance
door on the north wall. When a production order for the part is received, a factory forklift truck is
dispatched to the warehouse to retrieve the billets. The forklift truck must wait while the warehouse
crew locates the billets in storage, takes a pallet out of storage using the same type of forklift truck,
and delivers the pallet to the dock where it is transferred to the factory forklift. The pallet is then
brought back to the factory and delivered to the forge shop. The billets must wait their turn in the
production schedule before being pressed into the desired shape by one of the forge presses. From the
forge shop, the parts are moved to the machine shop where they are machined on two different
machine tools, a milling machine, and a drill press. From the machine shop, the parts travel to the
finishing department for painting and baking (to cure the paint). From the finishing department, the
parts are moved back to the machine shop, where additional milling is accomplished to provide two
machined metal surfaces that will mate with other components in the final product. The parts are then
moved to the shipping and receiving department for shipment to the customer.

(a) Develop the flow process chart


(b) Based on your flow process chart, what are some changes in the production process that you
would recommend?
(c) Develop a revised procedure for the production process, documenting your revision in the form of
a new flow process chart.

Excel Sheet
Question 2

The video in the link below includes two different stations with different tasks and workers. Evaluate
and analyze both stations using Therbligs and Motion Economy Principles.

Video Link: https://drive.google.com/file/d/10TNDAWmnUFamckeQcGeGXBAWSlAf2J4q/view?


usp=sharing

Therbligs Feedback
In this part, the motion in the video has been defined in terms of therbligs in order to evaluate the
effective vs. ineffective motion elements in order to be able to give a specific and clear
recommendations.

Effective Therbligs Ineffective Therbligs


Element Check Element Check
Transport Hold
Grasp Pre-Position
Transport loaded Position
Release load Search
Use Plan
Assemble Unavoidable Delay
Disassemble Avoidable delay
Inspect
Rest

The inefficient elements could be reduced or eliminated referring to the guidelines of how to
design the workstation. This can be used to eliminate the delays of the process, inefficient
bending and searching.
Principles of Motion Economy Feedback
Highlight in case that the item is applied for the man in Posture I
Highlight in case that the item is applied for the man in Posture II
Highlight in case that the item is applied for the man in both Postures
Lack point in both postures

Posture I: It is the man who is making the subassembly of the part being passed to the worker in
the other posture. He is using the tool called pop in the assembly process for this subassembly.

Posture II: The worker who is doing the assembly of the larger part using the other subassembly
came from station I.

Figure 1: Posture I Figure 2: Posture II

Use of Human Body Workplace Design of Tooling &


Arrangement Equipment
Item Item Item
Design work to fully utilize both hands Locate tools and Work-holding devices
materials in fixed should be designed for the
positions within the task
work area
The two hands should begin and end Locate tools and Hands should be relieved
their motions at the same time to materials close to where of work elements that can
distribute the work equally to hands they are used be performed by the feet
using foot pedals
Hand and arm motions should be Locate tools and Combine multiple
symmetrical and simultaneous to materials to be functions into one tool
minimize hand/arm-eye coordination consistent with sequence where possible
of work elements
Design work to favor preferred hand Use gravity feed bins to Perform multiple
deliver small parts and operations simultaneously
fasteners rather than sequentially
Worker’s two hands should not be idle at Use gravity drop chutes Where feasible, perform
the same time for completed work operation on multiple parts
units where appropriate simultaneously
Method should consist of smooth Provide adequate Design equipment controls
continuous curved motions rather than illumination for operator convenience
straight motions with abrupt changes in and error avoidance
direction
Use momentum (mass * velocity) to A proper chair should be Hand tools and portable
facilitate task provided for the worker power tools should be
–Adjustable to the size designed for operator
of the worker –Seat comfort and convenience
height and back
adjustments –Padded
seat and back

Take advantage of gravity – Don’t Mechanize or automate


oppose it manual operations if
economically and
technically feasible
Method should achieve a natural rhythm
of the motions involved
Finger
Finger and wrist
Finger, wrist, and forearm
Finger, wrist, forearm, and upper arm
Finger, wrist, forearm, upper arm, and
shoulder
Minimize eye focus and travel
Design method to utilize feet and legs
where appropriate

In Summary

Posture I Problems Posture II Problems


1- Long time standing 1- Un comfortable chain
2- Searching and positioning 2- Not smooth movements
3- Lack of safety tools to prevent pop 3- Positioning and searching
industries 4- Large reach for picking the
4- Back and neck MSDs subassembly
5- Un organized workstation
Posture I Recommendations Posture II Recommendations
1- Have a lower chair to resolve the fatigue 1- Lower the chair
issue of standing and unsuitable reach of 2- Reallocate the used tools to
parts used achieve smoother flow
2- Safety towards pop usage 3- I guess it would be totally
3- Having a fixed crate to hold the different if the worker does not
subassemblies finished know that there is someone
watching

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