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Work Data Management II

Process and Time Types

Module REFA Basic Training

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 REFA Standard:
Process Types related to Work System Tasks

Main Execution SH

Task Execution SD Ancillary Execution SN

Additional Execution SZ
In Task
SI
fulfillment
Process Related
Interruption
SA
Work System S

Interruption of Failure related

Not in Task SK Interruption
SS
SL Task Execution
fulfillment

Personal related
Interruption
SP

Out of operation SR
Recovery related
Interruption
SE

Unidentifiable SX

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 REFA Standard:
Process Types for Work System use

System
SI
In use

System System
SIR SIA
Setup Execution

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 REFA Standard:
Process Types „Execution“ – operator related

Main activity MH

Actvity MT Ancillary activity MN

Additional activity MZ

On duty MI
Process related activity
Interruption MA
Man M

Activity Failure related activity

Off duty ML MK Interruption MS
Interruption

Personally activity
interruption MP

Out of
MR
operation
Recovery time
ME
Activity Inetrruption

Unidentifiable MX

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 Main and Ancillary Activity - Example

Main Activity Ancillary Activity

Process workpiece Collect workpieces according to plan,

Feed workpieces in magazine

Paint facade Mix color

Write text using a PC Put new sheet in printer

Assemble part Count workpieces previously collected

Read word instructions

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 REFA Standard:
Process Types „Setup“ – Operator related

Main Activity - Setup MHR

Ancillary Activity –
Setup Activity MTR MNR
Setup

Additional Activity –
Setup MZR

On duty MI
Process related
MAR
Interruption
Man M

Setup Activity Failure related

Off duty ML MKR MSR
Interruption Interruption

Personal related
MPR
Interruption
Out of
MR
operation
Recovery related
Interruption MER

Unidentifiable MX

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 Influencable and Non-Influencable Process Types (MI)

On duty

Influenceable B Non-Influenceable U

Fully Conditionally
Influenceable Influenceable

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 Example for Influencable and Non-Influencable
Processes (MI)

Fully voll
Influenceable
beeinflussbar Conditionaly Influenceable Non-Influenceable

Assemble
Zusammenbauen, Löten,
Solder, Schweißen,
Welding selbstä
Monitor independently
Change
Rad wechseln,
wheel Turning with manual feet Prozess
running ü
process
Read
Zeichnungen
drawingslesen, an Fließ
Inspection of gas bottles Automatic feed
Write
Textedata
schreiben, kontrollieren,
on assembly line
Clamp
Werkstücke
and de-clamp
ein-und DriveAutofahren
a car
workpieces
spannen

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 Process Types from the Perspective of
Ergonomics (MT)

Mainly
Energetic Perform MV

Activity
Monitor
Observe MU
Control
Mainly
Informative
Intelectual activity
in a strict sense MG

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 REFA Standard:
Equipment related Process Types

Main utilization BH

Utilization BT Ancillary utilization BN

Additional utilization BZ

On duty BI

Process related
BA
Interruption
Equipment B

Failure related
Off duty BL BS
Interruption
Interruption of
BK
utilization
Personal related
BP
Interruption
Out of
BR
operation
Recovery related
BE
Interruption

Unidentifiable BX

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 Examples and Causes for „Out of Utilization“ –
Equipment related

Examples for Causes

„Off duty‘‘
Lack of orders Equipment planned as a reserve, market-induced
shortage of orders, production order not released

Planning error Shortage in work force, material, tools, lack of energy

and missing information

Operator absent, not scheduled Medical condition, non-observence of work hours

Equipment stopped Maintenance, Repair, Reconfiguration, Power shortage

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 REFA Standard:
Process Structure „Setup“ – Equipment related

Main Utilization
BHR
– Setup

Ancillary Utilization
Utilization - Setup BTR BNR
– Setup

Additional Utilization
BZR
– Setup
On duty BI
Process related
BAR
Interruption
Equipment B

Failure related
Off duty BL BSR
Interruption
Interruption of
BKR
Utilization – Setup
Personal related
BPR
Interruption
Out of
BR
operation
Recovery related
BER
Interruption

Unidentifiable BX

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 Methodical Approach to the Determination of
Operator related Process Types

Available for Direct

Task tasks
M task MI MT Scheduled? MH
y execution? y y fulfillment? y
execution?

n n n n
MN

Not available
MZ
for an
extended ML
period of
y
Process
time? MK Scheduled? MA
y related? y
n
n n
ME

Interruption Failure
MS
due to plant MR related? y
shut down? y

n n MP

MX

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 Methodical Approach to the Determination of
Equipment related Process Types

Available Direct
Equipment tasks
B for task BI BT Scheduled? BH
y utilized? y y fulfillment? y
execution?

n n n n
BN

Not
BZ
available for
an extended BL
period of y
Process
time? BK Scheduled? BA
y related? y
n
n n
BE

Interruption Failure
BS
due to plant BR related? y
shut down? y
n
n BP

BX

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 REFA Standard: Work Object related Process
Structure (Process Type Analysis)

Change Form AVEF

Processing AVE
Change Properties AVEZ

Change AV
Change Place
AVFT
(transport)
Transfer AVF
Change Position
AVFH
(manipulate)

Additional Change AVZ

Check AP
Work Object A

Process related lie ARA

Lie AR

Additional lie ARZ

Store AL

Unidentifiable AX

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 Change of Form and Properties

Change of Form AVEF

Processing AVE
Change of
AVEZ
Properties

Example:

Change of Form Change of Properties

Cutting, Pressing, Heating or cooling during hot forging

Skinning, Spinning,
Shreding of files Curing after gluing
Apply glue for bonding coat

Recycling

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 Structuring of Process Type „support“

Change location
Transport AVFT Between work systems

Transfer AVF

Change position
Manipulation AVFH Within work system

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 Example for Manipulation and Transport

Manipulation
Handhaben Transport

position pallets to work area within transport of work objects between

work station, manually load and storage areas with crane, truck,
unload transport cart, pick up work forklift, transport on conveyor belt
objects and place in device

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 Example: Process related and Additional Queuing

Process related lie ARA Additional lie ARZ

 Stockpiling of work objects in work  Queuing of work objects due to failure

station (known as Buffer) of the work system/equipment
 Provision of work objects between  Organizational failure
work systems or after processing  Wrong material
 Buffering due to equipment setup  Personal related activity interruption
 Queuing due to recovery related  Current status of order processing
activity interruption of operator unknown
 Insufficiently balanced capacities
other than process and failure relate
interruptions

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 REFA Standard:
Process Structuring of Information

Processing IVV

Transfer and Collection

Change IV IVÜ
of Data

Additional Change IVZ

Testing IP

Information I
Process related Backup ISA

Backup IS

Additional Backup ISS

Long-term Storage / Archiving IL

Unidentifiable IX

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 Example of a process structured for M, B and A
(see 4.1, Praxis Application) - Abstract

Aufgabe:
Task : Assembly
MontageofAuf-
components,
und Anbauten,
Mini Truck
Mini-LKW Process
Ablaufarten
Types

Nr.
No Process
Ablaufabschnitte
Steps Operator
Monteur
(M)
(M) M B A
1 Manually place(4-Loch)
Lochplatten perforated plate (4-bore)
hochkant vorn upright at front of2 von
an Baugruppe
component 2, hold
Hand anlegen, halten
2 Manually
Lochplatteplace perforated
(3-Loch) querplate
an (3-bore) across
Lochplatte perforated
(4-Loch) vonplate
Hand
(4-bore), hold
ansetzen, halten
3 Manually
Schrauben place
(6 bolt
mm)(6von
mm)hinten
from rear through
durch bracket
Winkel undund
perforated
Lochplatteplate
von Hand einsetzen
4 Manually placeHand
Muttern von and run-down nut andrehen
aufsetzen,
5 Operator
Austretenabsent due to personal matters
(Toilette)

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 Relationship between Process and Time Types

Main Activity MH ∑t
MH

Ancillary Activity MN ∑t
MN

Additional Activity MZ ∑t
MZ

Process related
MA ∑t
Interruption MA

Failure related MS ∑t
Interruption MS

Recovery related ME ∑t
Interruption ME

Personal related MP ∑t
Interruption MP

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 Process Time Structure

Prozess Time TP

Process Process Time

Lead Time TDP Requirement TDP

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 Process Lead Time TDP and
Process Time Requirement TAP

Work System
Connecting line without time aspect
Process Lead Time TDP

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 REFA Standard:
Structuring of the Work System Lead Time TD

Process
Structuring of Time Types
Types

Main Main Execution

tSH thS
Execution time

Execution time tdS

Ancillary Ancillary
tSN tnS
Execution Execution time

Work System
TDS
Process related Lead time
Interruption of tSA Interruption time tuS
Execution

Failure related
Interruption of tSS
Execution

Additional
tSZ Additional time tzuS
Execution

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 Standard Time for Operator and Equipment

Standard Time

Reference quantity: operator equipment

Order quantity m Order time T Occupancy Time TbB

Unit quantity 1 Time per Unit te1 Equipment Time teB1

100 te100 per Unit teB100
1.000 te1000 teB1000

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 REFA Standard:
Order Time Structure

Order Time

Setup Time Processing Time

Time per Unit

Setup Setup
Setup Recovery Allowance Basic Recovery Allowance
Basic Time Time Time Time Time Time

further structuring possible

Functional Personal
Activity Wait
Allowance Allowance
Time Time Time Time

Non-
Influenceable Influenceable
Activity Time Activity Time

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 REFA Standard:
Occupancy Time Structure
Occupancy
Time

Equipment Equipment
Setup Time Processing Time

Equipment
Time per Unit

Equipment Equipment Equipment Equipment

Setup Basic Setup Basic Time Allowance Time
Time Allowance Time

further structuring possible

Main Utilization Ancillary Utilization Interruption

Time time time

Influenceable Main Non-Influence- Influenceable Non-Influence-

Utilization able Main Ancillary able Ancillary
Time Utilization Time Utilization Time Utilization Time

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 REFA Standard:
Structuring of the Time per Unit Te

Process Types Structuring of Time Types

Main Activity ∑tMH

Activity time tt

Ancillary Activity ∑tMN

Basic time tg

Additional Activity ∑tMZ Wait time tw

Process related
∑tMA
Interruption
Functional
ts
Allowance time
Failure related
∑tMS
Interruption te
Allowance time tv Time per Unit

Personal related Personal

∑tMP tp
Interruption Allowance time

Recovery related Recovery time ter

∑tME
Interruption

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 REFA Standard: Setup Time Structure Tr

Process Types Structuring of Time Types

Main Activity Setup ∑tMHR

Setup Activity
trt
time

Ancillary Activity Setup ∑tMNR

Setup Basic time trg

Additional Activity Setup ∑tMZR Setup Wait time trw

Process related
∑tMAR
Interruption of Setup
Functional Setup
trs
Allowance time
Failure related
∑tMSR
Interruption of Setup Setup Allowance
trv Setup time tr
time

Personal related Personal Setup

∑tMPR trp
Interruption of Setup Allowance time

Recovery related Setup Recovery

∑tMER trer
Interruption of Setup time

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 REFA Standard:
Structuring of the Time per Unit – Equipment TeB

Process Types Structuring of Time Types

∑tB Main Utilization

Main Utilization th
H time

∑tB Ancillary Utilization

Ancillary Utilization tn
N time
Equipment
tgB
Basic time

Additional Utilization ∑tBZ

Equipment Time
teB
Per Unit
Process related
∑tBA
Interruption of Utilization

Failure related Equipment

∑tBS tvB
Interruption of Utilization Allowance time

Personal related
∑tBP
Interruption of Utilization

Recovery related
∑tBE Interruption time tb
Interruption of Utilization

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 REFA Standard: Structuring of the Time per Unit –
Equipment Setup TrB
Process Types Structuring Time Types

Main Utilization
Main Utilization Setup ∑tBHR trh
Setup time

Anciliary Utilization
Anciliary Utilization Setup ∑tBNR trn
Setup time
Equipment
trgB
Setup Basic time

Additional Utilization Setup ∑tBZR

Equipment
trB
Setup Time
Process related Interrup-
∑tBAR
tion of Utilization - Setup

Failure related Interrup- Equipment Setup

∑tBSR trvB
tion of Utilization - Setup Allowance time

Personal related Interrup-

∑tBPR
tion of Utilization - Setup

Recovery related Interrup- Interruption

∑tBER trb
tion of Utilization - Setup Setup time

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 REFA Standard:
Methods for Determination of Time

TIME DETERMINATION

Collect Time Define Time

Collect time by Collect time by Define time by Define time Define time
interview measurement comparing by calculating by
and compilation
estimating

 BDE (Production Data  Standard Data

Collection)  REFA
 Time Study Standard Data
Elements
 Self-recording
 Predetermined
 Agreement Time Systems

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 Systematics of Time Data Determination

TIME DETERMINATION

Collect Actual-Times Define Target-Times

External-recording Self- Standard Time calulate

recording

Measure Interview Standard Time estimate

Register formulas

 Continual  Sample  Continual *

 Sample  Sample
Predetermined Time agree
 Activity Sampling  Activity Sampling Systems (SvZ)

*(BDE)

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 Option for Influencing Time Consumption

Process Time
Durchlaufzeit

Execution Time Additional

ZusatzzeitTime Transport Time
Transportzeit Queue Time
Liegezeit Buffer Time

technical- improve improve or inform or

technological work and re-design qualify
improvements information flow work situation employees

reduce failure balance

rate capacities

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 Observed work process for praxis example
„Assembly of Components“

Task: Assembly of Components, Mini Truck Process Types

No. Process Steps Operator (M) M B A
1 Manually place perforated plate (4-bore) upright at front of component 2, hold
2 Manually place perforated plate (3-bore) across perforated plate (4-bore), hold
3 Manually place bolt (6 mm) from rear through bracket und perforated plate
4 Manually place and run-down nut
5 Operator absent due to personal reason
6 Tighten nut with Phillips screw driver and open-end
7 Private conversation with colleague
8 Manually place bracket (2-bore) at end of angled plate, hold
9 Manually place bolt (6 mm) from the outside
10 Part slipped from hand
11 Manually place and run-down nut
12 Tighten nut with Phillips screw driver and open-end
13 Work related conversation
14 Get refreshment from vending machine
15 Power shortage (30 min)
16 Wait for material (5 min)

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 Observed work process for praxis example
“Drilling of Frames”

Task: Drilling of Frames Process Types

No Process Steps Process Steps M1 M2 B A

Machine operator (M1) Assistant (M2)
1 Receive and read order/drawings Collect tools from tool store
2 Clamp drill and adjust drilling Provide empty cart
machine
3 Wait Get cart with unfinished frames
4 Pick 1st frame from cart and place on Pick 1st frame from cart and place on
drill ing table drilling table
5 Align 1st frame (1st bore) Align 1st frame
6 Drill 1st bore, manual feed Wait
7 Align 1st frame (2nd bore) Align 1st frame
8 Drill 2nd bore, manual feed Wait
9 Pick 1st frame from drilling table and Pick 1st frame from drilling table and place
place in cart in cart

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 Observed work process for praxis example
“Drilling of Frames” (cont.)

Task: Drilling of Frames Process Types

No Process Steps Process Steps M1 M2 B A

Machine operator (M1) Assistant (M2)
10 Pick 2nd frame from cart and place Pick 2nd frame from cart and place on
on drilling table drilling table
(process corresponding to 1st frame) (Process corresponding to 1st frame)
11 change brocken drill Wait
12 Pick 8th frame from cart and place on Pick 8th frame from cart and place on
drilling table drilling table
(Process corresponding to 1st frame) (Process corresponding to 1st frame)
13 Pick 10th frame from cart and place Pick 10th frame from cart and place on
on drilling table drilling table
14 Clean drilling machine, check drill Transfer cart with finished frames

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 Observed work process for praxis example
“Drilling of Frames” (cont.)

Task: Drilling of Frames Process Types

No Process Steps Process Steps M1 M2 B A

Machine operator (M1) Assistant (M2)
15 Reposition empty cart Get cart with unfinished frames
16 Pick 11th frame from cart and place Pick 11th frame from cart and place on
on drilling table drilling table
(Process corresponding to 1st frame) (Process corresponding to 1st frame)
17 Work related conversation with Wait
superior
18 Wait Operator absent due to personal reason
19 Pick 18th frame from cart and place Pick 18th frame from cart and place on
on drilling table drilling table
(process corresponding to 1st frame) (process corresponding to 1st frame)
20 Recovery break Recovery break
21 Pick 32nd frame from cart and place Pick 32nd frame from cart and place on
on drilling table drilling table
(Process corresponding to 1st frame) (Process corresponding to 1st frame)

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 Observed work process for praxis example
“Drilling of Frames” (cont.)

Task: Drilling of Frames Process Types

No Process Steps Process Steps M1 M2 B A

Machine operator (M1) Assistant (M2)
22 Power shortage (37 min) Power shortage (37 min)
23 Pick 50th frame from drilling table and Pick 50th frame from drilling table and
place in cart place in cart
24 Clean drilling machine, check drill Transfer cart with finished frames
25 Remove drill Return empty cart
26 Logout order Return tools to tool store

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 Observed work process for praxis example
“Roof Assembly, Mini Truck”

Task: Roof Assembly, Mini Truck Time Types

No Process Steps Target M B
time
in min
1 Manually install angled plate (1114) at front of component 4, hold 0,5

2 Manually install component 5 at angled plate (1114), hold 0,5

3 Position 1st bolt (6 mm) from back through angled plate and component 5 and 0,2
position nut, run down
4 Position 2nd bolt (6 mm) from back through angled plate and component 5 and 0,2
position nut, run down
5 Tighten nut 1 and 2 with Phillips screw driver and open end wrench 1,0

6 Manually install 1st bracket (2-bore) from down side at angled plate, hold 0,5

7 Manually install 3rd bolt (6 mm) from side and position nut, run down 0,2

8 Manually install 2nd bracket (2-bore) ) from down side at angled plate, hold 0,5

9 Manually install 4th bolt (6 mm) from side and position nut, run down 0,2

10 Tighten nut 3 and 4 with Phillips screw driver and open end wrench 1,0

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 Observed work process for praxis example
“Drilling of Flanges”

Task: Drilling of Flanges Time Types

No Process Steps Target Time M B A

in min.

1 Receive and read order 2,0

2 Read drawings and determine tools 2,5
3 Collect and prepare tools 3,8
4 Prepare drilling machine for drilling 1,2
5 Pick up, clamp and align workpiece, switch on drilling machine 1,7
6 Drill 1st bore (automated feed) 0,5
7 Align workpiece for 2nd bore 0,4
8 Drill 2nd bore (automated feed) 0,5
9 Turn off drilling machine 0,1
10 De-clamp workpiece and put aside 0,3

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 Observed work process for praxis example
“Drilling of Flanges” (cont.)

Task: Drilling of Flanges Time Types

No Process Steps Target Time M B A

in min

11 Change tool for deburing (countersink), once per order 1,6

12 Pick up workpiece, align and clamp, switch on drilling machine 1,7

13 Countersink 1st bore, manual feed 0,1

14 Align workpiece for 2nd bore 0,4

15 Countersink 2nd bore, manual feed 0,1
16 Turn off drilling machine 0,1
17 De-clamp workpiece and put in bin 0,3
18 Clean work station and drilling 4,1
19 Return tools 3,8
20 Fill in and sign work 4,9

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 Work Process “Draw Press“

No Process steps Target Time Time Types

in min. M B

1 Install draw die in press 8,00

2 Test cycle and inspection 1,30

3 Pick up board and transport to press 0,10

4 Place board in draw die 0,05

5 Activate press with both hands, press cycle 0,15

6 Remove protection cup from draw die 0,08

7 Put aside protection cup 0,06

8 Walk from transport box to palette 0,06

9 Remove draw die 5,00

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 Work Process “Milling Station“

Nr. Process step Target Time types

time
in min. M B
1 Read order and drawings 0,8
2 Provide milling cutter and clamping tool 0,9
3 Clamp milling cutter 2,0
4 Adjust machine 1,5
5 Pick up workpiece and place on milling table 0,8
6 Clamp workpiece 1,2
7 Adjust milling cutter and switch on machine 0,4
8 Monitor milling and first cut 1,0
9 Milling (without monitoring) 3,5
10 De-clamp workpiece 0,8
11 Put aside workpiece 0,3
12 Return milling table (No 5-12 is repeated 49 times) 0,4
13 De-clamp milling cutter 1,8
14 Put aside milling cutter and clamping tool 0,7

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 Work Process “Stamping Press“

Work task: Stamp Steel Washers

Work object: Input: steel band Output: washers  15 mm
Equipment: 80-t-Press, 10-fold stamp die
Order quantity m: 20 000 zv = 10 % zer see data sheet
No Process Steps Target Process step
time
in min. M B
1 Insert steel band in tool 0,4
2 Stamp 10 washers (ejected into transport box) 0,3
3 Feed steel band 0,1
4 Change transport box 0,8
5 Bring transport box to pick-up point 2,5
6 Change steel band roll 2,0
7 Bring stamping waste(offcuts) to pick-up point 1,8

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 Work Process “Stamping Press“ (cont.)

Additional tasks:
Process steps 2 and 3: ea. 10 washers z er = 1 %
* Process steps 4 and 5: ea. 400 washers z er = 12 %
* Process steps 1, 6 and 7: ea. 2.000 washers z er = 14 %

* Since these two groups of process steps can be executed by other operators than
the ones currently operating the press seperate standard times are necessary.

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