PROCESS SEQUENCES includes the following CHARTS

Operation Process Chart Flow Process Chart Man , Material and Equipment Type

Two Handed Process Chart

Process Chart Symbols

Operation
Indicates the main steps in a process, method or procedure. Usually the part, material or product concerned is modified or changed during the operation.

Inspection
Indicates an inspection for quality and / or check for quantity

Transport
Indicates the movement of workers, materials or equipment from place to place

Process Chart Symbols

Temporary Storage or Delay

Indicates a delay in the sequence of events : for example, work waiting between consecutive operations, or any object laid aside temporarily without record until required.

Permanent Storage

Indicates a controlled storage in which material is received into or issued from a store under some form of authorization; or an item is retained for reference purposes.

The Outline Process Chart

An outline process chart is a process chart giving an overall picture by recording in sequence only the main operations and inspections

It does not portray the details delays , movements, and storage

It does not go into the details of the details of the place of activity, the person who performs it, or the physical means of achievement In making an outline process chart we start with a vertical line down the right hand side of the page to show the operations and inspections undergone.

The Outline Process Chart- Example

For the purpose of illustration , the case of the repair of a bicycle is taken.

In this example it is assumed that the bicycle had been involved in a minor accident and required restricted repairs to the front wheel, the left pedal and the steering handle.
The Outline Process Chart would be

OBSERVATIONS

After operation number 15, the next operation shown is number 23. Operations 16 to 22 are covered by the seven repetitions of operation 15. Similarly , the gap between Inspection number 3 and 11 is accounted for by the seven repetitions of inspection 3.

FLOW PROCESS CHART (FPC)

It is a process chart setting out the sequence of the flow of a product or procedure by recording all events under review using appropriate process chart symbols.

BENEFITS: In identifying ways of improving the process by eliminating unnecessary idle time, minimizing the distances things must be moved or rearranging tasks for greater efficiency

Three types of flow process charts

MAN TYPE:

Flow chart which shows the actions of a person

MATERIAL TYPE:

Flow chart which shows what happens to a product or item

EQUIPMENT TYPE:

Flow chart which shows how a tool or other piece of equipment is used

Flow Process Charts- Material Type

An FPC (Matrl) sets out the sequence of flow of a product or a document , recording all the events that affect the material or document being processed.

Illustration : The process of charging of batteries by Umesh Motors(P) Ltd. Is as follows. Customers deposit discharged automobile batteries at the Reception Bay of the workshop, and obtain a receipt. After three days, they collect their respective batteries from the Delivery Bay of the workshop, on presentation of the receipt and payment of service charges. The reception clerk marks each battery with a customer-identification number. He stacks the batteries on a steel shelf.

The chargeable batteries are collected twice a day from the Reception Bay by mazdoor Dharam. He transports the batteries on a stillage truck , and delivers them to the charging shop, which is 50 meters away from the Reception Bay. At the Charging Shop , the battery is tested, cell by cell , for voltage and specific gravity. The cells are topped up to the correct level. The battery is then moved to the charging bench, and placed on charge by connecting the terminals to the bus bars. While on charge , it is tested every four hours for specific gravity. On completion of charging, which is determined by the specific gravity of the electrolyte , the connections to the bus bars are removed. The battery is tested for voltage of each individual cell. It is then placed on a stillage(small wooden platform with low legs)

Mazdoor Dharam collects a stillage of charged batteries and transports them, by a stillage truck, to the delivery bay , which is 35 meters away from the charging shop . Here the Delivery Clerk takes over the batteries and places them on a steel rack.

Flow Process Charts- Man Type

An FPC(Man), sets out the sequence of activities of an individual performing a task under study . Only four symbols are employed- operation , inspection, delay, transport

TWO HANDED PROCESS CHARTS

Two handed process charts is a chart in which the activities of a workers hands individually(or limbs) are recorded in the relationship to one another

SYMBOLS AND THEIR DESCRIPTIONS FOR TWO HANDED CHARTS

Operation
Is used for activities for grasp, position, use, release etc. of a tool, component or material

Transport
To represent the movement of hand to or from the work, or a tool, or material

Temporary Storage or Delay

Denotes time during which the hand being charted is idle (although the others may be in use)

HOLD

In two handed process chart , hold is used to represent the activity of holding work , tool or material i.e when the hand being charted is holding something

MULTIPLE ACTIVITY CHART

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 interrelationship

Useful in organizing teams of operatives on mass production work and also on maintenance work when expensive plant cannot be allowed to remain idle longer

Time (Hours) 5

WORKER 1 Disassembly of lathe

WORKER 2 Disassemble lathe. Head stock, bed, fed and lead screws, carriage and tailstock

WORKER 3 Disassemble head stock, Remove main spindle, speed change mechanisms, and change gears. Wash with thinner to remover grease and clean parts Idle

WORKER 4

10 15

Inspection to determine fault

Repair carriage bed and lay out screw, nuts, etc.

Repair and assembly of feed gear box

20 25

Repair carriage bed, check and repair feed screw and apron of the carriage.
Fit saddle to bed

Repair and assemble feed gear box

Grind lathe beds

Assemble and mount bed and headstock on stand Assemble tailstock. Fit cross slide and top slide

Repair carriage way and lay out screw, nuts, etc.

30 Repair and assembly of apron 35 Installing feed gear box apron and feed red Running in and finishing Testing the lathe Run in and finish

Assemble cooling system

Install electric motor

Assemble tailstock

Install feed gear box, apron and feed rod Mount electric motors and fit reservoirs Run in and finish Test and calibrate assembly

Idle

MAN-MACHINE CHART
Variant of Multiple Activity Chart Present a picture of the operations performed simultaneously by a man and one or more machines Useful for 1. Better coordination between man and machine 2. Reduction / elimination of idle times of man and machine to improve the utilization 3. Exploration of alternative man-machine arrangements suitable to the plant conditions

TIME Min.
2 4 5 6 8 10 12 15

Man
Remove finished casting clean with compressed air Gauge depth on surface plate Break sharp edge and clean with compressed air

Machine

Idle Place in box obtain new casting Clean machine with compressed air Locate castig in fixture: start machine and automatic feed Idle Mill second face

20

EXAMPLE
Draw a man machine chart showing one man(the operator) operating two semi-automatic lathes. The cycle consists of load M/C , min., Machine part , 1 min (the machine stops automatically at the end of cut) and unload Machine, min. The two machines are alike and each completes the machining operation and stops automatically. The manmachine chart is to show the operator starting the machines in the morning with both machines empty and continues until each machine completes two cycles, i.e. it has machined two pieces. The man-machine chart should have one column for the man and a column each for machine 1 and machine 2.

CONTD..

DIAGRAMS INDICATING
MOVEMENTS
String

Diagram Travel Charts Flow Diagrams

STRING DIAGRAM

String diagram is a useful tool to record the distance traveled by a worker in the working area. The string diagram is a scale plan or model on which a thread is used to trace and measure the distance traversed which has to be minimum by WORKERS MATERIAL OR EQUIPMENT during a specified sequence of events

Observe the clusters of points, pins, turning points. Also observe the grid lines which represent a measure of the distance between the points. Red is the staring point and yellow is the ending point

CONSTRUCTION OF A STRING DIAGRAM

Step-1

Produce a scale map of the work area Identifying all machines, furniture and other equipments in the diagram that can be moved. These could be shaped as pieces of card that can be pinned to the work area map Identify the points in the process where actions take place and also identify the doorways, pillars etc that effect the path movements and mark the positions of these on the map with map pins and action symbols. Tie the end of a pieces of string to the pin where the process starts and then wrap it around each pin in turn, following the movement around the process

Step-2

Step-3

CONTINUE..

Step-4
Mark the string at the start and finish points, using a pen.

Step-5

Measuring between the pen marks, will give the total distance travelled during the process. Rearrange the movable items on the map, aiming to reduce the total distance

Step-6

Strategies for deciding layouts include:

Mobility:- Rearrange items and movements around fixed or immovable items such as heavy machines. Function:- Put machines or people together that perform the same function. This is useful when varying loads may be between machines. Product:- Put machines or people together that make the same product. This works well when each machine is used for only one product.

TRAVEL CHART

A travel chart is a tabular record for presenting quantitative data about the movements of workers, materials or equipment between any number of places over any given period of time.

The travel chart also identifies movement, when movements along complex paths are involved.

WHY TRAVEL CHART ?

Although the string diagram is a neat and effective way of record the movement of worker or material
o o

They take long time to construct ; Look increasingly like a complex maze with increasing complexity of movement paths.

When the movement patterns are complex, the travel chart is quicker and more manageable to record.

Count of occurrence Distance between places

FLOW DIAGRAM

While the flow process chart describes the flow of a product or process, it is generally supplemented with a flow diagram. While the flow process chart records travel distances and time taken for various operations, the flow diagram is a plan , drawn to scale of the work area, correctly indicating the position of machines and working positions. The example shown indicates the flow diagram of receiving, inspection, marking and storing materials.

IMPROVED FD OF INSPECTION AND MARKING

Suitability of different recording techniques:Types of Jobs Complete manufacture Sequence Examples Recording Technique of Manufacture of an electric motor from Outline process chart raw material to dispatch; Flow process chart Transformation of thread into cloth from Flow diagram preparation to inspection; Receipt, packing and dispatch of fruit

Factory layout : movement of Movements of a diesel engine cylinder materials head through all machining operations. Movements of grain between milling operations.

Outline process chart Flow process chart material type Flow diagram Travel chart

Continue..
Types of Jobs Factory layout : movement of workers Examples Recording Technique Laborers servicing spinning machine with bobbins Flow process chart-man type String diagram Cooks preparing meals in a restaurant kitchen

Handling of materials

Putting materials into and taking them out of stores Loading lorries with finished products.

Flow process chart material type Flow diagram String diagram

Workplace layout

Light assembly work on a bench Typesetting by hand

Flow process chart-man type. Two-handed process chart. Multiple activity chart.

Continue..
Types of Jobs Gang work or automatic machine operation Movements of operatives at work Examples Assembly line Operator looking after semi-automatic lathe Female operatives on short cycle repetition work Operations demanding great manual dexterity Recording Technique Multiple activity chart Flow process chart-equipment type Multiple activity chart Flow process chart equipment type