Workplace Organization

Dr. Hajime Yamashina

Professor Emeritus, Kyoto University
Fellow of RSA, U.K.
Member of Royal Swedish Academy
of Engineering Sciences, Sweden
1. Introduction
2. Material Handing
3. Layout
4. Visibility
5. Visual Management for Improving Productivity
6. Elimination of MURI, MURA, and MUDA by operational
improvement
7. Multi-Skilled Labor
8. Systematic Introduction of LCA
9. Controlling abnormal situations and achieving stable production
10. The principles of effective operation
11. Economic Measures
 1. Introduction
The basic concept of workplace organization is to improve productivity by
1) minimizing material handling
2) eliminating MURI (difficult and unnatural operation), MURA
(irregular operating) and MUDA (non-value added operation) by
operational improvement
3) creating multi-skilled labor
4) introducing LCA systematically
5) achieving stable production by minimizing disturbances caused
by various problems such as machine breakdowns
6) controlling abnormal situations by minimizing production of
defectives and minor stoppages
and
7) separating labor from equipment
 2. Material Handling

The most important point in mass production

is to minimize material handling.

What is the principle of material handling?

It is the minimal movement of material.

Throughout whole production activities. minimal material

handling is the basic production technique.
 Kind of waste

1. Waste of tentative placement

• Standardize operation in such a way as to make it easy to handle
things
2. Waste of being idle
• Because of the lack of material to process
• Because of being engaged in watching operation
• Abolish over-division of the job and train multi-purpose workers
3. Waste of movement
• From sitting to standing up
• Lay out necessary materials and parts properly
 Kind of waste -2

4. Waste of overproduction
• Determine the standard number of in-process inventory and
maintain it strictly
5. Waste of readjustments, defects and returned goods
• Introduce proper jigs and food proof devices
6. Waste of set-up
• Make a check list of set-up times and make improvements
7. Waste of transportation
• Introduce proper transportation vehicles
8. Waste of processing technique itself
• Employ a more suitable method by V.A.
 Increase of value added operation in molding

1. Casting of knuckle steering – before

Casting Finishing Painting

Painting
I Deburring I
Shot
Melting blasting

I I

The deburring operation is

indeed, no value added Inspection Deburring Inspection
operation

Check

Conveyance

Eliminate
 2. Casting of knuckle steering - after

Casting Finishing Painting

Melting Shot blasting Painting

I
 Kind of waste -3

9. Waste of material and sub-material

10. Waste of rewriting
11. Waste of improper order and arrangement
• Abolish unnecessary things
12. Waste of mis-communication
 Methods to reduce inventory

 To control over-production (kanbans, standardized number of

in-process inventory)
 To leave no space for storing over-produced items
 To control earlier production than scheduled (do not release
production schedule until necessary)
 To make it mechanically impossible to store in-process
inventory (full-work system)
 To prevent the production of unnecessary items because of the
change in plans, etc. (withdrawal from subsequent stages)
 Methods to reduce inventory -2

 To improve the constitution of the shop in such a way as not to

produce in a large lot
 To eliminate the supplementary inventory at the time of machine
breakdowns (TPM)
 To try not to produce unnecessary items (improvement of neck
machines, synchronization of the lines)
 Not to make any spot where items can stay (synchronization of
the lines)
 To receive and deliver items in a small lot
 Inventory is the worst waste

Before improvement After improvement

 Inventory is the worst waste
Learning effect
The local optimum is not the overall optimum

Net
operating
time

Loading Unloading

Efficiency of the machinery

Efficiency of the labor, the inventory and the machinery
Productio Piercing Facing Piercing U Forming Tapping Nut Points for improvement:
n quantity bending welding
per day 1.Abolition of in-process
1 2 3 4 5 inventory and
3,200 6 7
80t 60t 45t 75t 80t elimination of wasteful
Cycle movements of workers
time
2.Synchronization of the
7 sec. line and layout in order
Worker to cope with production
7 change
3.Reduction of lead time
p p in g ben U 4.Reduction of workers
a d in
r c in g T g F
Pie 4 or
Productio 5 mi
3 ng
n quantity 70t 6 Multi-purpose
Multi-purposeworker:
worker:
per day
Facing 4 5t 80 1.Workers
3,200 t 1.Workers
7→3
7→3
2
Cycle 2.In
2.Inprocess
processinventory
inventory
time 60t 1800→7
1800→7
4 sec. 7 Nut 3.Lead
3.Leadtime
time
Worker welding 211 minutes→03
211 minutes→03
3 1
Piercing 80t
 Before
Before After
After
Heat
1st turning 2nd turning Grinding treatment

Buffer Buffer Buffer

Gear cutting Rolling

Buffer
Buffer Buffer

U shape layout + one piece flow

Lot Lead Defective

WIP Workers
size time rate
10,000-
Before 600 10 8.2% 8
12,000
After 14 100 1 0.6% 2
Lot Increase of WIP
Lotproduction
production Long lead time
Latent waste is invisible

One
Onepiece
pieceflow
flow
Efficient manufacturing
• Layout change of the operators
• Layout change of the facilities
• Reduction of WIP
• Reduction of quality checking time
• There are three physical units, mass, distance and
time.

• Human beings have solved the mass problem by

material handling device, the distance problem by
vehicles such as trains and airplanes, and the time
problem by computer network.
 Conventional way

Forming

Shipping
Assembly
Parts receipt
 The new way

Information system Logistics system Scheduling Identification system

 Material Handling

 The principle of mass production is minimal

material handling

 The basics of material handling are not to

move or to minimize movement

From a macroscopic viewpoint, minimize the product movement.

From a microscopic viewpoint (individual operation/process) ,
minimize the personnel movement.
 The roller conveyor is not a means of transportation

A bad layout in the first place requires transportation

between processes by roller conveyors.

"Do not use a roller conveyors as a storing place.“

If a roller conveyor is installed as a means of

transportation, it will inevitably become a storing place.

The principal role of the roller conveyor is the working

stand.
 If used as the assembly stand of smaller parts, they can
be sent to the next process easily without the need of
power. Also during assembly operation, the roller
conveyor gives good operationability since it can be
stopped.

• "Eliminate roller conveyors as a means of transportation.“

• "If necessary, use power conveyors in order not to make

roller conveyors as storing places.“

• "Hanger conveyors are not recommendable, either."

As for hanger conveyors, indirect operations such as
loading and unloading parts are required.

Assembly workers have to run around each time they

want to get parts.

There are many other better methods of supplying

workers with parts than hanger conveyors.
 The ceiling cranes are the very cause of idleness.

For material that needs handling, the monorail must

be used.

Before After

A measure against being idle because of waiting for the crane

Some means must be devised in the way of
hanging portable lifters.

Too long cables, which are often found in the Western

industries, create problems. It is comparatively easy to
move a lifter up and down since it is hung by a balancer.

But when it comes to moving the lifter back and forth or

right and left, or changing the angle of the lifter, it needs
a lot of muscle work. it is more than material handling.
Try to avoid the operation for which the
operator must bend himself. That is, try to
eliminate the changes of operator's body
position.
Necessary tools and parts must always be
placed close to operator's hands.
If an operator must walk three steps to get some part,
going to and from requires six steps : If this is
repeated 50 times per hour, it will make 2,4OO steps
in 8 hours. It becomes almost 2km in the total
distance.

In carrying or moving article, try not to change the

center of gravity.

For heavy items, if necessary, move them only

horizontally.
3. Layout

3.1 Basic concept of layout design

3.2 Types of Layout
3.3 Some consideration of layout
 Basic concept of layout design

1. Minimize the moving distance of operators and products.

• From a macroscopic viewpoint, minimize the product movement.
• From a microscopic viewpoint (individual operation/process),
minimize the personnel movement
2. Minimize the transportation of materials and
supplementary materials. Minimize piping
3. Build flexibility into the layout to accommodate demand
changes and taller or shorter operators.
• Layout easier to cope with the situation when the production
volume increases ex. Increase a line
Increase a piece of equipment
4. The basic of layout is to sequence stations in the
progressing order with minimum material handling
 Techniques of Layout

The objective of layout is to arrange equipment

to ensure minimal material handling.

Layout must be planned and designed with the

objective that operations are to be carried out
easily and smoothly with the minimal personnel.

Layout is to make proper arrangements for work.

In making a layout, the most important thing is to make
clear "what are done there?" and to make arrangement
so as to carry out all the operations easily, smoothly
and timingly.

"What are done there" does not consist of direct

operations only.

Indirect operations such as supply of material and

parts, elimination of scraps and chips, maintenance,
inspection, repair, and exchanges of tools or molds
must also be considered in making a layout.

A layout can be evaluated as good or bad, based on

the arrangement of all these operations.
Examination of the entrance and the exit

It is necessary to carefully check where the entrance

should be located in order to receive parts, or where the
exit should be at the end of the production system in
order to be connected to the next production system
smoothly.

It is advisable to install the entrance and the exit

separately.
Examination of the sequence of processes

When making a layout plan, try to list up lengthways all

the machines. Equipment and processes in order on the
left hand side of some paper. This is the route of the
products to be processed.

On the next column, contents of the operations in the

most possible detail must be written out. Imagine what
kind of actions the worker at each process takes and
evaluate the necessary time for it. For walking time, two
steps needs about one second.
Installing equipment into the workshop

It is not until this stage that the drawings of the building

and pillars are made and the layout of equipment is
studied.

In case of assembly, it is better to predict how scraps

and carton boxes are removed, how lubrication oil is
changed or refilled.
 Types of layout
1. Product oriented layout

• Limited variation/large volume/repetitive production

• The sequence of processes does not differ for each product. By exchanging jigs
or attachments, any type can be produced
• By promoting standardization of product design, mixed production can be made

FMS
Automatic tandem production
 Layout configurations

I L U
• Can look at a glance • Compact layout
• One direction for material feeding • Small area for operation
• Material flow is most simple • The points of material feeding and
• Easy to automate material handling delivery are the same area
• Less possibility to accumulate WIP in
the processes
• Long line • Rather complicated layout
• Wide area for operation • Many directions for material feeding
• Possibility to accumulate WIP in the • Walking distance for material feeding is
middle of the line long
• Long access to the common space • Layout change is difficult
(utility)
 Increase of value added operation in machining

Non value added

operation (2) Non value added
Non value added operation (1)
operation (3) Air flow
Twist
Temporary placement
From
down
to up

Non value added

operation (4)

Meandering
moving line
Debarring

Non value added

operation (5)
 Streamlined line
The processing
points are the
same height

Elimination of non
value added operations
and non value added
processes
 2. Process group line

• Medium/large variety and medium volume production (production of the same type or
similar types)
• Classification into groups in such a way that there exist less variations in each group

Analysis method: process group analysis

 3. Functional layout

• Many variety and small volume production

• Lot size differ before and after processes
• No similar process sequences can be found
• Different manufacturing environments, cleanness, anti-explosion, legal regulations
• Equipment capacity differs a lot at each process
• Operation styles differ before and after processes

Analysis method: From-To chart

 Some considerations on layout

(1) Painted lines on the floor

* layout of the machinery in a rectangular way

* clear and straight gangway
* gangway by the wall
 Random
Random Rectangular
Rectangular Crooked
Crooked Straight
Straight
placement
placement placement
placement gangway
gangway gangway
gangway

*Space effectiveness *Space effectiveness *Collision, damage *Safe

is poor. is high. *Risky *Smooth flow
*Hard to transfer. *Easy to take *Need to stop many
times
(2) Wiring and piping
 Place them not on the floor but on the ceiling

Piping in Piping on Piping above Piping on the

the earth the floor the floor ceiling

*Corrosion * Corrosion *Avoidance of *Flexible to

* Damage corrosion layout change
* Hard to clean * Difficult to walk
(3) Tools
 Make them unneeded as much as possible.
 Reduce the number of needed tools.
 Place them as near as possible to the needed area.
 Identify home positions for tools.
 Put them in order.
 Place tools conveniently.
 If taken, they can be used as they are without re-holding them.
 If released, automatically they return to the original position.

less than 10cm

target size target size
allowance
• Develop jigs to eliminate manual holding of materials.
• Use ergonomic tools (i.e., tools that are easy to grip,
encourage good hand/wrist posture, and minimize forces and
vibration).
• Combine tools where possible
(e.g., use a T-wrench instead of a socket wrench and
screwdriver)
• Combination of pliers and screw driver

Whenever possible, combine procedures, using your

tools as extensions of your hands and feet. Try to
combine two or more tools into one.

• Where possible, use balancers that automatically withdraw

the tool from point of use.
(4) Material, WIP, etc.
 Fixed areas to place them
 Identify home positions for materials
 Place materials conveniently
 Practice of FIFO
 Eliminate double handling
 Don’t move material from one point to another just so
it can sit in a different place.
 Move parts horizontally. Avoid vertical part
movement.
 Try to keep from fighting gravity with the materials
you are handling ; wherever possible, move them down,
not up. See if you can use a chute or other device to
transport your product away by its own gravity.
 (5) Others

• Try to set your stool, chair, or desk at the most

comfortable position

• Ensure adequate lighting

Make sure your lighting is bright enough and at a
good angle.
• Use colors.
• If possible, use U-shaped layouts so that process start and end
points are side by side.
4. Visibility
The factory should be arranged in such a way that
anything abnormal can be detected immediately from
a distance by providing it with visibility.

Thus, ideally, everything, including machinery and

labor, should be clearly be seen at the eye height.

If visibility is lacking in some area, then provide it with

a means to assure visibility in some way or another.
The surface of the shop floor is a mirror of the activities
going on over the floor.
1) The visual tools must be seen at a glance from a
distance.
2) The visual tools must be put on those items
which require "management" and "control."
3) If something goes wrong, everybody should be
able to notice it by the visual tool.
4) Everybody can easily use the visual tools. The
visual tools must be convenient for doing jobs.
5) With the visual tools, it should be seen how
quality is built in at each process.
6) Everybody can observe and follow using the
visual tools, and correct them if needed.
7) The factory becomes light, neat and streamlined
with the visual tools.

“In a world class plant, there is a system which makes it

possible to highlight any abnormality visually in such a way
that anybody can recognize it as a problem.”
 10 steps
Pressure
Gauge

Check lists
5. Visual Management for
Improving Productivity

Management of production volume and

timing
 Observance of the production schedule
 Hourly production volume control-use of the pace monitor
 Pace monitor

 Cyclic operation
 Hard to see whether operational pace has been kept
 By making possible to see the every hour’s output, make
pace for the operators and see
 It is very important to build in the mechanism to watch the
output result into the system at the time of operational
design
Pace monitor (cont’d)
6. Elimination of MURI, MURA, and
MUDA by Operational Improvement

6.1 Muri (Difficult and unnatural operation)

What is a difficult and unnatural operation?
6.2 MURA (Irregular operation)
6.3 MUDA (Non value added operation)
 Elimination of the three main enemies of productivity

Cause Solution Comments

Difficult or unnatural Ergonomic study Without trial, this
operation problem cannot be
MURI understood.

Irregular movement Standard operation Unless being observed

for some time, this
MURA problem cannot be
recognized.

Waste Reduction of N.V.A.A. If observed properly,

this problem can easily
MUDA be noticed.
 Muri (difficult and unnatural operation)
What is a difficult and unnatural operation?

Movements
Movementsand
andoperations
operationswhich
whichcause
causefatigue
fatigue

1. Operations that require power Muscle fatigue

2. Unnatural posture Fatigue cause by a poor posture
3. Operations that requires Mental fatigue
attention Emotional fatigue
4. Unpleasant operations
 Flexion angle of the Rotation angle of the Height of the working arm
waist waist
Levels of Level 1 Level 2 Level 3 Level 1 Level Level 3 Level 1 Level 2 Level 3
movement 2
At the At the
more more 15º- Higher height of height of
than 30º 15º-30º 0º-15º than 45º 0º-15º than the the
45º shoulder shoulder waist

Flexion and stretching angle of the Rotation angle of the wrist Pick up parts and
knee materials
Level 1 Level 2 Level 3 Level 1 Level Level 3 Level 1 Level 2 Level 3
2
It is It is easy
more more 90º-
Difficult to
handle possible to
pick up the
to pick up,
without
than 60º 30º-60º 0º-30º than 180º 0º-90º It is
necessary to object changing
180º pay attention stretching
the arm
ones’
place

Working range Walk Transport

Level 1 Level 2 Level 3 Level 1 Level Level 3 Level 1 Level 2 Level 3
2
more more 5-9 0-4 more 3-less 0-less
than 90º 45º-90º 0º-45º than 10 steps steps than than than
steps 5 Kg 5 Kg 3Kg
 Movements on the job/Manual labour process evaluation matrix
Moveme Raising Bending Wrist
Bending Waist the arms and Wrist rotation Work Transport
nts on at the rotation to straighten- rotation Walking a-tion of
the job waist angle accomplis ing the angle angle range weights Evaluation points
h the task knees
Level 1: 3 points
3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 Level 2: 2 points

It can be picked up with a hand

more than 10 steps

by reaching out with the arm
Level 3: 1 point

0-less than 3 Kg
5-less than 5 Kg
more than 5 Kg
above the shoulder

more than 60º

Must play attention

more than 180º
more than 30º

more than 45º

Difficult to handle.
without moving
Easy to pick up
shoulder height
to the waist

90º-180º

more than 90º

5-9 steps
0-4 steps
15º-30º

15º-45º

30º-60º

0º-90º

45º-90º
0º-15º

0º-15º

0º-30º

0º-45º
10
Manual
labour 15 20
process

1 Supply 16
wrapping 2 1 1 1 1 3 1 3 3
and
material
2 Glue 1 1 3 1 2 2 3 2 1
16
wrapping
3 Attach 2 2 1 2 2 2 1 1 1
1
4
chafer
4 Attach 13
upper 2 2 1 1 2 2 1 1 1
chafer
5 Attach
side A 2 2 1 1 1 1 2 1 1 12
chafer
(right)
0 0
6 Attach
side A 2 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 112
chafer
(left) 2
3 3 3 3 3 3
7 Attach 13
side B 4
chafer 2 2 1 1 1 2 2 1 1
(right)
8 Attach 6 6 6 13
side B 2 2 1 1 1 2 2 1 1
chafer
(left) 8
9
9 Clean 1
4
surfaces/ 2 10 3 1 1 10 1 1 3 1 1 10
packing( 11
A)
10 Clean 15
surfaces/ 2 3 1 1 1 2 3 1 1
packing(
B)
Example of making work to
be done easily Before
Improvement

• It’s very tiring.

• Only skilled worker can do
the job.
• Quality is not stable.

Position the back

cover. Pushing it, spot
weld by pressing the
foot pedal.
Example of making work to
After
be done easily Improvement

Point 1:
Set the back cover
by one-touch
device.

Improvement effect
Elimination of
unpleasant and
inefficient work
(production cost:$30)
Point 2:
The arm rotates by use
of a crank.

Anybody can do the job easily!

The strike zone of regular operation

Strike zone in
regular operation
Strike
Stand point
on tip
toe

Squat
 No walking !
No choosing !
No bending !

Height
Synchronized
carrier 1500mm

Long
moving
line
Temporary
placement

I m between
Horizontal walking
Nobody can do the body and
: 0 step at the line
assembly easily the line side
side No
in the assembly material on
line the floor at
the line
side
Increase of value added operation in assembly

Pass the part

from one hand
to the other
Walk here
and there

Temporary
placement of
Squat Stand
parts
on tip
toe
 Improvement of parts
shelves

Empty boxes can be

returned
horizontally.

Withdrawal is
possible from this
Smooth side.
Anything can be
fetched easily !
 Strike zone in irregular operations

Strike
Stand
zone
on tip
toe

Stairs

Unnatural
posture

Checking at
eye height

Squat
Checking at the start
of work
Checking without missing any
item can be done and does
not take time since all the
items are placed in the strike
zone.

It takes time to check

the inspection points
which are placed here
and there
 Some Considerations for Difficult or Unnatural
Operation

 Eliminate
Eliminateoperations
operationswhich
whichrequire
requirebending.
bending.
Avoid
Avoidbody
bodytwisting
twistingas
asmuch
muchasaspossible.
possible.

 Do
Donot
not carry
carryor
ormove
moveitems
itemsmanually
manuallywhich
whichweigh
weigh
more
morethan
than10Kg.
10Kg.
MURA (Irregular operation)
 Approach
Step1: Investigation of the variation of the cycle time of each
operator/operations.

1
2
3
4
5
6
7
8
50 70 90 110

Step2: Reduce the variation of the cycle time of the operator who has the
biggest variation of the cycle time among all.
Step3: Investigation of the average cycle time of each
operator/operation
Step4: Improve the average cycle time of each
operator/operation up to the minimal average cycle time
of the best operator/operation.
Step5: Current operation – value added operation
non value added operation.
Step6: Reduce and/or eliminate non-value added operation.

Repeat Step 1-6.

*Improvement of operational method

-- The heights of the working tables must be the same.

-- The moving surface of the workpiece must be horizontal without
roughness.
-- The workpiece must be easily loaded, unloaded and handled.
-- The three dimensional movement of the workpiece must be changed
into two or hopefully one dimensional movement.
-- The transfer distance of the workpiece must be shortest and its
movement should be linear movement.
 MUDA (Non value added operation)

(1) Value added operation, semi-value added

operation and non-value added operation
(2) Labor loss : flow of motion improvement
(3) Golden zone
(4) Productivity deployment
(5) Kinds of waste
(6) Inventory is the worst waste
(7) Methods to reduce inventory
(8) Step by step development of value added operation
(1) Value added operation, semi-value added operation and non-value added operation
[Value Added Operation]

[Semi-Value Added Operation]

[Non Value Added Operation]

 LABOR TIME SPLITTING UP

MEAL and REST

Looking for, Recording, Filling in, Adjusting,
NVA Talking, Removing, Checking,
ACTIVITIES Keeping/Putting (for transportation)
NO VALUE ADDED

WAITING In Side Cycle

Walking (to reach a side)

WALKING Moving/Transportation (to walk moving
objects)
MACHINE Set up, Breakdown, Minor stoppages,
LOSSES Scraps, Change material
(O.E.E.) Waiting (for management problem)
Gripping, Moving (by hand), Holding,
SEMI VALUE ADDED Preparing, Loading, Stretching out,
Unloading, Positioning
Assembling, Joining, Rolling, Cutting,
VALUE ADDED Rasping, Putting solution.
 Effective utilization of the labor

Available time
•Rest/Meeting
Loading time
Losses out of the cycle
•Set-up
•Adjustment
Net operating time •Breakdown
•Start-up
•･･････････
Not value added activities
•Balance loss/waiting
•Checking
Effective time •Walking/Bending
•Short stops
•Material correction
•Writing/reading
•･･････････
Semi value added activities
•Feeding materials
Value added time •Handling jigs
•Picking
•Handling tools
•･･････････
 Labor loss : flow of motion improvement

Observation of motions by
Set the target
video taping

Investigate the
Motion analysis
countermeasures

Value added operation Investigate and implement

analysis the optimal measures

Detection of non-value added Confirmation of

operations results/effects

Revision of standards
 Golden Zone
Machine

60º B
AA
A

400 Man
C
D
700
 Evaluation criteria

All the items can be provided to the assembly point within the
AA field of vision and without changing the heights of the item
supply points.
Items are placed within the region of three times as big as the
A assembly unit. Items can be taken by stretching out elbows.
Both hands can be used.
Items can be taken by stretching out elbows although they go
B up beyond the shoulders’ height. Items are placed within the
region of six times as big as the assembly unit.

C Items can be picked up by turning the body.

D Items can be fetched by walking.

1. Correct Movement
1) Repetition of rhythmical movement (cycle time variation ： ca within 10% )
2) Simultaneous usage of both hands ( bigger than 30% of total movement)
3) Inventory
4) No reverse movement (A hand’s or arm’s movement is not reverse to
the progressing direction of the body).
5) Work must be carried out right in front of the body.

Give priority to placing equipment and parts

to process and let the operator follow accordingly.

Give priority to the human movement and install

Equipment and place parts accordingly.
6) Twisting (body, arms --- less than 45 ）

７） Idle walking --- less than half a step

8) Unevenness --- less than 5 cm

(the variation of the heights of parts, jigs and/or equipment)

9) Zigzag --- less than 5 cm

The hand(s) zigzags back and forth.

10) Interval step --- less than 10 cm

People can’t move with the same steps.
11) [Step] --- Move the foot in the progressing direction slightly backwards,
make the other foot cross the front of the body.
12) Tentative placement --- No such placement
13) Do not shift a part from one hand to the other.
1. Slightly bend forward 2. (A) lateral step
Open two feet to the extent that the
distance between them is about the size
of a fist.

28 – 30 cm

3. (B) Interval step

28 -- 30 cm
 Make a layout focusing mainly on human movement
Operation point
Working table
1. Allocate operation points on
Standard line
the working table

Point
Establish the interval step in the
most comfortable way. Man : 30 cm
Women : 28 cm

2. Arrange tools to be used

at the operation points.
Point
Arrange tools in such a way that
no back walking or no reverse
movement takes place. Operation point
(Allocate tools in the sequence
of assembly operations.)
3. Allocation of parts at the operation
points and their adjustment to have
the same height.
Point Leveling at the standard line

There should be no unevenness at

the operation point and placing
positions of parts.

Zone of assembly
movement
4.Set the assembly positions at The height of parts
the same distance from the front
of the working table.
Assembly
Point position
Assembly position and operation
points should be within ca 5 cm
from the standard line. The front Standard line
of the
working
table
• Work should be done in the “golden zone”.
• Maintain appropriate body posture.

Keep materials and tools in specified places in front of and around you.
Lay them out to be picked up in the order that you routinely use them.

As shown in Figure 2, if you are inserting the end of a pin held at an

angle of zero degrees from the workbench, you cannot avoid twisting
your head to see where you are inserting it. The closer you get to
inserting it at a 90-degree angle (directly in front of you), the less time
and effort you will waste in turning your head. Therefore, the 90-degree
angle is the work position for minimizing time and effort.
 Step by step development of value added
operations
5th step
4th step
Promotion of
3rd step Reorganization
LCA
• Promotion of
of work automation
•Process
2nd step Improvement of integration
movement
•Elimination of
non-value added
1st step Operation
operation
improvement
•Improvements of
Making operation irregular operation
to be done easily
•Improvements of
difficult and
unnatural
operations
 Applying the Principles of Motion Economy
The principles of motion economy help reduce fatigue and
productivity.
1. Guidelines for Economy of Motion
• Hand movements should be symmetrical and concurrent.
• Two-handed motions should be as compact as possible.
Move both arms in unison or move them symmetrically,
but do not move just one arm at a time.
 Side-to-side eye movements are less tiring than up-and-
down ones. Arrange your work to avoid eye fatigue.

 Motion should flow freely.

 Light work should be done with the hands and forearms,

rather than the upper arms and shoulders.
The following illustration shows the correlation between
arm movement and working time.

The point is to minimize body movement by limiting movement to body parts

with low time rankings while still performing the job satisfactorily. Add up the
body motions in terms of their rank numbers (1 through 4 ) and discover how to
do the work with as low a total as possible. The less movement you perform,
the less energy you expend and the less tired you become.
 Keep hands free as much as possible

You can minimize fatigue by repeating motions with a

natural feeling of rhythm and by making your curved
movements as smooth as possible.
Do as little holding or adjusting of materials
as you can.
Use standards or jigs to hold your materials and/or tools
for you.
Try to keep both hands involved in your work.
If you utilize your legs and feet, you can lighten the load
on your arms and hands. However, be sure to avoid
having to move your feet around a lot or having to take
steps.
Space utilization – easy picking
 Storing parts in containers that permit easy grabbing

To grab long narrow wires Place parts on a sponge Nuts stored in a box-shaped
and rods easily. Set them for easier grabbing. hopper fall into the apron area
in a container such as in in the front where they can
the one shown in the figure. be retrieved.
Place all the parts going in
the same direction and
shake the container a little
so the next piece sticks out
for grabbing.
Positioning of a jig

Guide

Do not place
parts higher
than this one.
[Placement of a hammer] [Picking a washer] [Picking a screw]

Grasp Grasp Grasp Use it as it is

Unload Passing No passing from one hand to another
from one
Passing from one
hand to
hand to another
another

Place sponge at the bottom.

Coming out one by one
Workpiece Content of Characteristics of Principle
improvement the workpiece
Source of power Function of power
transition
Bolt, nut One-piece feeding Material : iron • Rotation of the • The principle of
motor lever
• Magnetic power • Chute
• Gravity of the
workpiece

Bolt, nut One-piece feeding Material : iron •Rotation of the • Gravity (water)-
(required quantity) motor driven clapper
• Magnetic power • Chute
• Gravity of the
workpiece

Snap ring One-piece feeding Flat and thin ring • Air pressure • Insertion guide
(The thicknesses
of the pushing
plate must be the
same as that of
the workpiece.)
Label One-piece feeding Thin and easily •Rotation of the • Label separating
piled up motor plate
(Difference of the
sticking power of
the tape and the
label when the
tape rotates.)
Felt washer One-piece feeding Thin, light and • Compressed air • Container
round • Gravity of the • Chute
workpiece (The
width of the
rotating shooter
must be the same
as the thickness
of the workpiece.)
Shim One-piece feeding Thin Magnetic power • Insertion guide of
(Utilization of the the workpiece
force of repulsion
between S pole
and N pole)
Round bar One-piece feeding Heavy • Vertical motion • Pushing out
of a plate by air plate
cylinder (The
thickness of the
pushing out plate
must be the same
as the cross
section area of
the workpiece.)
Steel ball One-piece feeding Small, flexible • Gravity • Insertion guide of
• Finger force balls
• The principle of
lever
O ring One-piece feeding Flexible •Compressed air • Container of
(Feed out by picking out O rings
stirring) • Chute

Piston ring One-piece feeding Flexible • Air • Spiral insertion

(direction : fixed) guide
 Automation of picking up one label from the tape at a time

Effect : Deduction of operation time from 2 sec. to 0.3 sec,

Production cost : ∈ 150
Problem : Due to the operation by two hands, it takes
time to remove the label from the tape and the label
cannot be easily removed due to the use of the glove.
Power source : Electricity
Function of power transition : Hold the label
Geared motor roller Glove

Due to the use of a

glove, the label
easily slides. The label is liable to stick
to the glove.
Content of Improvement

The geared motor

rewinds the tape.
The sensor
detects the
label and stops
the motor.

3
Photo cell
sensor

Label
separator

Rewinding
roller
Geared motor

Photo cell sensor The glove can be used.

 Device of picking up fixed quantity of plastic pins

Effect : Picking up only needed quantity of plastic pins

Production cost : ∈2,000
Problem : It takes time to pick up 8 pieces at a time.
Power source : Pressure, electricity
Function of power transition : Air chute

I need
one
more pin
!
 When 8 pins are taken, the rotating disk
will rotate.

The guide Air

picks up one
Sensor pin inside
Guide
the rotating
disk.

Pick up mouth Rotating disk

The counter will stop the rotating

The pins on the disk when pick up mouth has got
guide will be the needed quantity.
blown to the
pick up mouth. Air

Count
er
 Programmable
controller

Rotating disk Motor rotation and stopping

Pick up mouth
Air blowing and stopping
Counter

Guide

The detector Pins

of picking
operation
 Picking up one part utilizing wire and spring

Effect : Reduction to time 2 sec. 1 sec.

Production cost : ∈50
Problem : Difficult to pick up oil stuck cylindrical parts from
a box
Power source : Air
Function of power transition : Air press

Parts
Cylinder rod

Wire

Lift bar
Lever

When the cylinder rod goes down, the wire When the cylinder rod goes up, wire
gets loosened and the lift bar goes down gets tightened and the lift bar goes up.
by the spring.
Air press cylinder Wire

Part
Lever

Lift bar

Pick up one part at a time by using a motion of

pushing the switch of the air press.
 Picking up one pin easily utilizing a jig

Effect : Reduction to time 1 sec. 0.5 sec.

No drop of pins
Production cost : ∈500
Problem : It is difficult to pick up a pin of D 3mm x 20mm
from the container and also passing the pin from one hand to
another is required.
Power source : Air and electricity
Function of power transition : Chute, guide rails
 The next pin will
come down.
Pick up a pin.

The pin hits The pin will

the tilted erect by being
surface and pushed by the
gets inserted next one.
into the hole.
Air cylinder

Control Hose
box

The proximity
switch will
detect whether
there are pins or
not.
 Automatic bolt feeder

[Transfer mechanism]
Separation plate [Transfer mechanism]
Lift up bolts 2-3 Drop a bolt by the
Magnet pieces from the separation plate
hopper by magnetic and put it into the
force. rails.

[Counting mechanism] [Separation mechanism]

3 piece pick
up plate
Take bolts by the Take the picked up bolts.
cam plate which is
designed to pick up
the needed quantity.

Pick up lever
Push
 Separation
Magnet (10 pieces on the
Chute of removable Chute plate chain)
type for different
diameters

Pick up cam plate

Chain

Pick up
lever

Sprocket
Motor

Bolt hopper
 PRODUCTIVITY DEPLOYMENT
DIRECT LABOUR MAP (FACTORY:12/2002)

Factory

Mixing Room

Semi finishing/Extrusion

Semi finishing/Street

Semi
finishing/Textile
Semi finishing/Bead

Building
Curing

Final inspection

V.A. S.V.A. O.E.E. Walk Waiting Org. Problem TPM

Relax
 LOSSES REDUCTION – PLANNED 2002
LOOSSE
100 TOOLS MAIN ACTIONS J F MAMJ J A S OND
S

6.2% •Reorganization of activities in the metallic rim

WORK
preparation area.
REDUCTION ANALYSIS
•Work cell between RM 30 and bead filler
OF NVA WALKING &ECRS
applicator.
FLOW
•Use a carriage to manually move the beads.
93.8 ANALYSIS
•Work cell between finishing dispatch and OTR
&ECRS
tires flashes removal.
•Increase speed of sidewall extrusion
•Increase speed in calendaring the metallic ply.
WORK •Optimized cycle at the TRG/A tire building
NVA WAITING ANALYSIS machines.
&ECRS •Run 2 metallic ply cutters with only 1 operator.
•Increase the number of machines for the curing
NVA presses operators.
ECRS •Collection of samples on the mills.
ECRS& •Rebalance of the semifinished products
ORGANI-
WORK
ZATIVE ANALYSIS transportation activities.
ECRS
•Change the X-Ray control method.
•Installation of sensors under the conveyor table
SCRAPS (FISCHER).
REDUCTION •Congruity radius between the vacuum cups and
the drum (RM30).
SVA SVA •Adaptation of an SAE 660 bronze bushing
O.E.E. B/D (Banbury 7).
REDUCTION •In the conveyor belt replace by flexible wires (RM
VA VA 30)
DONE
•Production program by product family (Banbury PLANNED
SET UP nº7)
REDUCTION
•Spare tower for replacement (preajusted) (TRG/A)
7. Multi-skilled Labor

7.1 Horizontal multi-machine handling vs. vertical

multi-process handling
7.2 Step by step development of multi-skilled labor
7.3 What knowledge is required of the average
operator?
Horizontal multi-machine handling vs. vertical multi-process
handling

Horizontal multi-machine handling Vertical multi-process handling

(one operator operates many of the (one operator runs all the machine in a
same type of machines) cell. The machines are of different types.)
Step by step development of multi-skilled labor
 7.3 What Knowledge is required of the average
operator?

1.
1. Key
Keypoints
pointsofof work
work
2.
2. Criteria
Criteriafor
forjudgment
judgment
3.
3. Check
Checkresults
resultsofof work
work
4.
4. Major
Majorequipment
equipment design
designdata
data
5.
5. Operating
Operatingprinciples
principlesofof the
theequipment
equipment
6.
6. Managing
Managingequipment
equipment based
basedon onthe
theoperating
operatingprinciples
principles
(key
(keypoints)
points)
7.
7. Main
Maincomponent
component partspartsfunction
functionand
andprecision
precisionto
tobe
be
maintained
maintained
8.
8. Method
Methodforformeasuring
measuringprecision
precision
7.3 What Knowledge is required of the average operator?
<continued>

9.
9. Parts
Partsreplacement
replacement and
andcheckup
checkupmethods
methods
10.
10. Adjustment
Adjustment methods
methods
11.
11. Control
Controlmethods
methodsand
andsystem
system
12.
12. Detection
Detectionand
andtreatment
treatment of
of abnormalities
abnormalities

★
★IfIf information
informationisisdisorganized
disorganizedand andtraining
trainingisisnot
not thorough,
thorough,
workers’
workers’lack
lackof of knowledge
knowledgewillwillresult
result in:
in:
・・Incorrect
Incorrect actions
actionsand andwork
work
・・Incorrect
Incorrect assumption
assumptionabout about causes
causesand andineffective
ineffective
corrective
corrective action
action
・・Aggravation
Aggravationof of existing
existingtroubles
troubles
8. Systematic Introduction of LCA
8.1 The Six Principles of LCA
8.2 Priority of LCA
8.3 The Concepts of LCA for Machining
8.4 The Concepts of LCA for Assembly
8.5 The Concepts of LCA for Transfer
8.6 The Method of Transportation
8.7 Line Feeding System
2. The operator should mainly be engaged in loading.

Mainly loading operations only

 Effects of LCA of machining on purpose

Processing
sequence
1 2 3 4 5 6 7 8 9 10
Parts
receiving
Parts
placing
Parts
fastening
Switching
on
Feeding
Stopping
Tool
returning
Unload-
ing the
parts
Result
confirm-
ation
Trans-
porta-
tion

Purpose

Quality ◎ ◎ ○ ◎
Delivery
volume ○ ◎ ○ ◎
Manpower
productivity ○ ○ ○ ◎ ○

The effectiveness of LCA of 3-8 and 10 are high.

 Effects of LCA of assembly on purpose

Assembly

1 2 3 4 5 6 7 8 9
operation Assembly
Product Parts Parts Position- Tool Tool Unload- Result
sequence
receiving selecting taking ing fetching returning ing the confirm-
product ation

Purpose

Purpose ◎ ○ ◎ ◎
D /Volume ○ ○
Manpower
productivity ○ ◎ ○ ◎ ○ ○

The effectiveness of LCA of 2,3,7 and 9 are high.

3. One touch loading and on touch unloading
The heights of the carriers and the shelves of the store must
be the same.
The route for loading and route for unloading must be
separated in either height or position.

Assembly

Store
Empty boxes
9. Controlling Abnormal Situations
and Achieving Stable Production

9.1 Abnormal situations

9.2 The steps toward creating a flow of products
9.3 Prerequisites for competitive manufacturing
9.4 Conditions for making a clear flow of
products in the shop
９．１ Abnormal situations

• Defectives

Countermeasures • Short stoppages

• Shortage of parts
against
• Excessively provides parts
• Operational delay

Note : The countermeasures against stoppages are

also the ones against safety and quality
problems.
9.2 The steps toward creating a flow of products.

Step 1: Leveled demands receiving by proper business

activity
….Competitive powers by Q. C. D.
Step 2: Understanding of the necessity of making a flow
2.1. Short lead times
2.2. Avoidance of over division of work
…Large lot production helps to improve the efficiency
of a local machine but does not improve the overall
efficiency of the shop.
2.3. Arrangement of the machines in the order
…Product oriented layout
…Connection of processes
…Multi-purpose workers
…Standardizations of the number of in-process
inventory
2.4. One-piece flow production

Do not care very much for the efficiency of a machine

which costs less than 2 M yen.
Step 3: PQ analysis
A : 1- 70%
B : 71- 90%
C : 91-100%

For A, classify into several groups, based on the

processes and establish lines.

For B, depending on the processes, look for the

similar products in either group A or B and look for the
possibility of flow production.

For C, conventional way.

Step 4: Process analysis and process improvements
Difficulty degrees :
A : 2 – 3 times average process time
B : 3 – 4 times average process time
C : more than 4 times
 For process of producing very complicated parts, make a
separate process before or after the main line.
 For those process which are rarely used, put them
separately from the main line.
Step 5: The shape of the layout should be either I or L
or U.

Step 6: Reduce the set up times.

Step 7: Establishment of the cycle times

Notice
Machines should be installed in such a way
that layout change can be easily done.
9.3 Prerequisites for Competitive Manufacturing

1. To have many outstanding engineers of production

techniques as many as possible.
Especially, production techniques of improving quality,
and reducing
Costs
and
lead times (delivery,
manufacturing, etc.)
2. To get excellent foremen for continuous improvement.
3. To motivate workers via QC circle activities, etc. in
order to maintain the absenteeism rate as low as
possible.
9.4 CONDITIONS FOR MAKING A CLEAR FLOW OF PRODUCTS
IN THE SHOP

1. No missing parts
 standardized store
 use of kanbans
 check list of missing parts
 due date control table
 introduction of concept of “just in day” production
2. No repairs, defects and mis-manufacturing
 establishment of a committee for eliminating defectives
 clarification of standard numbers of parts, products and inventory,
etc.
 sequential inspection, self check
 utilization of proper jigs
 fool proof devices
3. Short set up
 reduction techniques
 training
4. No machine breakdown
 every day's routine check by operators
 Total productive maintenance
5. Standardization
 easily performed standard operation in such a way that
everybody can do it.
6. Synchronization
[Synchronization means zero waiting time and it must be aimed at as
a target.
It is most efficient when parts are directly fed to the next machining
after the completion of casting, and at the completion of machining,
they are connected to the assembly line.
“All the process must be synchronized.”]
 fair job assignment to workers
 establishment of proper standard
 team work
7. Multi functional workers
 destroy sectionalism
 education and training
8. Avoid abnormal absenteeism
 proper share of the company profit
 inform the foreman of absence in advance
 introduction of relief man
10.The Principles of Effective Operation

1. Separation between manual work and machine operation.

2. Development of devices for detecting something abnormal.
3. Adoption of one touch gauges and foolproof devices.
１１． Economic Measures
1. Operating revenue(S)-Proportional costs*(M)= Marginal profit(P)

*material cost, distribution cost, etc.

Marginal profit(P)
2. 100=Marginal profit rate(ρ).
Operating revenue(S)

3. Value added/person(V)= Operating revenue(S) Marginal profit rate(ρ)

Number of people(N)
 Labor cost(W) **
4. 100=Labor distribution rate(R).
Marginal profit(P)

**salaries, bonuses, welfare cost, reserved fund for retiring people, etc.
For manufacturing industries:
40% ideal
48% normal
50% caution
65% limit

5. Equipped level/person(E)
Property, plant and equipment(P)
=Equipped level/person(E)
number of personnel(N)
6. Inventory level(I)
Inventory level in terms of
=Inventory level in terms of weeks(i)
Weekly sales(S/52)
money(I)
 Step77
Step

Step66 Standard
Step work
sequence
Standardi-
Step55
Step zation

Step44 JIT parts

Step supply

Product
Step33
Step characteristics
education

Step22 Tentative
Step standard

Step11 Tidying up
Step process
Fig. 1 : Work Place Organization
Initial
cleaning
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

1. Initial cleaning Learn “cleaning is • Teach the importance of 5S and apply it.
Established basic conditions

inspection” through • Thoroughly remove unnecessary

cleaning and removing materials.
unnecessary materials • Eliminate trash, dirt and dust.
from work area. • Put parts shelves, part boxes, working
tables, jigs and tools in order.
• Conduct survey and analysis for
dropped parts, and take remedial action.
• Tag the area where there is any problem.
• Clearly display storage area for parts,
tools and jigs.
• Clearly display storage area for defects
(scraps, items to be repaired).
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

2. Tidying-up Look for ease of reading • Take countermeasures against the sources of
trash, dirt and dust.
Established basic conditions

process and workability through

• Countermeasures against heavy items (manual
tidying up work area moving up and moving down, transportation).
• Eliminate bending operation.
• Eliminate irregular turning operation.
• Display legible labels for parts shelves.
• Modify parts shelves for ease of use.
• Practice FIFO for these parts placed on the
parts shelves.
• Review installation methods for parts
containers.
• Ask the following four questions :
- How do you do this work?
-How do you know you are doing this work
correctly?
- How do you know that the outcome is free
of defects?
- What do you do if you have a problem?
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

• Establish autonomous quality checking for the
difficult parts to check their quality at later
Established basic conditions

stages by either
- self-inspection
- next-stage inspection
- use of a quality check man or
- the introduction of fool proof devices
• Review improvements and confirm these
results.
• Install some measures for preventing scratches
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

3.Tentative Set tentative standards • Set tentative cleaning and inspection

Established basic conditions

standards to maintain process standards.

conditions attained in • Practice visual control.
Steps 1 and 2. • Improve line efficiency.
• Establish standard operation.
• Thoroughly follow rules set by
operators themselves.
• Install some measures for prevention
of wrongly assembled parts and non-
assembled parts.
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

Established usage conditions and work methods

4-0. Product Learn about structure and • Identify the worst five quality
characteristics function of product to problems occurring in process
education attain quality assurance allocated, and learn about quality
in assembly work. by solving relevant problems.
4-1. Overall tool Conduct overall • Obtain optimal tools, jigs,
inspection inspection in terms of measuring, apparatus and mistake
4-2. Overall jig hand tools, jigs, proofs to assure quality results.
inspection measuring apparatus and • Obtain easy-to-use tools and jigs
mistake proofs to assure along with easy-to-work, safe
4-3. Overall
quality results. processes so as to attain accuracy
measuring
apparatus and durability in manual work.
inspection
4-4. Overall mistake
proof inspection
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

5. JIT parts supply Remove wastes from • Obtain optimal job assignment.
and line balance inventory and human • Introduce parts feeders where
motion. applicable.
Standardize

• Obtain optimal height and

direction of each part in the part
shelves.
• Review parts shelves to make
them optimal.
• Review stocked parts to attain
optimal inventory control.
• Review allocation of materials and
human motion in and around
assembly to search for optimal
combination.
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

6. Standardization Review and improve • Prevent quality defects.
tentative standards to • Minimize irregular operation as
make them easier to much as possible.
Standardize

follow. • Establish rhythmic operation to

minimize fatigue by repeating
motions with a natural feeling of
rhythm.
• Compare in detail tentative
standards with given work
procedures to finalize operators’
routine work standards.
• Create multi-skilled labor
(3-3-3)
• Take proper countermeasures
against cycle time changes.
 Work Place Organization in Assembly Department
Focus : Labor
Target : Quality and productivity

Step Aims Activities

7. Standard work Implement standard • Establish standard work systems.
sequence work sequences to • Attain flexible process against
Standardize

remove qualitative variability of production output.

variability. • Raise skills to cope with the needs
of vertical startup of assembly for
new product.