Ch10 Motion Study

Motion Study and Work Design
Sections: 1. Basic Motion Elements and Work Analysis 2. Principles of Motion Economy and Work Design Motion study
Definitions
Analysis of the basic hand, arm, and body movements of workers as they perform work
Chapter 10
Work design
Design of the methods and motions used to perform a task Design of the work system Includes:
Workplace layout and environment Tooling and equipment used in the task such as workholders, fixtures, power tools, etc.
Work Systems and the Methods, Measurement, and Management of Work by Mikell P. Groover, ISBN 0-13-140650-7. 2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Basic Motion Elements

Frank Gilbreth first to analyze and classify the basic motion elements Therbligs 17 basic motion elements
Spelled backward except for th Basic building blocks of virtually all manual work performed at a single location (so the primary interest is the hand motions) With modification, used today in several work measurement systems, e.g., MTM (Methods-Time Measurement)
Basic Motion Elements (continued)

Therbligs 17 basic motion elements
Some of the motion element names and definitions have been revised Involves both physical an mental elements Although it is first used in production and logistics, the principles are also applicable to service industry.
17 Therbligs
1. 2. Transport empty (TE) reach for an object with empty hand today we call it reach Grasp (G) grasp an object by contacting and closing the fingers until control has been achived Transport loaded (TL) move an object with hand and arm today we call it move Hold (H) hold an object with one hand Release load (RL) release control of an object Use (U) manipulate/use a tool
17 Therbligs (continued)
7. Pre p - osition (PP) position object for next operation 8. Position (P) position object in defined location 9. Assemble (A) join two parts 10. Disassemble (DA) separate multiple parts that were previously joined 11. Search (Sh) attempt to find an object using eyes or hand
3. 4. 5. 6.
17 Therbligs (continued)
12. Select (St) choose among several objects in a group (hand e - ye coordination is involved) 13. Plan (Pn) decide on an action (a short pause or hesitation in the motions) 14. Inspect (I) determine quality of object using the eyes 15. Unavoidable delay (UD) waiting due to factors beyond worker control 16. Avoidable delay (AD) worker waiting 17. Rest (R) resting to overcome fatigue
Therbligs
Therbligs
Therbligs
Therbligs
Therbligs
Example
Classification of Therbligs
Effective therbligs: Physical Basic Motion Elements: Transport empty Grasp Transport loaded Release load Use Assemble Disassemble Mental Basic Elements: Inspect Delay Elements: Rest Ineffective therbligs: Physical Basic Motion Elements: Hold Pre-position Physical and Mental Basic Motion Elements: Position Search Select Mental Basic Elements: Plan Delay elements: Unavoidable delay Avoidable delay
Method study at the therblig level seeks to eliminate or reduce ineffective therbligs.
Micromotion Analysis
The main idea of method study at the therblig level: seeks to eliminate or reduce ineffective therbligs. Each therblig represents time and energy enpended by a worker. If task is repetitive, this will be performed many times. Then, it becomes meaningul to analyze therbligs. Known as micromotion analysis
Micromotion Analysis
Analysis of therbligs that make up a repetitive task Objectives:
Eliminate ineffective therbligs if possible Avoid holding objects with hand Use workholder Combine therbligs Perform right-hand and left-hand motions simultaneously Simplify overall method Reduce time for a motion, e.g., shorten distance
Checklists:
Checklist1 (discussed in the in class) Checklist2 (given in the book Table 10.3)
Principles of Motion Economy

Developed over many years of practical experience in work design Guidelines to help determine Work method Workplace layout Tools, and equipment Objective: to maximize efficiency and minimize worker fatigue Many people dont understand why these principles are necessary, but you know that these principles are violated in work systems (think about your summer training).
Three Categories of Principles

1. Principles that apply to the use of the human body Principles that apply to the workplace arrangement Principles that apply to the design of tooling and equipment
2.
3.
Use of Human Body

Most applicable to manual work 1. Design work to fully utilize both hands 2. 3. The two hands should begin and end their motions at the same time to distribute the work equally to hands Hand and arm motions should be symmetrical and simultaneous to minimize hand/arm-eye coordination Avoid different independent motions of hands/arms Design work to favor preferred hand Work units should enter the workplace on the side of the workers preferred hand Workers two hands should not be idle at the same time except for the rest breaks
Work forget the Methods, Measurement, and Management of be Dont Systems andMikell P. Groover, ISBN 0-13-140650-7. can Work organized according to that not all tasks by 2007 principles. these Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
An experiment
A relatively simple task Reaching, selecting, grasping, transporting, releasing small parts. Two types of containers A rectangular bin A bin with a tray The worker performed the work cycle with each container using Only the right hand Only the left hand Both hands performing symmetrical and simultaneous motions.
4.
5.
Use of Human Body

Utilize laws of physics 6. Method should consist of smooth continuous curved motions rather than straight motions with abrupt changes in direction
Although shortest distance between two points is a straight line Because straight-line path sequence includes start and stop actions (accelerations and decelerations) consume workers time and energy
7.
0.72 sec / work unit 0.54 sec / work unit
Use momentum (mass * velocity) to facilitate task Carpenter using a hammer to strike a nail Take advantage of gravity Dont oppose it Method should achieve a natural rhythm of the motions involved
8. 9.
Use of Human Body

10. Use lowest classification of hand and arm motion (five classifications) 1) Finger 2) Finger and wrist 3) Finger, wrist, and forearm 4) Finger, wrist, forearm, and upper arm 5) Finger, wrist, forearm, upper arm, and shoulder
Movement of the fingers only as when picking up a cotton roll.
II
Fingers and wrist motion as used when transferring an instrument to the operator, or manipulating a hand instrument.
III
Fingers, wrist, and forearm as when reaching for a handpiece.
The entire arm and shoulder as when turning around to reach for equipment from adjacent fixed cabinetry.
IV
The entire arm when reaching for supplies away from the work area, or to adjust the operating light.
Use of Human Body

For using body members other than the hands, and arms 11. Minimize eye focus and travel
Minimize the distance between the object
Workplace Arrangement
Design of the workplace 1. Locate tools and materials in fixed positions within the work area Locate tools and materials close to where they are used To minimize the distances to be covered Locate tools and materials to be consistent with sequence of work elements Decrease the time required for searching
12. Design method to utilize feet and legs where appropriate

Since they are stronger than arms
2.
3.
Normal and maximum working areas in the workplace
Design for average user
Illustration of First Three Principles

Poor arrangement of parts and tools in workplace
Illustration of First Three Principles

Good arrangement of parts and tools in workplace
Numbers indicate the sequence of operations

Numbers indicate the sequence of operations

4. Use gravity feed bins to deliver small parts and fasteners
5. Use gravity drop chutes for completed work units where appropriate 6. Provide adequate illumination
Also color, constrast among items, location of the light source are important
Two types of bins used for small parts and fasteners in the workplace: (a) gravity feed bin (b) conventional rectangular bin
7. A proper chair should be provided for the worker Adjustable to the size of the worker Seat height and back adjustments Padded seat and back
Adjustable Chair for Workplace

1. 2.
Design of Tooling and Equipment

Workholding devices should be designed for the task Hands should be relieved of work elements that can be performed by the feet using foot pedals sewing machine Combine multiple functions into one tool where possible Pencils designed for writing and erasing Perform multiple operations simultaneously rather than sequentially Multiple-spindle drill presses to drill holes in PCBs
3.
4.
Design of Tooling and Equipment

5. Where feasible, perform operation on multiple parts simultaneously
Machines in a cake factory
6.
Design equipment controls for operator convenience and error avoidance

Controls should be located within easy reach to minimize the body motions required to access them
7.
Hand tools and portable power tools should be designed for operator comfort and convenience
e.g. tools that can accomodate both right-handed and left-handed workers
8.
Mechanize or automate manual economically and technically feasible

operations
if

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Motion Study and Work Design

Basic Motion Elements

Basic Motion Elements (continued)

Principles of Motion Economy

Three Categories of Principles

Use of Human Body

Use of Human Body

Use of Human Body

Movement of the fingers only as when picking up a cotton roll.

Fingers, wrist, and forearm as when reaching for a handpiece.

Use of Human Body

12. Design method to utilize feet and legs where appropriate

Design for average user

Illustration of First Three Principles

Illustration of First Three Principles

Numbers indicate the sequence of operations

Numbers indicate the sequence of operations

Adjustable Chair for Workplace

Design of Tooling and Equipment

Design of Tooling and Equipment

Design equipment controls for operator convenience and error avoidance

Mechanize or automate manual economically and technically feasible

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