TOPIC 2:

METHOD STUDY
(PART IV)
4. Develop Solution

◼ During critical analysis of the task being

study, ideas on how to improve it
emerges.

◼ The next step will be to develop these

ideas into feasible solutions and select
the optimum one.
BASIC PROCEDURE/APPROACH FOR METHOD STUDY
i. Select

ii. Record
iii. Examine

iv. Develop

v. Evaluate

vi. Define
vii. Install
viii. Maintain
4.1 Factors to be considered in solution development:

i. Material flow and material handling.

▪ Improve layout.
▪ Choose the right material handling
equipment.
▪ Minimize material handling – non
productive activity.
 Different types of material handling equipment

Conveyor Trolley Hoist

Skid Fork lift / industrial truck Crane

 Possible method of handling an object

Trolley Crane & Hoist

Conveyors Robot

Truck
ii. Workers movement in the work place
◼ Minimize or eliminate ineffective movement.

iii. Method and movement in the workplace

◼ Simplify method of doing work.
◼ Minimize ineffective movement.
4.2 Principles that may be used:
i. Principles of motion economy.
ii. Poka Yoke (Mistake proofing method).
iii. SMED (Single Minute Exchange of Die)
iv. DFMA (Design For Manufacture & Assembly).
v. Ergonomics.
i. Principles of motion economy

◼ Divided into 3 categories:

1. The use of the human body.

2. The arrangement of the work place.
3. The design of tools and equipment.
 Category 1. The use of the human body
a) Both hands should begin as well as complete their motions at
the same time.

b) Both hands should not be idle at the same time except during
rest periods.

c) Motions of the arms should be made in opposite &

symmetrical directions & should be made simultaneously.
Symmetrical motion balance each other
and reduces the shock on the body and
requires less mental and physical effort.
d) Motions should be confined to the lowest degree /
classification as possible to perform the work satisfactorily.

◼ Material and tools should be located as

close as possible to where it is used.
◼ Hand motions should be a short as the
work permits.
◼ Lowest classification usually need least
time and effort.
e) Momentum should be used wherever possible but should be
reduced to a minimum if it must be overcome by muscular
effort.
The motion of worker need to be
so arrange that the forcible stroke
is delivered when it reaches its
greatest momentum.

Momentum = mass X velocity.

f) Smooth continuous curved hand
motions are better to straight line
motions that involve sudden and
sharp changes in direction.

◼ Abrupt changes in direction are time

consuming and cause fatigue.
g) Ballistic movements are faster, easier and more
accurate than restricted or controlled movements.

◼ Less fatiguing as muscle only contract at

the beginning of the movement and are
relaxed during the rest of the movement.

◼ Eg: Swinging a hammer in driving a nail.

h) Work should be arranged to permit an easy and natural
rhythm wherever possible.

◼ Rhythm – regular repetition of a certain

cycle of motions.
◼ Uniformity, ease and even speed of work
are assisted by proper arrangement of
workplace, tools and materials.
◼ Less mental effort is required.
i) Work should be arranged such that eye motion is limited to
one comfortable area without requiring frequent focus change.
i. Principles of motion economy

◼ Divided into 3 categories:

1. The use of the human body.

2. The arrangement of the work place.
3. The design of tools and equipment.
Category 2. The arrangement of the work place

1. There should be a definite and fixed

place for all tools and materials.

◼ This encourage habit formation.

◼ Able to perform operation with least
conscious mental direction.
◼ No need for eyes to direct the hands.
2. Tools and material should be placed
first to reduce search activity.

◼ Preparation and initial set up can

eliminate delay and searching for
tools and material later on.
3. Gravity feed, box or container should be
used to deliver material.

◼ Gravity is free, use it.

4. Tool and material should be placed within the maximum
working area and as close as possible to the worker.

Forearm-only (preferable) and full-arm (satisfactory) reach limits for men and women in
working areas shown in the horizontal and vertical planes.
5. Material and tools should be
located to permit the best
sequence of motions.

◼ The material required at the start

of a cycle should be placed next
to the point of release of the
finished product (end of a cycle).

◼ Material should be arrange

according to sequence of task.
6. Drop deliveries or ejectors
should be used.

◼ Use gravity.

◼ Free the hands to do other

important activities.
7. Adequate illumination and good contrast should be
provided.

◼ Sufficient intensity for that particular task.

◼ Proper color and without glare.

◼ Light from the right direction.

 General lighting Localized-general lighting Local (or task)
lighting

Local (or task) lighting increases

Localized-general lighting uses light levels over the work and
General lighting provides fairly uniform
overhead fixtures in addition to immediate surroundings. Local
lighting. An example would be ceiling
ceiling fixtures to increase lighting lighting often allows the user to
fixtures that light up large areas.
levels for particular tasks. adjust and control lighting and
provides flexibility for each user.
8. Ergonomically designed chair and workplace
should be used.

◼ Height of workplace and

chair should fit user.

◼ Should permit good

posture.

◼ Should allow user to vary

posture.
i. Principles of motion economy

◼ Divided into 3 categories:

1. The use of the human body.

2. The arrangement of the work place.
3. The design of tools and equipment.
Category 3. The design of tools and equipment

1. Hands should be free from all work that may be done

better with a jig, fixture or a foot-operated device.
2. Two or more tool should be combined.

◼ Eliminate the need to change tools each time a different

one is required.
3. Load should be distributed in accordance to the inherent
capacities of the fingers.

◼ The fingers have unequal inherent capacities for doing

work.
4. Handles of tools should be designed so as to allow as
much surface area of the hands to be in touch with it.

◼ The more surface area in touch with a handle, the

stronger and more comfortable the grip will be.
5. Levers,hand wheels, and other controls should be located
such that it can be manipulated with the least change in
body position and the greatest mechanical advantage.
ii. Poka Yoke (Mistake proofing method)

◼ Introduced by Shingeo Shingo in the 80s.

◼ Poka-Yoke device is any mechanism that either stops a

mistake from occurring or make it so obvious at a glance.
The concept behind poka-yoke is :

◼ Error occurs due to mistake made by workers and defect

occur because the error is ignored.

◼ Thus, error will not change to defect if it is detected and

eliminated before the defect occur.
Poka Yoke Example in Automotive

Collision warning feature Lane assist feature

Poka Yoke Example in Electronic

USB cable can Washing machine is

only enter facing Child safety lock on water
automatically locked
one side purifier
during spin mode
Poka Yoke Example in Nature
•Coughing is a natural reaction
that prevents the error of foreign
bodies from entering into the
lungs. The sensitive wall linings
of the respiratory tract detect
and eject minute particles
through coughing.
Poka Yoke Example in Food

• No need to shake it Upside-down

• No messy residue on the cap tomato ketchup
• Minimizes the runny liquid
There are opportunities for Poka-Yoke devices
everywhere, turn your ingenuity and creativity loose
and challenge them to find places to eliminate
defects, increase safety, reduce problems and
confusion, etc.
SMED (Single-Minute Exchange of Die)

▪ Developed by Shigeo Shingo in 1980s.

▪ A systematic approach to reducing machine set-up time.
▪ To convert as many machine set-up time (changeover)
steps as possible to “external” (performed while the
equipment is running).
▪ Machine set-up consists of:
Extract tool Change to Adjustment & Trial run
new tool correction
Examples of SMED:
◼ Improve the availability of material.
By using large stackable containers so that more material can be
placed nearer to the production line.

◼ Increasing activity while machine is operating.

Preparation work is conducted while machine is running such tools
set-up and presetting.

◼ Provide additional equipment.

Machine can use one equipment / tool while the other is being
serviced or repaired.
For many people, changing For a racing car pit crew,
a single tire can easily take changing four tires takes
15 minutes. less than 15 seconds.
Some restaurants offer three menus
– breakfast, lunch and dinner.
Steps to SMED:
1. Identify the types operations:

▪ Unnecessary operation
▪ Operation that MUST be done when machine stops
(internal set-up).
▪ Operation that can be conducted when machine is running
(external set-up)
2. Eliminate unnecessary operation.
Change internal set-up to external set-up.
3. Simplify assembly and clamping.
4. Reduce adjustment and trial runs.
5. Work together.
Benefits:
1) Lower Manufacturing Cost: faster changeovers mean less equipment
downtime
2) Smaller Lot Sizes: faster changeovers enable more frequent product
changes
3) Improved Responsiveness to Customer Demand: smaller lot sizes
enable more flexible scheduling
4) Lower Inventory Levels: smaller lot sizes result in lower inventory
levels
5) Smoother Startups: standardized changeover processes improve
consistency and quality
Design For Manufacture and Assembly (DFMA)

◼ An approach where design of a product is analyzed and

modified to simplify the manufacturing and/or assembly
process.

◼ DFMA is applied at the design stage as this is where the

actual cost of a product is determined by the designers.
DFMA achieved its objectives by:
1. Reducing the number of components in a product.
- save material (less component) and time (faster to assemble)

Spot welded panels (many Front end module

individual panels) (one assembly part)
DFMA achieved its objectives by:
2. Simplify product design
A simple design is usually easier to process, assemble and
produce.

Bolts can be inserted in any orientation

(i.e. the symmetry plate)
 Assembly location
Assembled from only
visible and easily
one side
accessible
DFMA achieved its objectives by:

3. Using modular assembly approach.

▪ The assembly process is divided

into a few modules.
▪ Each module is simultaneously
assembled before finally
assembled into one product.
▪ Faster than if the product is
assembled in series.
DFMA achieved its objectives by:
4. Using self locating characteristics
This reduces the activities of alignment or finding the point of
assembly.

Self Locking Screws No Washer Needed

Design For Disassembly and Recyclability

◼ A concept where a product is designed for ease of

disassembly and recyclability.

◼ Disassembly is usually required for product

maintenance and sustainability.
The engine splash shield design was improved to allow for tool
extension to be used while accessing the washer tank fastener
 The undercover was redesigned to avoid radiator coolant splashing onto
the undercover while draining the radiator coolant underneath the vehicle
The fuse boxes are visible underneath the
steering assembly
The air-conditioner blower motor is easily replaced without
removing the instrument panel (dashboard) assembly
 Basic Fixture Design

◼ Specialized tooling can save cost in industry.

◼ Without it :
• Labour cost increase
• Product cost increase
• Interchangeability decrease
• Quality decrease
 Group of Tools
◼ Material removing – saw, mill, lathe.
◼ Assemble material – welders, glue dispenser,
riveters.
◼ Assure accuracy – rulers, gauges, calipers.
◼ Holding devices (fixtures) – vices, clamps.
 Fixture
◼ To hold workpiece as it is being
processed, moved, assembled or
inspected.

◼ To guide workpiece to be in the right

position or orientation.

◼ Essential in effort to move to

automation.
Components of Fixture
◼ Fixture may contain one or more of these:

1. Frame
• base to hold all the remaining
components.
• must be strong enough to hold
workpiece, fixtures and process.
Typical beginning of a fixture design layout. First the part is traced onto the drawing,
and then the fixture frame is started. As the design progresses, the fixture designer
will develop the components which will fill up the gap.
2. Locators
To locate workpiece onto the frame in a position most
convenient for the operation and the operator.
The second step in designing the fixture is the addition of locators to position the part
in the fixture. Fixture design usually progresses from back to front, starting with the
part and designing the fixture around it.
3. Clamps
• To hold workpiece to the
locator.
• Select the appropriate type.
• Examples; g-clamps, clip, bolt
and nuts.
As the fixture design continues to develop from the part outward, the pressure foot
and then clamp are added. This particular pressure foot is specially made to fit the
contour of the part.
4. Bushing
• As a guide for tools to perform their appointed task.
• Guiding ensure absolute accuracy and consistency
of the manufactured part.
Guide bushing and other fixture components are continually added to the part as
needed before mounting provisions are made for them. Here we have located our
bushing to guide a tool that will operate on the workpiece.
5. Brackets
• To hold components in the required position.
Brackets are added next to mount all of the existing fixture components. Notice the
addition of a “template drop assembly” at this point. This is specialized type of
bracket, which is available commercially, to allow other fixture components mounted
to it to be swung out of the way. This will help ease loading and unloading of the part.
6. Fasteners
• To hold all the other components together.
• Example; screws, bolts & nuts, pins, keys and
adhesives.
 Other Considerations in the Design of Fixture.
1. Fixtures must not interfere with the process.
– Should facilitate process
Fixture component located
away from operators

Gas
welding
torch
– Should not effect process

Weld

Fixture
components
set back

Fixture components contacting the workpiece should be located.

Always allow ample room for operator to perform the job easily.
 – When involve moving parts check for crash

The clamp appears to crash with the template drop assembly, bushing, and
bracket. However, since the clamp would normally close before and open
after the template drop assembly, these two devices can be “sequenced” to
operate in this location without being in a crash condition.
2. Use standard components whenever possible.
– Cheaper to buy standard components that to custom built.

G-clamp Adjustable wrench Grinder

Wall storage tool board / tool rack
Examples of standard components.

Toggle clamps are the workhorses of fixture clamp family. They are very
secure during their over-center locking handle mechanism; the separate
pressure foot is adjustable.
 Commercial item magnetic V-blocks are available in a
variety of sizes and fastener placements. V-blocks are only
used for holding cylindrical workpieces.
Thank you