EN412300 Industrial Work Study and Productivity Improvement

Activity Analysis

Asst. Prof. Sirawadee Arunyanart

Department of Industrial Engineering
Khon Kaen University
 Man–Machine Chart
▪ A man-machine chart graphically represents the relationship between the manual
work performed by one or more operators and one or more machines involved in a
manufacturing process.
▪ Given the different work steps required in a production process to load, operate,
and unload machines in conjunction with the process times of the machines
themselves, the man-machine chart is used to determine the highest production
level that can be achieved given the resources available.
▪ This process usually involves performing as much manual work as possible internal
to the machine cycles, i.e., when the machine is running, so that when the machine
cycle is complete, the production generating machine cycle can be restarted again
with as little downtime as possible.

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▪ The man-machine chart is in the form of a bar chart, in which the axis displays the time
scale of the operation of man and machine.
▪ A color bar is used as a symbol to represent the individual activities of man and machines.

A Man or machine working independently (independent activity)

Man and machine working together (joint activity)
No activity (idle time)

How to draw man-machine chart:

1. Develop the chart into columns according to the number of
men (operators) and machines.
2. The column of man is on the left, and the machine is on
the right.
3. Divide time slots for each column.
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4. Draw the color bar symbol on the chart.
 Symbols for analyzing activities of man and machine
Symbol Type of work Type of activity Detail Example
Activities that each man or Man
machine performs -work preparation
Independent independently without -doing work
Operation
activity interaction. -inspection
Thus, the sequence of Machine
activities can be rearranged. -machine running
Activities that man must - Taking the workpiece
perform with machine(s) or with out of the machine
Operation Joint activity others. Thus, the activities - Setting up the machine
cannot be rearranged - Man and control
independently. machine
Man does not work, does not
have activities to do, or the
Non-operation Idle time
machine is not being run or
operated.
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 Step for analyzing man-machine chart
Step 1: Record the time of each type of activity (independent activity, joint activity, or no activity)
performed by man or machine.
Step 2: Write down the time and activity symbol on the man-machine chart to show the time of
each activity performed by man and machine. The activities that are recorded should
complete one work cycle.
Step 3: Calculate the current cycle time, proportion of work, and idle time of man and machine.
Step 4: Analyze work activities thoroughly to find out the independent activities that can be
rearranged in order to reduce waiting time or eliminate some working steps.
Step 5: Develop new work methods and record activities on a man-machine chart to keep as a
standard of operation.
Step 6: Calculate the new cycle time, proportion of work, and idle time of man and machine.
Step 7: Calculate the appropriate number of machines for the work of man, and record the activities
of man and machines on a man-machine chart.
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 Determining the number of machines suitable for
the work of man
Let: a = Working time of man, including independent and joint activities
T = Total cycle time
n/ = The number of machines per one man (integer)

1) Calculate the appropriate number of machines for one man

T
n =
a

Case 1 The value of n/ is an integer: the number of machines per one man is n/
Case 2 The value of n/ is not an integer: choose between n or n+1 machines
(n < n/ < n+1) by following step 2) and 3)
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2) Calculate the proportion of expense (Cost analysis)

Let: Co = Wage of man (baht per hour)

Cm = Machine operating cost (baht per hour)
Co
The proportion of expense: E=
Cm
Yn
3) Calculate the ratio of to determine the number machines
Yn +1
Yn E+n n
= *
Yn+1 E + n + 1 n

If choose n+1 machines

choose n machines 7
 Start

Value of T and a

is integer
Wage of man per hour (Co)
n/ Machine operating cost per hour (Cm)
machines

n+1 n
machines machines

Stop 8
Determining idle time of man and machine

Let: i = Idle time

n = The chosen number of machines

i n
= 1−
T n

If i > 0, man is idle

i < 0, machine is idle

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 Example
A motorcycle factory wants to buy a new CNC machine to manufacture a product according to the desired
shape. The factory has to determine the number of machines and workers necessary to meet the amount of
production required. The details of various activities are as follows:

Sequence Detail Duration

1 Worker takes the workpiece from the tray to place it in front of the machine. 20 sec.
2 Put the workpiece into the machine. 30 sec.
3 Machine is in the process of automatically making product. 3 min.
4 Worker takes a product out of the machine. 20 sec.
5 Worker checks the finished product. 30 sec.
Wage of operator per hour 100 baht
Machine operating cost per hour 150 baht
Question :
1) Draw a man-machine chart of the current method and analyze the work rate and idle time of the worker
and machine.
2) Make improvements and draw a man-machine chart of the improved method. Then calculate the rate of
work and idle time of the worker and machine.
3) Calculate the number of machines that are suitable for workers. Then draw a man-machine chart to show
the operation of workers and machines.
Step 1: Record the time of each type of activity (independent activity, joint activity,
no activity) performed by man or machine.

Type of activity
Sequence Detail Duration Independent Joint Idle

Worker takes the workpiece from the tray to

1 20 sec.
place it in front of the machine.
2 Put the workpiece into the machine. 30 sec.
Machine is in the process of automatically
3 3 min.
making product.
4 Worker takes a product out of the machine. 20 sec.

5 Worker checks the finished product. 30 sec.

✓ worker
✓ machine
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Step 2: Write down the time and activity symbol on the man-machine chart to show the time of each
activity performed by man and machine. The activities that are recorded should complete
one work cycle.
Man Machine
Step Time (s) Step Time (s)
Take the workpiece
from the tray to place Idle
in front of the machine Step 3: Calculate the current cycle
Put the workpiece into Put the workpiece into time, proportion of work,
the machine the machine and idle time of man and
machine.
Machine is in the Man Machine
Wait for the machine process of
automatically making Idle time 180 sec 50 sec
product
Working time 100 sec 230 sec
Take a product out Take a product out Total time 280 sec 280 sec
of the machine of the machine
% working time 35.71 % 82.14 %
Check the finished % idle time 64.29 % 17.86 %
Idle
product

Step 4: Analyze work activities thoroughly to find out the independent activities that can be
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rearranged in order to reduce waiting time or eliminate some working steps.
 Step 5: Develop new work methods and record activities on a man-machine chart to
keep as a standard of operation.
Man Machine
Step Time (s) Step Time (s)
Current cycle time = 280 sec
Put the workpiece into Put the workpiece into
the machine the machine
Improved cycle time = 230 sec

Take the workpiece from

the tray to place in front
of the machine
Step 6: Calculate the new cycle time,
proportion of work, and idle
Check the finished
product time of man and machine.
Machine is in the
process of Man Machine
automatically making
product Idle time 130 sec 0 sec
Working time 100 sec 230 sec
Idle
Total time 230 sec 230 sec
% working time 43.48 % 100 %
% idle time 56.52 % 0 %
Take a product out of Take a product out of
the machine the machine 13
Step 7: Calculate the appropriate number of machines for the work of man, and record activities of
man and machines on man-machine chart.
From man-machine chart: Working time of operator (a) = 100 sec
Total cycle time (T) = 230 sec
• Find n/
T
n =
a

n/ = 2.3 which is not integer

From n < n/ < n+1 so n = 2 and n+1 = 3
• Find E

• Find Yn
Yn +1

< 1 choose n machines

Therefore, the number of machines that is suitable for one worker is 2 machines. 14
 Man Machine 1 Machine 2
Time Time Time
Step (s) Step (s) Step (s)
Put the Put the Machine 2 is in the
workpiece into workpiece into process of
automatically making
machine 1 machine 1 product
Take product from Start machine 1 Take product
machine 2 from machine 2
Put the Put the
workpiece into workpiece into
machine 2 machine 2
Start machine 2
Check the finished
products from both Machine 1 is in
machine 1 and 2 the process of
automatically
Previous cycle making product
Take two workpieces Machine 2 is in
from the tray to the process of
place in front of
machine 1 and 2 automatically
Next cycle making product

Idle

Take product from Take product from

machine 1 machine 1 15
 Man Machine 1 Machine 2
Idle time 30 sec 0 sec 0 sec
Working time 200 sec 230 sec 230 sec
Total time 230 sec 230 sec 230 sec
% working time 86.95 % 100 % 100 %
% idle time 13.05 % 0% 0%

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 Exercise
A factory wants to buy a new CNC machine to manufacture a workpiece according to the desired
shape. The factory has to determine the number of machines and workers necessary to meet the
amount of production required. The details of various activities are as follows:

Sequence Detail Duration

1 Worker takes the workpiece from the tray to place it in front of the machine. 2 min
2 Put the workpiece into the machine. 3 min
3 Machine is in the process of automatically making product. 15 min
4 Worker stops the machine to adjust the position of the workpiece. 3 min
5 Machine is in the process of automatically making product. 15 min
6 Worker removes product from the machine. 3 min
7 Worker checks the finished product. 2 min
8 Pack the product into the box. 2 min

Wage of operator per hour 100 baht

Machine operating cost per hour 150 baht
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Question :
1. Draw a man-machine chart of the current method and calculate the current cycle
time, work rate, and idle time of the worker and machine.
2. Make improvements and draw a man-machine chart of the improvement method.
Then, calculate the new cycle time, rate of work, and idle time of the worker and
machine.
3. Calculate the number of machines that are suitable for one worker. Then draw a
man-machine chart to show the operation of workers and machines.
4. If the factory needs a production capacity of 390 pieces per hour, how many
machines and workers does the factory require in order to gain maximum utilization
of the machines?

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