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1、IndustrialEngineering WorkDesign PreparedbyKenLeung WorkDesign MethodsImprovementErgonomicsAssemblylinebalancingPrinciplesofmotioneconomyVarioustypeofchartsWorkmeasurementTimestudyActivitysampling Ergonomics DefinitionApplyinformationabouthumanbehavior abilities limitations andothercharacteristicsto
2、thedesignoftools machines system tasks jobs andenvironmentsforproductive safe comfortable andeffectivehumanuse Objectives Toenhancetheworkeffectivenessandefficiency IncreasedconvenienceofuseReducederrorsIncreasedproductivityToenhancehumanvalues ImprovedsafetyReducedfatigueandstressIncreasedcomfortGr
3、eateruseracceptanceIncreasedjobsatisfactionImprovedqualityoflife TwelvePrinciplesofErgonomics 1 Workinneutralpostureseg Wristrestsforkeyboardandmouse 2 Reduceexcessiveforceseg Boxeswithhandholdsforcarrying ErgonomicsPrinciples 3 Keepeverythingineasyreacheg Keepmaterialswithinthe reachenvelope ofthea
4、rm ErgonomicsPrinciples 4 Workatproperheightseg Heavyworkshouldbeperformedlowerthanelbowheight precisionworkshouldbehigher ErgonomicsPrinciples 5 Reduceexcessivemotionseg Usepowerscrewdriver 6 Minimizestaticloadeg Useapencilgrip ErgonomicsPrinciples 7 Minimizepressurepointseg Providepaddingforhandgr
5、ips 8 Provideclearanceeg Providevisualaccess cartondelivery ErgonomicsPrinciples 9 Move exercise andstretcheg Changeadjustmentsofthechairforthosesitforalongtime 10 Maintainacomfortableenvironmenteg Considerthequantityandqualityoflightattheworkstation ErgonomicsPrinciples 11 Makedisplaysandcontrolsun
6、derstandableeg Clickingiseasierthanmemorizingcommands 12 Reducestresseg Designtasktofitpeople Anthropometry DefinitionMeasurementofthehumanbodyanditsbiomechanicalcharacteristics Biomechanicalreferstothemechanical machine like capabilitiesofthehumanskeleton muscularsystems Measuresoursizesandhowwemov
7、eandmoveeasily NeedofAnthropometryWearenotinthesamesize Poordesignformechanicalabilitiesofthehumanbodycanleadtodiscomfortorinjury Eg Heightofkeyboardforacomputer AnthropometricData Staticmeasures areusedtodeterminesizeandspacingrequirementsofworkspace eg height weight seattoelbowheight andwingspan D
8、ynamicmeasures areusedtomatchthedynamiccharacteristicsofcontrolstouser eg rangeofmotionforvariousjoints andstrengthoffingers AnthropometricData Theanthropometricdataisperformedinnormaldistribution 50thpercentileisthemostofthepopulation 5thand95thpercentilesaretheextremes Howtouseanthropometricdata D
9、esignforextremesAstandardistodesigntofit5thor95thpercentilesofthepopulation Designformostofthepopulation50thpercentileofthepopulationshouldbeused MakethedesignadjustableThedesigncanfit5thto95thpercentilesofthepopulation Examples AssemblyLineBalancing Equalizeworkloadamongtheassemblies Identifythebot
10、tleneckoperation Establishthespeedoftheassemblyline Determinethenumberofworkstations Determinethelaborcostofassembly Establishthepercentworkloadofeachoperator Assistinplantlayout Reduceproductioncost TableforAssemblyLineBalancing Majoritems operationdescription R value cycletime numberofstations ave
11、ragecycletime percentload hoursper1000pieces andnumberofpiecesperhour Anexampleisasfollows 1 2 3 4 5 6 7 ItemsforAssemblyLineBalancingTable R value plantrate Takttimeortimeneededtoproduceaproduct effectiveproductiontime requiredproductionvolume Cycletime Standardtimeforoperation Collectedfromtimestu
12、dy stations Cycletime R valueAveragecycletime Cycletime stations 1 2 3 4 ItemsforAssemblyLineBalancingTable Load Tellhowbusyeachworkstationiscomparedtothebusiestworkstation Load Avg cycletime highestavg cycletime Highestavg cycletime 100 station isthebottleneck 100 stationisreducedby1 thenwewillsave
13、1 forallstations Thelesspercentloaded themoredesirabletobesub assembledorcombined 5 ItemsforAssemblyLineBalancingTable Hours 1000 Thehoursper1000unitsproduced Choosethebottleneckstation Avg cycletime 60mins x1000Formorethanoneworkersatthestation hrs 1000 workersx hrs 1000 ofbottleneck Becauseeveryon
14、eonanassemblylinemustworkatthesamerate Pcs hr Numberofunitsproducedhourlybyoneworkeratthestation 1 Hrs 1000 X1000 6 7 ImproveAssemblyLineBalancing CalculatetheLineBalancerateReducingthebottleneckstation Combiningthebottleneckstationwithanoperationinfrontorbehind Combiningotheroperationstoeliminateon
15、eofthem Example OriginalLineBalance Producingnewplasticcharger 1200unitsper8 hrsshift with300minseffective Example OriginalLineBalance Originallinebalancerate totalcycletime highestcycletimestationxno ofstations 1 354 0 25x7 77 4 Pcs hr 60 0 25 240Improvethebottleneckstationbycombiningwithanoperatio
16、ninfrontorbehind Combineandeliminateworksteps Re designthejig fixture Operations Bottleneckor100 loadstation Example ImprovedLineBalance Improvedlinebalance Example ImprovedLineBalance Improvedlinebalancerate totalcycletime highestcycletimestationxno ofstations 0 878 0 229x4 95 9 Pcs hr 60 0 229 262Increaseinoutputwithdecreaseinno ofworkstations Operations Bottleneckor100 loadstation PrinciplesofMotionEconomy Guidelinesforefficientandeffectiveworkstationdesign Summarizedto4majorelements Eliminat
