Methods Engineering
- 1. METHODS ENGINEERING AND OPERATIONS ANALYSIS Methods engineering is the analysis and design of work methods and systems, including the tooling, equipment, technologies, workplace layout, plant layout, work environment and human capital management. Other names for methods engineering: •Work study •Work simplification •Methods study •Process re-engineering •Business process re-engineering •Continuous Improvements
- 2. OBJETIVES IN METHODS ENGINEERING •Increase productivity and efficiency •Reduce cycle time •Reduce product cost •Reduce labor content Other Objectives •Improve customer satisfaction •Improve product and/or service quality •Reduce lead times and improve work flow •Increase flexibility of work system •Improve worker safety •Apply more ergonomic work methods •Enhance the environment (both inside and outside the facility)
- 3. OPERATIONS ANALYSIS Study of an operation or group of related operations for the purpose of analyzing their efficiency and effectiveness so that improvements can be developed relative to specified objectives. Objectives in operations analysis •Increase productivity •Reduce time and cost •Improve safety and quality Methods engineering and operations analysis are very similar, except that methods engineering places more emphasis on design.
- 4. Can be divided into two areas: • Methods analysis and Methods design. • Methods analysis is concerned with the study of an existing method or process. HOW TO APPLY METHODS ENGINEERING Systematic Approach in Methods Engineering • Has its basic in the scientific method used in science, research and development, engineering design, and other problem areas. • The systematic approach in methods engineering consists of the steps described below.
- 5. Step 1: Define the Problem and Objectives. The problem in methods engineering study may be low productivity, high cost, production cycle time , standby, inefficient methods, or the need for a new method or a new operation. The objective is the desired improvement or new methods design. Possible objectives are to increase productivity, reduce labor content and cost, improve safety, or develop a new method, new operation or improve information flows .
- 6. Step 2: Analyze the Problem. Data collection and analysis activities for the type of problem being studied. Activities often used in this step include the following: • Identify the basic function of the operation. • Gather background information. • Observe the existing process or observe similar processes if the problem involves a new work design. • Collect data on the existing operation and document the details in a format that provides itself to examination. • Conduct experiments on the process. • Develop a mathematical model of the process or utilize an existing mathematical model. • Perform a computer simulation of the process. • Use charting techniques.
- 7. Step 3: Formulate Alternatives. There are always multiple ways to perform a task or accomplish a process, some of which are more efficient and effective than others. • The purpose of this step in the problem-solving approach that is not to identify the best alternative but to formulate all of the alternatives that are feasible. Step 4: Evaluate Alternatives and Select the Best. This step consists of a systematic assessment of the alternatives and the selection of the best solution among them, based on the original definition of the problem and objectives.
- 8. Step 5: Implement the Best Method. Implementation means installing the selected solution: introducing the changes proposed in the existing method or operation, or installing the new method or process. • This may involve pilot studies or trials of the new or revised • Implementation also includes complete documentation of the new or revised method and replacement of the previous documentation Step 6: Audit the Study. Perform an audit or follow-up on the methods engineering project. • How successful was the project in terms of the original problem definition and objectives? • What were the implementation issues? • What should be done differently in the next methods engineering study? For an organization committed to continuous improvement, answers to these kinds of questions help to fine-tune its problem-solving and decision-making skills.
- 9. TECHNIQUES OF METHODS ENGINEERING & BASIS DATA COLLECTION & ANALYSIS TOOLS • Data gathering and statistical tools • Charting and diagramming techniques • Motion study and work design • Facility layout planning • Work measurement techniques • New approaches • Histograms • Pareto charts • Pie charts • Check sheets • Defect concentration diagrams • Scatter diagrams • Cause and effect diagrams • Hypothesis testing
- 10. TECHNIQUES OF METHODS ENGINEERING & BASIS DATA COLLECTION & ANALYSIS TOOLS • Data gathering and statistical tools • Charting and diagramming techniques • Motion study and work design • Facility layout planning • Work measurement techniques • New approaches • Histograms • Pareto charts • Pie charts • Check sheets • Defect concentration diagrams • Scatter diagrams • Cause and effect diagrams • Hypothesis testing