INEN 255 Final pt. 1

Discuss Frederick Taylor's major contributions to methods engineering.

"Founder" of time study, Pig-iron experiment, and shoveling experiment.

State more fact on ADA for written part..

"limits Major life activity" - hearing seeing speaking, breathing "must be able to preform with or without reasonable accommodations"- doesn't put owner in hardship but helps with the job/work environment ( nothing expensive, or disruptive)

5 Steps to cost benefit Analysis

1. Determine what is changed (quality, safety) 2. Express changes in monetary units 3. Determine costs 4. Divide cost by benefits = ratio 5. SMALLEST ratio determines best alternative

List and describe the 3 types or inspection processes

1. Spot inspection: Periodic check to assure established standards are being met. 2. Lot-by-lot inspection: Sample are examined to determine quality of the production run or lot. Sample size depends on allowed defects and size of lot. 3. 100% inspection: Each and every unit is inspected..NOT 100% effective.

How many employees must a company have to hold ADA standards?

15 or more

Stay below ____% of maximum voluntary force

15%

What percent of people are at risk for CTDs?

15-20% of workers in key industires

What percent of occupation illness is associated with repetitive motion?

61%

Define machine coupling

A single worker operates more than one machine at a time.

What differences should be considered when designing tasks for workers?

Age, gender, and handedness differences

5th class movement:

Body motions(includes upper and lower extremity movements

Explain the purpose of a critical path

Bolded and represents the slowest route of a process.

Why should robots at least be considered for methods improvement?

Can reduce labor cost, consistently repeatable quality, predictable output, flexibility(re-programming), and safety considerations

Problems from Cumulative Trauma Disorders ?

Carpal tunnel Syndorme, tendonitis, trigger finger, white finger

Calculate required cycle times and production rates from a specified daily production goal.

Cycle time = time/per unit Production rate(single machine) = 1/ cycle time Production rate(total) = (1/cycle time)*(number of machines)

Explain why tolerances and specifications should be examined in operation analysis

Designers may incorporate specifications more rigid than necessary which can cause an increase in number of operations, assembly time, and rejection rates. Also, can become too liberal.

Compute the efficiency of a simple assembly line.

E = summation of SM/summation of AM * 100%

Major contributors to CTDs are..

Excessive force, Awkward/Extreme joint motions, High repetitions of same movement, Lack of sufficient rest

Dynamic strength data is not very situation-dependent.

False, is situation-dependent

Slower movements result in higher momentum.

False, lower momentum

Completely isometric task in industry are common.

False, uncommon

Less blood flow leads to:

Faster fatigue

3rd class movement:

Figer, wrist, and lower arm motions

2nd class movement:

Finger and wrist motions

1st class movement:

Finger motions

4th class movement:

Finger, wrist, lower arm, and upper arm motions

Discuss Frank and Lillian Gilbreth's major contributions to methods engineering.

Founders of modern motion study technique to established most efficient motion sequence.

Define the purpose crossover charts.

Helps in decisions where there may be tradeoff between two different tool vs their expected life

Provide 2 major objectives of methods, standards, and work design

Increase productivity, increase product reliability safely, and lower unit cost.

Name 2 professional organizations associated with IE and methods improvement.

Institute of Industrial Engineers (IIE), Human Factors and Ergonomics Society (HFES), and Ergonomics Research Society (ERS)

based off the crossover graph how would you explain you findings?

It cost the same at this point, So based off how many we want to make this is the tool we should use.

Which muscle group should be used for task requiring strength?

Large muscles, leg and trunk muscles

Provide reasons why balanced assembly lines are beneficial.

Less costly, and lead to better work morale.

What type of force should be used for precise movements or fine motor control?

Low force

Tell what operations could/should be improved based of the PERT chart

Methods improvements should be focused on operations along the critical path.

List corollaries associated with objectives of methods, standards, and work design.

Minimize time required to perform tasks, conserve resources/minimize cost, maximize health, safety, well-being of employees, protect the environment, and continually improve quality and reliability.

What class of movement is most efficient? Least efficient?

Most: 1st class Least: 5th class

What type of checklist is sufficient to use when analyzing a job?

Motion economy checklist

How do you perform a motion study and record associated data?

Motion studies should be done by simple visual analysis (modernly video recording) and record data on two-hand process chart.

________ is essential to smooth automatic task performance.

Natural frequency

Why is it better to eliminate an operation before trying to improve it?

No installation, no delay for development, no training required, and resistance to change is minimized.

Describe process layout and its advantages/disadvantages.

One type of plant layout, functional. Advantages: Grouping of similar facilities, appears neat/organized, promotes good housekeeping, easy to train new operators, and simplify job. Disadvantages: Long moves(possible backtracking between departments), and larger volumes of paperwork required to issue orders/control production between departments.

Describe product layout and its advantages/disadvantages.

One type of plant layout, straight-line. Advantages: Popular for mass production, and limit material handling cost. Disadvantages: Dissatisfied employees (salary differences), appears unorganized (poor housekeeping), difficult to find competent supervisors, and large initial investment.

Identify examples of synchronous and random servicing problems from problem wording and/or data provided

Operator has too many machines (machines idle for portion of work cycle) or too few machines (operator idle for portion of work cycle)

Compute proportion of machine hours lost in a random servicing problem.

P(M of N) x 8 hours= machine hours lost per machine. total hours lost/(# of machines x 8 hours)=total proportion of machine hours lost

Name 5 techniques that can be used to select a project for methods improvement

Pareto analysis, fish diagram, Gantt chart, PERT chart, and job/worksite analysis guide

Use the ranked positional weight of assembly line balancing to assign operations to work stations.

Positional weight= summation of estimated time for work unit(s) that proceeds Organize by positional weight (highest-lowest) Available time per work station= 480 minutes/required production per day Each work group must not exceed available time per work station.

If strength demand required for extended periods of time, you need to consider:

Psychophysical strength

What type of motions are preferred due to our joint configurations?

Rounded, continuous curved motions.

What type of work-rest cycles should be used?

Short, frequent, intermittent work-rest cycles

Explain the Hawthorne Effect.

Story: Increase in illumination.. increased productivity. Changed the lights without change in illumination still increased productivity.

Compute total expected cost to select best assignment of machines in a synchronous servicing problem.

TEC(N1)=[(l+m)(K1 + N1K2)]/N1 Total expected cost for each machine

What is a disability that would not be covered under ADA?

Temporary injuries aren't covered

Define/explain motion study.

The careful analysis of body motions employed in doing a job. Created by the Gilbreths to eliminate or reduce ineffective movements and facilitate speed effective movements.

Define productivity improvement

The increase in output per work-hour or time expended.

What can relieve some of the burden on hands?

The use of feet simultaneously.

Do not attempt precise movements or fine control immediately after heavy work.

True

Downward motions are more effective than upward due to assistance of gravity.

True

Motions should begin and end with both hands symmetrically and simultaneously.

True

Rest required to recover is a function of force exerted and holding time.

True

There is a typically a speed-accuracy tradeoff.

True

The "most important" question during operation analysis:

WHY?

What is the importance of the Hawthorne Effect method of improvement?

When people know they are being "advanced" the do better. Parabola effect in productivity. Short-term fix

Identify the appropriate symbols for operation process charts and flow process charts.

circle: operation square: inspection triangle: storage arrow: transportation D: delay

Explain why "Follow up" is so important.

ensure that installation was correct and keeps everyone "sold" on new method. May shed light on other necessary improvements.

First principle of motion is achieving the maximum muscle strength at the all range of motion.

false. ( midrange motion)..A task requiring maximum exertion should be designed to make sure the primary muscles involved are at their optimum position

The Gilbreths initiated what design of work?

motion studies and principals of motion

What is the purpose of the Americans with Disabilities Act (ADA)?

to outlaw discrimination in employment again a QUALIFIED individual with a disability(physical or mental). ( hiring, promotion, pay, job assignments)

Achieve maximum muscle strength with slow movements.

true

Muscle length can change from 50% (at contraction) to 180% (at complete extension) of its resting length.

true