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Improve The Operation

EFFECTIVE & INEFFECTIVE WORKER MOVEMENTS

In “Time the Operation” we examined the build up of a study using a technique of defining the job by splitting it into various elements. Once we have done this we need to ask “how do we check the effectiveness of the operation?”  In the case of an operation we need a method or check-sheet to recognize non-value adding or restricting activities.

The technique of reviewing INEFFECTIVE WORKER MOVEMENTS is the basic form of the analysis. It is an easily applied approach to recognizing and improving the operation. To apply this however we must once again acquire the ability to see the continuous operation in the form of a series of discreet units or physical movements. We can then evaluate each movement and test for its effectiveness.
Common Ineffective Movements: -
Hazardous Movement STOP THE JOB AND REPORT THE SAFETY ISSUE IMMEDIATELY
Blind Movement Movements made in positions not visible to person performing the job.
Hold Temporary halt of movement.
Awkward Movement Movements, which are difficult or require unusual body positions.
Change of Control Pick up in L-Hand change to R-Hand - part should be positioned so that it is possible to pick up in R-Hand.
Complicated Movement Movement requiring high manual dexterity.
High Effort Movement requiring above average force or leverage etc.
Wait Waiting, ready to start the following activity.
Eye Directed Movement Movement can only be completed when eyes have determined exact location.
Long Movement Any movement that can be shortened without it becoming awkward.
Tugging or Pulling Pull or strain at an object.
Positioning A series of repetitive short distance movements around a proper location before the part is finally located. (needle and thread)
Fumbling

Failure to grasp object securely and re-grasp required.   (greasy parts, awkward shaped parts etc)

Loss of Control Object put down and then picked up again almost immediately to perform next task. (hand start screw, pick up screwdriver, tighten screw, repeat operation - hand start all screws then tighten screws)
Obstructed Movement Movement detour from straight line to avoid an obstruction.
Unnecessary Movement Additional movements beyond what operation requires. (usually caused by wait and person keeps busy out of habit)

You will see that this check sheet focuses upon the person’s actions and so far we have not looked at a person interacting with a machine or group of machines.  It is well worth the time to briefly review this list against what is happening before jumping into trying to completely re-organize / re-engineer or re-tool an operation.                   

BUT before you do anything after checking safety issues ASK - IS THIS OPERATION ADDING VALUE?  If it is not, it should be ELIMINATED if possible.  If it is adding value then ASK – CAN WE FLOW THE OPERATION.  HEY WE’VE JUST STARTED THINKING LEAN MANUFACTURING!!!  MORE OF THAT LATER.
Improve the operation - ACT BREAKDOWN FORM