Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
: 16
:7
: December 3, 2014
METHOD ENGINEERING
OPERATION PROCESS CHART (OPC), PARETO, & FISHBONE
DIAGRAM
A. DESCRIPTION
Operation process chart (OPC) is a diagram that illustrating the steps of
process that will be undergone on the raw material and operating sequences
examination from the beginning into finished product or as a component intact, and
also contains the necessary information forfurther analysis. So in an operation process
chart, noting only occur on operating activities and examination, but sometimes at the
end of the process is recorded on the storage (Sutalaksana, 2006).
Pareto diagram is a method of organizing a mistake, problem or defect to help
focus on problem-solving efforts . This diagram is used for classifying problems
according to cause and symptoms. The problem will be sorted according to priority or
importance using a bar chart/histogram.
Diagram of fishbone/cause and effect diagram is a tool for quality control and
developed by Kaoru Ishikawa. The diagram is displayed in the form of a graph that
illustrates the relationship of the effects (the issue) with a potential case. Diagram of
fishbone is used to process try or devise an activity. Diagram of fishbone can help
stimulate rational thinking.
Purpose of Practicum
1. Understand the process of making and Assembly product.
2. Being able to determine the sequence of work/production process and designing
the Operation Process Chart (OPC) of a product.
3. Able to identify the cause of the damage of a product.
4. Pareto diagram is capable of designing and fishbone.
B. INPUT AND OUTPUT
input:
a) Data raw material required for production
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
: 16
:7
: December 3, 2014
b) Data production process
c) Product assembly sequence data
output:
a) Diagram of Operation Process Chart (OPC)
C. REFFERENCES
Sutalaksana, Iftikar.Z, Teknik Perancangan Sistem Kerja, Edisi Kedua, ITB,
Bandung, 2006.
Barnes, Ralph M., Motion and Time Study Design and Measurement of Work,
Seventh Edition, University of California, Los Angles, 1990, 61 pages.
Maynard, B H., Industrial Engineering Handbook, Third Edition, McGraw-Hill Inc.,
1971.
D. THEORY
1. Work map
Work Map is one of the tools to systematically communicate broadly and
simultaneously through the maps of this work we can get the information needed to
improve a work method (Maynard, 1971).
Study on a map work in improving the working methods of the production
process will more easily implemented andimprovements are possible, such as:
eliminate unnecessary operation , an operation combining with others,find systematic
work / production process better, determine economical engines, eliminating the delay
time between operations, and so on. Basically, all these improvements are intended to
reduce total production costs. Thus , this map is a good tool to analyze a job making it
easier to plan repair work.
2. Kind ofWork Map
Basically work map can be divided into two major groups based on their
activities, there are:
A. The maps are used to analyze work of whole activities.
a) Operation Process Map ( OPC )
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
: 16
:7
: December 3, 2014
b) Process Flow Map ( Process Flow Chart )
c) Working Group Process Map
d) Flow Diagram
B. The maps are used to analyze the work of local work activities .
1. Map of Labor , and Machines
2. Map of Left Hand and Right Hand (Micro motion Study)
3. Symbol On Work Map
In 1947, the American Society of Mechanica Engineer (ASME) standard
makes the symbol consisting of:
Table 7.1 Symbol Type of Activities
SYMBOL
ACTIVITY
DEFINITION
operations that occur when changing
workpiece properties, both physical and
chemical.
OPERATION
Operation
is
the
most
common activities in a process that
normally occurs in a machine or work
station.
inspection activities of the workpiece or
equipment, in terms of both quality and
INSPECTION
quantity. This symbol is used to conduct
an examination of a particular object to
conform to established standards.
Transport activity occurs when an object
is moved from one location to another.
TRANSPORTATION
When the displacement movement that
is part of the operation / inspection as
well as the loading / unloading of the
material then it is not including transport
Fakulty
Department
Practicum
SYMBOL
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
ACTIVITY
: 16
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: December 3, 2014
DEFINITION
activities.
Delay
occurs
when
a
material,
workpiece, the operator or facility is
stop working or did not have any
DELAY
activity. Usually forced to wait or
abandoned objects while until one day
done / required return.
workpiece store activities for longer
periods of time. If the workpiece will be
STORAGE
taken back usually perform specific
licensing procedures.
events that occur when operating and
DOUBLE ACTIVITY
inspection
activities
performed
concurrently or in a place object.
4.
Operation Process Chart (OPC)
4. 1. Definition of Operation Process Chart (OPC)
Operation Process Chart is a tool for recording a process in the same way, as a
means to better understand and improve the process. Operation chart usually begins
with the raw materials entering the factory and follow through each step, such as
storage transportation, inspection, machine operation, and assembly to be a part of a
unit or units to be assembled (Ralph M. Barnes, 1990).
The information that can be obtained in the operation process map is as follows:

Raw materials and supporting materials needed (represented by arrow
horizontally)

Operations required in each component or part of the raw material
(represented in the circle)
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date

The time required in the process

Machinery or tools used in the operation

Scrap (furious) generated (dumped) in the process
4. 2.
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: December 3, 2014
Function of Operation Process Chart
With the information that can be recorded through Operation Process
Chart, can be obtained following benefits:

Can determine the need for machinery and budgeting.

Can estimate the demand for raw materials (taking into account the
efficiency in each operation / inspection)
4. 3.

As a means to determine the layout of the factory

As a tool to carry out repair work the way that is being used

As a tool for job training
Principal of Making OPC
To be able to describe the OPC, there are several principles that should
be followed as follows :
1. First of all on the top line expressed is known as head “Operation
Process Map " followed by other identification such as : object name ,
the name of the map maker, date mapped how long or how now , map
number and picture number.
2. Material to be processed is placed above the horizontal line , which
indicates that these materials enter into the process.
3. Symbols are placed in the vertical direction, which shows the change
process.
4. Numbering of an operation is assigned sequentially ssuai the sequence
of operations required to manufacture these products , or in accordance
with the process.
5. Numbering of an independently administered examination activity and
the principle is the same with the numbering for operations.
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
: 16
:7
: December 3, 2014
In order to obtain a good picture Operations Map , the most widely usually
products require operation, should be mapped first, then mapped to a vertical line
on the right page of the paper .
Figure7.1 OPC Making Principle
Description:
W = The time required for an operation or examination, usually within hours
O-N = Number sequence for the operations
IN = Serial number for the inspection activities
M = Indicates machine or places where activities are carried out
The results of the OPC can be used to analyze and improve the production
process of a product because of the work map obtained:
a. Stream in chronological order process experienced by raw materials and
supporting materials as well as the type of components to packaging processes.
b. Logical arrangement of the entire sequence of operation and inspection process.
c. The necessities of engine needs to be made budgeting.
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
: 16
:7
: December 3, 2014
d. The necessities ofraw material needs to take into account the efficiency of each
operation.
e. Production linkages between components of the product.
f. Processing time / highest operation of the components
5. Working on OPC
Figure7.2 Product of Teak Chair
 Determine the main material
 Describe the process of production of the material symbols follow ASME (operation /
transportation / inspection / delay / storage)
 Give the number of operations (NO) in the operation symbol
 Give the number of inspection (IO) in the inspection symbols
 Embed the name of the machine and machining time (if any)
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
SANDARAN PAPAN JATI
ALAS PAPAN JATI
KAKI PAPAN JATI
: 16
:7
: December 3, 2014
BESI PROPIL
Figure 4.3. Operation Process ChartExample
Figure 7.3 Operation Process Chart (Sutalaksana, 2006)
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
: 16
:7
: December 3, 2014
Components:
1.Components of the framework, made of steel profiles
2.Components of the chair seat, made of teak wood
3.Components seat, made of teak wood
4.Component pedestal where writing, made of teak wood
In this case, the component order is the main component, so that the operation
the process map is mapped to the right of the paper. The time spent in each activity,
usually expressed in hours, although not binding.For the examination was not given
a specific time. In this case the examiner considered able to work in fixed / regular.
More details about the operation and inspection to manufacture teak chair is as
follows:
Operation 1. Iron propyl average length of 6 meters was measured according to
the size of the order-order the chair.
Operation 2. Once the appropriate size, then to iron profile is then cut using a
hacksaw.
Operation 3. For purposes of the merger later, there are some parts of the profile
that needs to be drilled in accordance with the size of bolt, using a
drilling machine.
Operation 4. The profile section is cut and hollowed, smoothed by grinding and
the overall profile aside from dirty-dirt rust by sanding.
Inspection 1 Profiles that have been cut in size once again checked so when the
spliced-connect with the weld does not change the balance
(comfortable) seats.
Operation 5. Profiles that have been cut spliced-connect with carbide welding,
forming the framework of the chair.
Inspection 2 The results of the foundation inspected, there may be parts that have
not been connected properly or otherwise any part of the excess
welds, so it needs to be filed / disposed.
Operation 6. Once the order is completed chair, then the frame is painted using
spray paint.
Operation 7. Teak wood planed boards formed so as to achieve the appropriate
thickness and smooth enough.
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
Operation 8.
: 16
:7
: December 3, 2014
Board is already quite smooth drawn using the mall to make the seat
according to the desired shape.
Operation 9. Having measured (drawn with stationery), then cut with a saw.
Inspection 3 Examined the results of cutting the size that we believe that the
process of measuring and cutting our already good.
Operation 10. To be comfortable wearing the seat, then the seat must be
established in accordance with the state of the human body by using
shavings.
Operation 11. Once formed, then smoothed with sandpaper and putty over and
over until really smooth.
Operation 12. Seating is already smooth, cleaned of dirty-dirt, then lacquered to
shiny as he examined both the color and quality of the varnish.
6. The Notion Of Pareto Diagram
Pareto Chart is a method of organizing the error, problem or defect to help focus on
problem-solving efforts. This diagram is used for classifying problems according to
causes and symptoms. The problem will be sorted according to priority or importance
using a bar chart/histogram.
Pareto diagram creation process can be described as follows :
a.
Select several factors the causes of a problem (can be known from the results of
the analysis of cause and effect).
b.
Collect data from each of the factors and calculate the percentage contribution of
each factor.
c.
Stacking factors in new order starting from the largest contribution percentage
and having to calculate the value of its accumulation.
d.
The form framework along with the diagram to the left shows the vertical
frequency, whereas vertical along the right side in the form of cumulative. High
along the left and right alike.
e.
Guided vertically along the left side, make the column sequentially along a
horizontal on describing the contribution of each factor.
Fakulty
Department
Practicum
f.
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
: 16
:7
: December 3, 2014
Guided vertically along the right side of the line, create cumulative percent,
starting from 0% at the lower end along the left to 100% at the top along the right
side.
Example for Pareto Diagram :
Table 7.2. Damage clothing data
Penyebab masalah Jumlah Kumulatif
Break
20
47%
Dirty
10
70%
Color Fade
5
81%
Tangled
5
93%
Smell
2
98%
Shrinking
1
100%
Total
43
50
45
40
35
30
25
20
15
10
5
0
120%
100%
80%
60%
40%
Jumlah
20%
0%
Picture 7.4 Pareto diagram damage clothing
7. Understanding Fishbone Diagram
Diagram of fishbone/cause and effect diagram is a tool for quality control and
developed by Kaoru Ishikawa. The diagram is displayed in the form of a graph that
illustrates the relationship of the effects (the issue) with a potential case. Diagram of
fishbone
is used for try or device process from an activity. Diagram of fishbone
can help stimulate rational thinking.
Fakulty
Department
Practicum
: Industrial Technology
Meeting
: Industrial Engineering
Module
: Physiology and Work Measurement Date
Example for fishbone diagram :
Figure 7.5 Causes of low customer satisfaction
: 16
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: December 3, 2014