3. Motion Study & Work
Design
TI 2111 Work System Design and Ergonomics
Operation Analysis Approach-1
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Method analysis
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Design analysis
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Eliminate, simplify, or combine operations
Reduce the number of parts
Design for manufacturability and assembly
Manufacture sequence
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Rearranging operations
Mechanizing manual operation
TI 2111 Work System Design and Ergonomics
Operation Analysis Approach-2
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Set-up and Tools
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Material Handling
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Reduce set-up time: SMED
Handling equipment
Ergonomic principles
Lay-out
TI 2111 Work System Design and Ergonomics
TI 2111 Work System Design and Ergonomics
The Four Principles of Motion
Economy
1. Reduce the Number of Motions
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Eliminate or reduce the number of motions
2. Perform Motions Simultaneously
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Design improvements in the methods and tools
which allow both hands to be used at the same
time
TI 2111 Work System Design and Ergonomics
The Four Principles (cont’d)
3. Shorten Motion Distances
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Reduce - walking, reaching, stretching, squatting
and turning, etc.
4. Make Motion Easier
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Work should be smooth and rhythmical, reduce
fatigue and promote safety
TI 2111 Work System Design and Ergonomics
Use of the Human Body
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Both hands should start and finish the
operation at the same time.
Reduce idle time for either or both hands
Arm motions should be symmetrical
Employ curved movements during the
operation
Employ rhythmical standard operation
Ensure a similar focal point for tools,
materials, etc.
TI 2111 Work System Design and Ergonomics
Arrangement of the Work Place
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Use fixed positions for tooling and parts to allow habits
to form easily
Use gravity feeding to ensure a common pickup point
Position parts, materials and tools to enable sequential
use
Use ejector systems or drop deliveries, so the operator
has minimal effort to pass on parts to the next
operation
Benches and chairs should be at the correct working
height to avoid interrupted motions
All equipment should be within the maximum work
area
TI 2111 Work System Design and Ergonomics
Design of Tools and Equipment
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Eliminate the need to use one hand purely to hold a
part
Use combination tools
Use counterbalances on heavy tooling
Ensure handles on tools are designed to use
maximum hand contact
Place tooling in the most convenient positions
Separate part supplies should be used for two
operators.
Tools should be placed to enable immediate use
Provide chutes for access of parts, and components
in/out of the workplace
TI 2111 Work System Design and Ergonomics
5S
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Seiri, Seiton, Seiso, Seiketsu, Shitsuke
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Sort, Clean, Set in order, Standardize,
Progress
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5R : Ringkas, Rapih, Resik, Rawat, Rajin
TI 2111 Work System Design and Ergonomics
Poka Yoke
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“Mistake proofing”
A manufacturing technique of preventing
errors by designing the manufacturing
process, equipment, and tools so that an
operation literally cannot performed
incorrectly
TI 2111 Work System Design and Ergonomics
Excuses…
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I like the way I am doing it now.
It's too radical a change.
I tried it once and didn't like it.
It sounds like a production line.
It won't work in our office.
I think we should look into it further before we
act.
It won't pay for itself.
I know a fellow who tried it.
We've always done it this way.
TI 2111 Work System Design and Ergonomics