Operation Analysis
INSY 3021
Auburn University
Spring 2007
Questioning Attitude
Why is this operation necessary?
 What can be done to make the job
safer?
 Who can best perform the
operation?
 When is the best time to schedule
this maintenance?
 How can the task be improved?
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Operation Purpose
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Try to eliminate or combine an operation
prior to improving it!
Some operations exist because the
previous work was unacceptable,
necessitating “touch-up” work supposedly
accomplished by the first operation.
Can an outside supplier perform the
operation more economically?
Questioning Attitude
Part Design
Review every design for possible
improvements.
 Simplify design to reduce # of parts.
 Make joining, machining, and
assembly easier.
 Design for manufacturing.
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Tolerances and
Specifications
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Designers may overcompensate with
very tight tolerances (high
production cost and time
consuming) because they are not
aware of the capabilities of the
manufacturing dept.
Cost vs. Machining
Tolerance
Materials
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Find a less expensive material
Find materials that are easier to process
Use materials more economically
Use salvage materials
Use supplies and tools more economically
Standardize materials
Negotiate best prices from vendors
Manufacturing Sequence
and Process
Rearrange operations
 Mechanize manual operations
(ergonomically designed tools)
 Use of robots
 Operate mechanical facilities more
effectively
 Manufacture near the net shape
(eliminates material removal)
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Setup Reduction (SMED)
and Tools
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Tooling amount based on production
quantity, recorders, labor, time limits and
capital.
Perform setup work while the machine is
running
Use efficient clamping devices
Eliminate large adjustments
Use templates or block gages
Maintain records of difficult setups
Machine Efficiency
Use multiple cutting tools to use
available power
 Use most efficient tooling
 Energy efficient motors
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Material Handling (MH)
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Depending on the part, 30%-50% of the
cost is due to MH
Reduce time spent picking up the material
Use mechanized equipment
Make better use of existing handling
facilities
Handle material with the greater care
Use bar-coding where applicable
Plant Layout
Layout types (product or straight
line & process or functional)
 Travel charts
 Muther’s Systematic Layout Plan
(SLP)
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Travel Chart
Work Design
Manual work and principles of
motion economy
 Ergonomic principles of workplace
and tool design
 Working and environmental
conditions
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Questions & Comments