JOINT PROCESS ANALYSIS

An IE technique to increase the efficiency of such operations,which usually contain a greater share of delays and obstacles than simple type of operations described so far. Also referred to as combined operation analysis. Broken down into
Operator-machine analysis
For studying operations involving atleast one person and atleast one machine.

Joint operation analysis

For studying operations involving several persons working together.

Various combinations of people and machines

One operator working with one machine One operator working with several machines Several people working together Several people working with one machine Several people working with several machines

PURPOSE OF JOINT PROCESS ANALYSIS

To clarify interrelationships between operators and machines or among several operators to find where time may be wasted and to make corrective improvements. Goals include
Eliminating machine ideal time Eliminating operator standby time Equalising distribution of work among operators and machines Assigning optimal number of machines per operator Assigning optimal number of operators to joint operations.

OPERATOR MACHINE ANALYSIS

Way of studying relation between respective operating times of human operators and machines. Operator-machine analysis studies how to Increase the production yield Calculate optimal number of machines per operator Maintain the current production yield using fewer machines

Steps in Operator Machine Analysis

Worker A operates two machines (1 and 2),but both machines requires a lot of assistance. Each machine has idle time while worker A is busy assisting the other machine. The example shows how to study the operations of worker A and the two machines with a view toward reducing the machines idle time and raising their capacity utilization rate.

Step 1:Conduct a preliminary study

Carry out operator process analysis and Process chart Clearly define the kind of improvement most needed(try to check with the workshop supervisor) e.g. -Higher Efficiency -More machines per operator -Fewer machines per operator Give precise quantitative goal For our study its :Reduce Machine idle time and raise the capacity utilization rate

Step 2 :Analyze one operation Cycle

Carry out separate operator process analyses for each operator or machine that performs operations in one operation cycle Draw Flow chart 6-1

Step 3: Arrange the timing

Study how the operator and machines work together and draw horizontal lines on the chart to show when work is being done simultaneously by the operator and one or more of the machines. Fig 6-2

Step 4 :Measure the time at each operation step

How much time required for each step observed in step 3 Arrange the timing so that the simultaneous operations match up properly

Step 5 :Draw up an operatormachine chart

Use the joint process chart symbols to describe the various steps in the operation cycle. Y-axis for time

 Figure 6-3

Step 6 : Organize the analysis result

Table 6-2

Data Chart

Step 7 : Work out an improvement Plan

Make a list of Improvement Concerns and draw up a new operator-machine chart 6-4. This improvement is estimated to result in a shortening of the total time from 8.2 to 6.2 minutes. Also an adjustment in machine 1s idle time percentage from 39 to 19 percent and in machine 2s idle time percenage from 9 to 11 percent. The production yield would also jump from 32 percent((8.2/6.2)*100)=approx 132)

 Figure 6-3

 Table 6-3

Step 8:Implement and evaluate the improvement plan

Evaluate the points that warrant further improvement efforts Although we reduced the operation cycle time by two minutes and boosted production yield more than 30 percent,it left a considerable amount of machine idle time and changeover time.

 Table 6-4

Step 9 :Standardize the improvement

Standardize the new arrangement to prevent backsliding