Worker-Machine Systems + Worker operates a poweredequipment + Examples: * Machinist operating a milling machine * Construction worker operating a backhoe * Truck driver driving an 18-wheel tractor- trailer + Worker crew operating a rolling mill * Clerical worker entering data into a PC {fhe css on teoroe Relative Strengths ‘Regge conto nono Aon nan ee na soe sPotomcongttons ey 07 ee detonsadey Relative Strengths Ss ‘+ Ina worker rachine system the worker and the machine both contribute their own strengths and capabilities ‘+The resultis synergistic ‘produces synergy. + Types of worker rathine systems: + Types of powered machinery used inthe system + Numbers of workers and mactines inthe system + Level of operator atlention required to run the machinery 1 2 Types of Powered Equipment Powered machinery: A source of power other than human (or animal) strength is used to ‘operate that tool (or machine). Portable power tools 1+ Potable power dil, chain saws, electic hedge ‘emmers ‘+ Light enough in weight so that they can be easily canes Mobile powered equipment ‘+ Transportation equipment, back hoos, fori ‘tucks, electric power ganerator at construction site + Heavy pieces of equipment but ransportable Types of Powered Equipment ‘+ Powered machinery: A source of power other than human (or animal) sirength is used to ‘operate that tool (or machine). 3. Stationary powered machines + Machine tools, office equipment. cash registers, heattreatmentfumaces + Perfom functions ina stationary location + notnoraly moved Classification of Powered MachineryNumbers of Workers and Machines Level of Operator Attention ‘One worker and (One worker and ‘One machine ‘Multiple machines ‘Taxicab driver and + A worker taxi operating several machines Multiple workers and Multiple workers and ‘One machine Multiple machines * Acrew on a ship ‘+ Emergency repair crew responding tomachine breakdowns in a factory + Fulsimeattenton + Wederspatoming ae waldog 1 Parttimeattenton during each werk eyele + Wore losing and unloading @protucien machine on semiatonatccjle + Peroci attention with regular servicing + Wore ding amactine every 20 clos + Pero attention with random servicing + Freighers responding to alas ‘+ Matsenance worker rpsiing machines Two welders performing are welding on pipe- requires {ult sme attention of workers (photo courtesy of Lineoin Electric Co.) Good Work Design for Machine-Worker ‘Systems + Design the contol of the machine ta be logical and easy to porte for he ware 1+ Design the work sequence so that. as much of he wore’ task 85. poseble can bo accomplished wil. the Tastine ‘petting 1+ Mime the i mas of bot the worker andthe machine, + Design the tak anc tha machine to be safe for he worker. + iC me sytem is ¢ mutole worker avand mutple machine {ytem, opmize the ramber of waters or machines nthe tom according a specie etre Cycle Time Analysis Case 2.a: Cycle Times with No Overlap Between Worker and Machine “Two cgtogaris of worker macine systems in tems of te tine Ss ae ‘Sys in which the machine tne deers on operator +A typist ying as of names ona typewriter 1 Catpentor using power saw to cut amber 1 Reonstucton wocter operating abackoe Cycle time analysis is same a for manual work eycle 2. Speen nen ane cont anges + Operator loading sem automate production machine Ourfocus ison his 2nd ype + Two ype: 1+ Worker elements and machine elements are sequential 1+ Thore is no over in work elements between the worker andthe machine ne wore busy, machine ile + Normattime or yele formal ime for he workercontroled portion ofthe fle tne, min T= Machine cycle time (assumed to be constart)Case 2.a: Cycle Times with No Overlap Between Worker and Machine Example 2.8: Effect of machine 1+ Standard ime foreycle Tas Tue (1 A) * To AQ) where Ta# Normal ime or the, min To Machine cycle tme (constant) A= Machine allowance factor + A,=80%: Workers love that since effclencies. are allowance on standard time + Given: The work cycle consists of several manual work elements (operator controted) land one machine element performed under semiautomatic control. The manual work elements: a normal time of 1 min and the semiautomatic machine cycle time is 2 min. Ag=15%. + Determine: the standard time using (@)A,=0 Example 2.9: Effect of machine Example 2.8: Solution +The normal ine forth werk cyl: F=1.0°20%20 min (ey rep t.0(10.15)¢2088.15 min (ge Tug) Tul AQ) Workers © (0) Tap 0(140.15)020(190.30)=3.75 min (Tag® Tog 1 Aug) * To (1 AQ) Workers ® allowance on worker efficiency ‘+ Ghen Standort tines nthe previous example (Exame 28). + Beenie Te wre cers #150 unt ae proiont solo: (3) Hc 180(3. 187472 Srin=7 875° (Hog! To) 1750-0 964-00. (Hal Ha) (0) = 180(8. 757562 Srin=9.375r (Hag OT) Ears ben s72=117.2% (EH Ha) Case 2.b: Internal Work Elements Some worker elements are performed while machine is working * Internal work elements performed simultaneously wih machine cyee + External work elements performed sequently wth ‘machine oye Desirable to design the work cycle with internal rather than external work elements + fits possible, include operator work elements that are performed while machine is running. Se Normal Time and Standard Time + Normal time vat ManTas Toh + Standardtime Ta (As ax Tol # Ay) Tall + Aad + Actual yee time Te 2 To! Py + Mas Ta/Py. Ted where 1ormal time forthe worker's external elements, min oral ime fer the werka's internal elements, min machine yee time, minExample 2.10: Internal vs external work elements in cycle time analysis Example 2.10: Internal vs extemal work elements in cycle time analysis Yon [mae os Element Dezegson ie” |e 1 ee aw Traor 7 [Wateracsip ev wotear anrtneemtonaws [ozs [ey 2 [tase cas pate msaresona near ‘smownatccrde 3 [iedreseneuonatcoce fan pars ———— roe fe 7 aemanan maa [oe Lome T=0.73+0,75=1.48min T=0.10+0.1200.7520.87 min elements in cycle time analysis Automated Work Systems 1+ The oye tine redced from 48 in 097 min, + ope bene ron (Ta Treat abo ory aseKo8 Rei! A8 min=0.68 uns per min + Rapes t1097 08 unis per min + iner980 Re Rame Rt +(103.088)0.88-%63, 890103809 RR eR Rare 068-1 03)0.68=-%58, Automation is the technology by which a process or procedure is accomplished without human assistance ‘+ Implemented using a program of instructions, combined with control system that executes the instructions + Power is required to drive the process and ‘operate the control system Levels of Automated Systems Levels of Automated Systems + Thaw isnot ainays 2 cear distinction between worker- machete’ a anaes. ystems bectee agree ofauiomaton.” 7m OP 1, Semiautamated machine "Pera spar be war ec nda son fn at Doosng ois oe ° ‘+ Operator most be present every cycle {Same chareterstes win werkar machine ystom + 9g.an automated lahe requires a workay fo unload arts SES a tah ang ny ot be 2, Fullyautomated machine + There isnot always a clear distinction between worker. machin systema ans autaratedsyioms. becnse Segréefautomaton ns OP 1, Semiautomated machine 2. Fullyaulomated machine * Operates for extended periods of tine wih no human teat (anger an ond wom eye 9. every muna Be! ‘roabe vals " ‘eg mac‘Automated robotic spot welding cell (photo courtesy of Ford Motor Company) Determi \g worker and machine Requirements Ss + How many workersimachines are required to achieve the organization's work objectives? * If too few workers are assigned to perform a given amount of work + The work cannot be completed on tie, customer service wil ster, * If too many workers are assigned to perform a ‘given amount of work "The payroll costs are higher than needed, and productivity wil suf Determining worker and machine Requirements + Workload (WL) Total hours required © compte 2 siven amount of work or to produce a given number of work unis scheduled during the period ‘+ Available time (AT): The numberof hours (inthe same Petiod) avaiable from one werker or werker-machine system + The basic appmach to debrmine the number of workers 4. Determine th total waload tat must be acomplia inacaran perod 2. Divide he totlwarktoad by avait rT. WL wortload scheduiad fr agiven perio, hr, “iF he wertoad includes, mile part or product styles that are ‘osleed byte same wor system mu=Sor, (Q-auantry of part or product sto pe, Teele te of part or ert sve pe : When Setup is not a Factor Example 2.11: Determining Worker Case + Number of workers and number of machines required: w= WLAAT, or n=WL/AT where w= number of workers, ‘9 = number of workstations, AT = available time of one worker in the period, hriperiod/worker requirements + Given: 800 shafts must be produced in the lathe section of a machine shop in particular ‘week. Each shaft is identical and T,.=11.5min. All the lathes are identical. There are 40 hours of available time on each lathe. Determine: Number of lathes and lathe ‘operators must be devoted during that week.Example 2.11: Solution Factors that affect the workload + Workload: WL=800(11.5 min}=9200 min=153.33hr Machine (and worker) requirements w=n=153.3/40=3.83 (round up) =4 lathe operators and lathes Learning effect As learning occurs in repetitive manual work, ‘worker efficiency increases, cycle time decreases. so that the workload is reduced, Factors that affect the workload Factors that affect the workload + Worker efficiency: Worker may perform either above or below standard performance. E,=Workload actually completed / Workload ‘completed at standard performance: += Worker efficiency greater than 1.00 reduces the workload, ‘Defect rate: Fracton of parts produced that are detective +A. gotoc rate greater han ze inceases he quanty of ‘Work units Tal ust be processed yield the desred ‘quantity So workloadincreases with dated ate, "The relationship between the starting quantiy andthe final ‘quantity producee: 020,19) where (G=quantiy of good unis made inthe process, (Q,rorginal or starting quantity, fraction defect rate. sThequmbned elect of wre ficency ane ele rates ‘ven WL(OTa)/Eaf-Q)) Availability Example 2.12: Effect of worker efficiency defect rate, and availability + A.common measur of realty fx equipment ‘+ Defined as the proportion of time the equipment is ‘vallabe fo run relative tothe fla ime i could be used. + Available time rereases as avaiabiliy increases H1=shift hours dung the petod, be, Aavalabily, expressed asa decimal faction * Given: Previous example, Anticipated availabilty of the lathes 95%. Expected worker efficiency during production=110%. The fraction defect rate=3%. * Determine: Number of lathes requiredExample 2.12: Solution We omit + Total workload WL =( 800 (11.5160) )/(1.10(4 1B) )= 1437 hr Available time ‘AT=40(0.95)=38hrimachine 1n=143.7/38-3.78 lathes (and lathe operators) =4 lathes (and lathe operators) + 2.4.2When setup timeis included @se 2 + 2.5 Machine Clusters