Motion and Time Study for Lean Manufacturing Book

1	Introduction to Motion and Time Study	1
	Questions	6
2	Motion and Time Study for the Lean Environment	8
	The Nature of the Lean Environment	8
	Approaches to Quality Measurement and Improvement	16
	Planning and Scheduling the Production System	17
	Steps toward Establishing a Lean Manufacturing Environment	20
	The Use of Motion Study Tools to Improve the Environment	22
	The Use of Time Study Tools to Maintain the Lean Environment	23
	Measures of Performance within the Lean Environment	24
	Questions	25
3	History of Motion and Time Study	26
	Frederick W. Taylor (1856-1915)	27
	Frank (1868-1924) and Lillian (1878-1972) Gilbreth	29
	Henry Laurence Gantt (1861-1919)	31
	Harrington Emerson (1853-1931)	31
	Ralph M. Barnes (1900-1984)	32
	Marvin E. Mundel (1916-1996)	32
	Shigeo Shingo (1909-1990)	33
	Professor Elton Mayo	33
	Controversy	35
	Questions	36
4	The Importance and Uses of Motion and Time Study	37
	What Is a Motion Study?	37
	The Importance and Uses of Motion Study	40
	What Is a Time Standard?	41
	The Importance and Uses of Time Study	43
	Techniques of Time Study	57
	Questions	66
5	Techniques of Methods Design: The Product Flow Macromotion	67
	Introduction	67
	Cost Reduction Formula	67
	Flow Diagrams	69
	Step-by-Step Procedure for Developing a Flow Diagram	72
	Notes About the Examples	72
	The Operations Chart	72
	Step-by-Step Procedures for Preparing an Operations Chart	74
	Process Chart	75
	Notes About the Examples	78
	Step-by-Step Description for Using the Process Chart	79
	Flow Process Chart	83
	Work Cell Load Chart	83
	Route Sheet	87
	Questions	89
6	Techniques of Micromotion Study: Operations Analysis	90
	Operations Analysis Chart	91
	Operator/Machine Chart	93
	Gang Chart	100
	Multimachine Chart	101
	Left-Hand/Right-Hand Chart	102
	SIMO Chart	103
	Questions	106
7	Motion Study: The Work Station Design	108
	Work Station Design	109
	Principles of Motion Economy	111
	Motion Patterns	126
	Questions	128
8	Predetermined Time Standards (PTS) Systems	129
	Introduction	129
	Methods Time Measurement (MTM) Family	131
	MODAPTS	131
	Predetermined Time Standards System (PTSS)	136
	Questions	153
9	Stopwatch Time Study	159
	Introduction	159
	Tools of Stopwatch Time Study	161
	Time Study Procedure and the Step-by-Step Form	172
	Rating Leveling and Normalizing	185
	100% Standards and Experiments	187
	Time Study Rater Trainer Form	192
	Allowances	196
	Foreign Elements	202
	Long Cycle Time Study	204
	Vertical Time Study Form and Problem	207
	Time Study Practices and Employee Relations	209
	Questions	210
10	Standard Data and Its Uses in Balancing Work	212
	Introduction	212
	Definition	213
	Advantages	213
	Methods of Communicating Standard Data Time Standards	214
	Work Cell, Assembly Line, and Plant Balancing	230
	Questions	252
11	Work Sampling	254
	Elemental Ratio Studies	255
	Performance Sampling Studies	266
	Time Standard Development Studies	268
	Process Effectiveness Studies	270
	Questions	274
12	Indirect Labor and Motion and Time Study	275
	Developing Measures/or Indirect Labor	276
	Material Handling	278
	Quality Control	279
	Manufacturing Plant and Industrial Engineering	280
	Supervision	280
	Maintenance and Tooling	280
	Warehousing and Shipping	281
	Receiving and Stores Department	284
	Factory/Clerical	285
	Other Indirect Areas	285
	Questions	286
13	Performance Control Systems	287
	The Functions of Any Control System	287
	Expert Opinion Standards System	290
	Backlog	290
	Time Card System	293
	Questions	301
14	Wage Payment Systems	302
	Salaries: Hourly, Weekly, or Monthly	302
	Incentive Systems and Commissions	305
	The Two Types of Incentive Systems: Individuals and Group	309
	Questions	318
15	Time Management Techniques	319
	Be Creative	320
	Be Selective	320
	Delegate	321
	Do It Now	322
	Set Time Standards for Yourself	322
	Eliminate the Unnecessary	322
	Respect Other People's Time	323
	Do Not Rationalize	323
	Questions	324
16	Attitudes and Goals for Industrial Engineers	325
	Attitudes of an Industrial Engineer	325
	Goals	330
	Questions	332
Appendix A	Forms	333
Appendix B	Answers to Problems	353
	Index	365