Improving Production with Lean Thinking

5

Equipment Efficiency: Performance and Motion Study

In this chapter we will examine the second equipment efficiency indicator based on two factors: equipment performance losses owing to minor stoppages (usually not registered) and equipment performance reduction caused by equipment component deterioration and/or wear. In Chap. 7 we will study equipment availability (setup reduction) and quality related to startup.

Small breakdowns or device (fixture and tooling) holdups are responsible for these machine stoppages. In other cases, an improper adjustment or interaction between the worker and the machine cycle also can create problems.

Time and motion study allows one to optimize the relationship between the worker and the machine, as well as to investigate whether the worker can tend more than one machine in those cases where the machine cycle is significantly longer than the worker cycle.

The main tools presented in this chapter are worker-machine and machine-machine diagrams. These tools help us to study the relationship between the worker and machine cycles (or between machines), eliminating or reducing idle time and optimizing the working cycle.

MOTION STUDY

Motion study (also known as movements study) is defined as the methodology whose goal is to decrease the amount of work (shorter working cycle) by improving the existing work methods and layout. The result of a well-conducted motion study is that idle times are decreased or eliminated completely, i.e., those nonproductive ...