Documenting a Method
Abstract
The problem was the use of left and right hand charts and the work simplification worksheets to gain familiarity in this method of improving work systems. This was done by observing a worker, filling out the left and right hand charts, and the work simplification worksheet. After analyzing the charts different ways to improve the process were found. The charts help engineers identify hidden problems in a work system.
Introduction
The problem is the continuing improvement of work systems through the utilization of both left and right hand charts and work simplification worksheets. These charts are important in assisting an engineer in understanding the body movements and posture of a worker. Using these charts helps pinpoint potential health problems that could occur if the system is not modified. This problem was investigated by observing a worker put together a motor, filling out the left and right hand charts and finally filling out work simplification checklist.
Materials and Methods
The materials used were the left and right hand chart and the work simplification worksheet.
The procedure used in the lab was the following:
- Observe a worker completing a task and record observations onto the left and right hand chart.
- Study the work area and operation; document the results on the work simplification worksheet.
- Study the left and right hand chart and the work simplification worksheet to determine possible modifications to the work system.
Results
The left and right hand chart, Appendix A, shows the movements and actions of the worker’s left and right hands throughout one cycle of the task. In Appendix B, the work simplification checklist shows potential areas of improvement.
Discussion
The left and right hand chart showed precisely what the worker was doing during each step of the assembly process. This chart clarified how one hand experienced “idol time” and what tasks were difficult enough to cause the worker to use both hands. The work simplification worksheet gave a clear indication of what the deficiencies in the workstation were and which would be the simplest and cheapest to repair or improve.
After studying the work simplification checklist there are several changes that an engineer could make to the current work system. The first is to reorganize the work station so that all the bins containing materials are located within easy reach and in an order that is easy for the worker to utilize. The bins should all be on the workstation table and should be arranged in the sequence the materials are used. This would reduce the physical stress caused by the worker reaching to the ground for materials and would make it easy for the worker to find the necessary part quickly.
The next improvement suggestion is adding a conveyor belt so the worker does not have to lift the completed part. This reduces stress on the worker, and reduces the time it takes the worker to complete the assembly cycle.
The next improvement is in the addition of the first clear piece to the product. The worker struggles with this step, and should be provided with additional or better tools or the product should be redesigned to make this part of the assembly easier or unnecessary.
Finally, the parts should be oriented in their bins to make it easier for the worker to use them without self-orienting every component.
Click here to view or download this document using Word.
