Integration of Methods Improvement and Measurement into Industrial Engineering Functions

227 Pages·2021·15.06 MB·English

by  Gerald J. Watson Jr.

Integration of Methods
Improvement and
Measurement into Industrial
Engineering Functions

Integration of Methods
Improvement and
Measurement into Industrial
Engineering Functions
Gerald J. Watson Jr.
with illustrations by Jesse J. Derouin
First edition published 2022
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742
and by CRC Press
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© 2022 Gerald J. Watson Jr. and Jesse Derouin
CRC Press is an imprint of Taylor & Francis Group, LLC
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Library of Congress Cataloging‑in‑Publication Data
Names: Watson, Gerald J., Jr., author. | Derouin, Jesse J., illustrator.
Title: Integration of methods improvement and measurement into industrial
engineering functions / Gerald J. Watson ; with illustrations by Jesse
J. Derouin.
Description: First edition. | Boca Raton : CRC Press, [2022] | Includes
bibliographical references and index.
Identifiers: LCCN 2021025351 (print) | LCCN 2021025352 (ebook) | ISBN
9780367720933 (hbk) | ISBN 9780367720940 (pbk) | ISBN 9781003153412
(ebk)
Subjects: LCSH: Operations research. | Continuous improvement process. |
Project management. | Work measurement.
Classification: LCC T57.6 .W38 2022 (print) | LCC T57.6 (ebook) | DDC
658.4/034--dc23
LC record available at https://lccn.loc.gov/2021025351
LC ebook record available at https://lccn.loc.gov/2021025352
ISBN: 978-0-367-72093-3 (hbk)
ISBN: 978-0-367-72094-0 (pbk)
ISBN: 978-1-003-15341-2 (ebk)
DOI: 10.1201/9781003153412
Typeset in Times
by Deanta Global Publishing Services, Chennai, India
Contents Contents
Dedication
This book is dedicated to my wife who helped me get out of
the Georgia Institute of Technology, not once but twice. She
then provided moral and financial support when I returned
at age 59 to work toward a PhD in Industrial and Systems
Engineering at the North Carolina Agricultural and Technical
University in Greensboro and earned it at the age of 64.
It is also dedicated to the many students over the years that
have helped me become a better person and instructor.

Contents
Foreword ................................................................................................................xiii
Preface......................................................................................................................xv
Acknowledgments ...................................................................................................xxi
Contributor biographies .......................................................................................xxiii
Glossary .................................................................................................................xxv
Introduction ................................................................................................................1
Chapter 1 Methods Improvement .........................................................................7
A. Brief review of a method and the methods of improvement ..........7
B. Existence of situations that demand improvements with
recommended solutions ..................................................................7
C. Reasons for the existence of and the need for continual
improvements ................................................................................14
D. C ritical questions to ask before attempting methods
improvements ...............................................................................14
E. Examples of successful and unsuccessful improvements .............15
The Current Process ......................................................................19
Analysis of Process........................................................................20
Modifications That Resulted from the Analysis ............................20
The Process after Methods Improvement......................................20
Process Steps Eliminated ..............................................................20
Opportunities for Further Improvement ........................................20
The Current Process ......................................................................21
Analysis .........................................................................................22
The Process after Methods Improvements ....................................22
Process Steps Eliminated ..............................................................23
Opportunities for Future Improvements ........................................23
Current Process .............................................................................27
Analysis .........................................................................................28
Process after Change .....................................................................28
What potential changes should be investigated for further
improvements? ....................................................................................29
Current process: .............................................................................30
Analysis .........................................................................................31
Proposed new process ..................................................................31
F. C ritical questions to ask following the implemented methods
improvements with solutions .........................................................32
vii
viii Contents
Chapter 2 Measurement ......................................................................................33
A. Brief Overview of the Criticality of Measurements and the
Need for Accuracy ........................................................................33
B. Critical Questions That Must Be Addressed ................................33
C. Potential Sources of Errors in the Use of Measurement ..............33
D. T he Reasons to Take Measurements ............................................34
E. What is driving the demand for these measurements? .................35
F. H ow will these measurements be used? ........................................35
Chapter 3 Integrating Methods Improvements for the Establishment of
New Direct Labor Standards or Existing Direct Labor Standards ......41
A. Brief Introduction to the Needs for Direct Labor Standards .......41
B. Critical questions to ask before establishing new direct labor
standards with solutions ................................................................41
C. Critical questions to ask for revision of existing direct labor
standards with suggested solutions ...............................................52
D. E xamples of successful and unsuccessful revisions .....................54
Chapter 4 Integrating Measurement into the Establishment of New Direct
Labor Standards or Revision of Existing Direct Labor Standards ....59
A. Brief Explanation for Integrating Measurement into the
Establishment of New Direct Labor Standards ............................59
B. Critical questions to ask for the integration of measurement
into recently installed direct labor standards with suggested
solutions ........................................................................................59
1. W hat techniques were used to collect the information? ...........59
2. What are Some Applications For Direct Labor Standards? .....60
3. Of what significance is the level of accuracy? ..........................60
4. H ow does the measurement relate to different crew sizes? ......61
5. What is the definition of a unit? ...............................................61
6. What was the goal of these applications? .................................61
7. What information will be monitored longitudinally reason
to track and evaluate progress? .................................................61
8. W hat benefits will result as a result? ........................................61
9. W hat is the most beneficial place to seek improvement? .........62
C. Critical questions to ask for the integration of measurement
into existing direct labor standards with suggested solutions ......62
1. W hat was the reason for the initiation of the new studies? ......62
2. What is the effectivity date of the change for either an
item with a changed specification or a component used in
the manufacturing process? ......................................................63
Contents ix
3. A change in a component used in the manufacturing
process ......................................................................................63
D. Examples of successful and unsuccessful integration of
measurement into direct labor standards ......................................63
1. An example of a successful implementation ............................63
2. An example of an unsuccessful implementation of
production standards ................................................................65
Chapter 5 Integrating Methods Improvement for a Possible Revision of an
Existing or the Installation of a New Incentive System .....................67
A. Brief explanation for need of methods improvement prior to
the installation of a new incentive system ....................................67
B. Critical questions to ask before installing a new incentive
system ...........................................................................................67
C. Critical questions to ask before initiating studies to modify
an existing individual incentive system with suggested
solutions ........................................................................................68
Brief explanation for the need for methods improvement for
an existing system ..........................................................................68
D. Examples of Successful and Unsuccessful Improvements ...........70
1. Examples of Successful Improvements ....................................70
2. A n example of a failure verification of incentive rates ............72
Chapter 6 Installing Measurement in a Recently Installed or Existing
Individual Incentive System ...............................................................77
A. Brief overview of the importance of measurement in an
individual incentive system ..........................................................77
B. Critical Questions to ask before installing measurement
in a newly established individual incentive system with
suggested solutions .......................................................................77
C. Critical questions to ask for possible potential need to revise
measurement tools in an existing individual system ....................78
D. Examples of successful and unsuccessful implementation of
method improvement in establishing direct standards .................80
1. Examples of a Successful Implementation ...............................80
2. An example of a failure verification of incentive rates ............82
Chapter 7 Integrating Methods Improvement in the Revision of an
Existing Group or Installation of a New Existing Group
Incentive System.................................................................................83
A. Brief Reason for the Existence of a Group Incentive System ......83