Performing a time study is relatively easy compared to only few years ago. The technologies available today allow studies to be conducted quite readily.
Time Studies and OEE (Overall Equipment Effectiveness)
The Performance factor for OEE is based on the Ideal Cycle Time of the process. For fixed rate processes, the Name-Plate rate may suffice but should still be confirmed. For other processes such a labour intensive operations, a time study is the only way to determine the true or ideal cycle time.
When measuring the cycle time, we typically use “button to button” timing to mark a complete cycle. It can be argued that an operator may lose time to retrieve or pack parts or move containers. Including these events in the gross cycle time will hide these opportunities. It is better to exclude any events that are not considered to be part of the actual production cycle.
When calculating the Performance factor for Overall Equipment Effectiveness (OEE), the efficiency shortfalls will be noted by the less than 100% performance. The reasons for this less than optimal level of peformance are attributed to the activities the operator is required to perform other than actually operating the machine or producing parts.
All operator activities and actions should be documented using a standardized operating procedure or standardized work methodology. This will allow all activities to be captured as opposed to absorbed into the job function.
The BlackBerry Clock – Stopwatch
One of the tools we have used on the “fly” is the BlackBerry Clock’s Stopwatch function. The stopwatch feature is very simple to use and provides lap time recording as well.
When performing time studies using a traditional stopwatch, being able to keep track of individual cycle times can be difficult. With the stopwatch function, the history for each “lap” time is retained. To determine the individual lap time or cycle time, we recommend dividing the total lapsed time by the number of completed cycles (or laps).
The individual lap times are subject to a certain degree of uncertainty or error as there will always be a lead or lag time associated with the pushing of the button on the BlackBerry to signal the completion of a cycle. Although this margin of error may be relatively small, even with this level of technology, the human element is still a factor for consideration.
Once the time study is complete you can immediately send the results by forwarding them as an E-mail, PIN, or SMS.
The BlackBerry Camera – Video Camera
Another useful tool is the video camera. Using video to record operations and processes allows for a detailed “step by step” analysis at any time. This is particularly useful when establishing Standard Operating Procedures or Standardized Work.
Uploading videos and pictures to your computer is as easy as connecting the device to an available USB port. In a matter of minutes, the data is ready to be used.
Video can also be used to analyze work methods, sequences, and also serves as a valuable problem solving tool.
Until Next Time – STAY Lean!