December 14, 2011

Systems Installation - Installing Proposed Methods

Industrial Engineering
Installation of design is the biggest stumbling block said, Nadler [Nadler, 1955]. In many cases everyone contacted in step 6 and step 7 of method study process will approve of a method, yet there are some difficulties in installing new the method and getting the required changes made.
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Steps in Method Study




1. Goal determination

2. Analysis of work

3. Application of principles of methods design

4. Selection of feasible solution

5. Formulation of recommended method/design

6. Review of design

7. Test of design

8. Installation of method

9. Standards setting



Installation of design is the biggest stumbling block said, Nadler [Nadler, 1955]. In many cases everyone contacted in step 6 and step 7 of method study process will approve of a method, yet there are some difficulties in installing new the method and getting the required changes made.


Steps in Installation of New Method




In general, installation of method calls for the following steps.


Approach to Foreman and Operator




If the analyst has reviewed the method and tested the method in cooperation with the foreman and the operator concerned, then the installation proper does not require selling the method. Otherwise, the first thing to do is to explain the foreman and the worker the details of the method and rationale for it.



Any approach to the worker should be made with and through the foreman or supervisor. Basic human relations principles are to be kept in mind in conversation with the worker. The worker needs to be explained the shortcoming of the earlier method from productivity/efficiency point of view so that he understands why the problem needs to be solved and cooperates. The suggestions of the worker are to be welcomed and incorporated into the proposed method at every stage. Even at this stage of preparing for installation of the method, the worker must be encouraged to give suggestions or ideas, so that the operator feels that he is contributing to the proposed method.



Economic fears of workers play an important role at the time installation of new methods. The industrial engineer should check the policies and procedures established by management in relation to these fear and use the information to gain the cooperation of operators. Especially important in some of the these situations is he policy regarding employees who are not required to be in the new method




Changes in product/production equipment/work place layout




This part involves obtaining authorization to complete the suggested changes in design of the product, material, equipment etc. After obtaining the authorization from the Committee or Executive responsible for authorizing such changes, they have to be sent to design department for incorporation in drawings. Orders are to be placed for various items required on the basis of new drawings. After the materials, parts, tools and equipment arrive, the proper department in organization has to install them in the work place.



An important problem during the installation of a new method is how to avoid excessive losses in production. In some situations, this problem can be solved by dong the changes after working hours and on holidays. Planning has to be done to minimize loss of production.


Training of operators and other staff including foremen/supervisors




Since the new method will usually a change in hand patterns, the operators should be give some opportunity to learn the new method. Training in some cases may be an oral explanation for few hours. In some cases it could be extensive training off the job and on the job [Barnes, 1980].


Follow-up




Follow-up of the method is to be done after some time subsequent to the start of regular production under the new method. Foreman has the primary responsibility to ensure that the new method is followed and also to solve any difficulties that crop up in the new method. But the industrial engineer, who has played a key role in the development of the new method, has a responsibility to make sure that the new method is contributing up to the expectations through a review exercise.



Follow-up is probably most important for operations which are not continually running but are performed according to orders. In these cases the operator may forget much of what was learned of the new method. Foreman has greater responsibility to make sure that new methods are used in such circumstances. But checking by the industrial engineer or IE department technician occasionally is not unwarranted. It is like insurance on the investment of time and effort spent on the developing new method.


References




Barnes, Ralph (1980), Motion and time Study: Design and Measurement of Work, John Wiley, New York.


Nadler, Gerald (1955), Motion and Time Study, McGraw-Hill, New York.

Originally posted in
Knol Number 100


Industrial Engineering Knowledge Revision Plan - One Year Plan


January - February - March - April - May - June



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