It is essential to have good quality guidelines about how to film a machine process to deeply analyze every movement.
The job of Lean Manufacturing businesses of any kind is to identify the best way to run the fastest and most efficient production method.
This way, they can improve their productivity and produce at takt time rate.
But, is there a manner to measure something like that? Is there a way to determine the best manner to do something, and if so, how?
This is where Time and Motion Studies take place.
A Time and Motion study examines every step of a manufacturing process on a recording, and determines how long they all take on an average basis.
So, the first step is to make an appropriate recording of our machine process.
But, how to do a good recording?
The aim of this entry is to explain the best way to film machine process.
How the time and motion study works
Time and motion studies allow us to go deeper in every machine process in order to identify and reduce or eliminate the eight wastes, also called TIMWOODS.
These wastes are draining time, effort and budget and may dramatically impact the success of any manufacturing business.
These are the steps to successfully complete a time and motion study:
Film the machine process
Recording rules may be different depending on the machine type.
A good recording allows the analyst to successfully check every single step of the machine process.
This way, it is easy to determine where the most significant amounts of time are lost and also how to improve these time periods.
To check the rules of every machine type, just navigate to the last section of the post.
Apply DGM to each recording
DGM is our advanced software focused on machine processes and the best way to do Time and Motion Studies in a professional manner.
It allows the user to import the recorded machine process and provides the most efficient tools for machine analysis.
Start by analyzing the machine process, identifying situations that are not adding value to the customer.
Then, the powerful Non-Value Added module from DGM allows the user to specify the tasks to be implemented in order to improve the machine cycle time. That is, reducing or eliminating lean wastes detected in the previous step.
Additionally, the complete Gantt Workflow module allows the user to build an Action Plan from the tasks above.
Finally, export all the relevant information about the initial state of the machine (upon recording) and of the improvement situation.
The document exported from the DGM software contains all the necessary information about the original time and motion study.
Furthermore, it contains the details of every improvement to be implemented in order to enhance the machine process productivity and the achievable results.
How to film machine process
As noted above, recording rules may differ depending on the machine type.
However, there are general rules that every single machine process recording must comply, regardless of their type.
- The filming must contain at least 2 whole machine work cycles.
- If the machine has an operation that is performed every N work cycles, at least one of the recorded work cycles must include this operation.
- The camera must be located in a fixed and stable place while recording.
- The camera must record the maximum number of movements of the machine with the minimum plane surface. That is, the camera must be located as close as possible to the machine, and recording the maximum number of movements.
- The recording speed will be appropriate to the machine cycle time and time resolution required. The recording frame rate must be at least 30 FPS (Frames Per Second) to guarantee a time measurement of 0.03 seconds, which is usually acceptable in most cases.
- For privacy purposes, be careful not to include identifying features of workers.
Number of takes
- For machines with a single working side, a single recording is needed.
- For machines with more than one working side, as many recordings as faces.
- In case of FMS (conveyor, transfer) machines, as many recordings as stations, considering also the number of faces per station. The transfer cycle between stations is not necessary.
- For turntable plate machines, as many recordings as stations, considering also the number of faces per station. All recordings must include the rotating plate division cycle or the rigid transfer cycle.