EIND 2303: Work Design & Industrial Ergonomics

Transcription

1 Department of Industrial Engineering EIND 2303: Work Design & Industrial Ergonomics Chapter 5 (6): Search for Solutions Learning Outcomes After successful studying this chapter You should be able to Define the term Creativity and discuss its types, Describe types of RESEARCH, (structured vs. unstructured), Define Brainstorming and discuss its advantages, Discuss The Nominal group technique and Groupware, Describe structured Search: SEARCH and SCAMPER 1

2 Creativity Creativity is finding, thinking and making new things. Creativity is any act, idea, or product that changes an existing domain, or that transforms an existing domain into a new one. Creativity (1) Ability to produce novel responses Divergent thinking: a variety of solutions Convergent thinking Focusing on best solution Measured by IQ test 2

3 Types of Creativity Systematic structured Creativity methods (Systematic structured search, structured search using the acronym SEARCH) Vs. unstructured creativity methods (Unstructured search) Systematic structured Creativity methods Morphological box (Morphological Analysis and Matrix Analysis) Mind mapping Synergy: Synergy is the creation of a whole that is greater than the simple sum of its parts. The term synergy comes from the Greek word synergia from synergos, meaning "working together". As for costs, synergies allow for the creation of economies of scale. For example, an union can reduce multiple levels of management and duplication and spread fixed cost technologies over larger operations. 3

4 Systematic structured Creativity methods Mind mapping: A mind map is a diagram used to visually organize information. A mind map is hierarchical and shows relationships among pieces of the whole Morphological analysis 4

5 Morphological analysis List the dimensions of the product or problem Generate a list of attributes under each of the dimensions Take combinations of attributes as stimuli for new ideas Unstructured creativity methods Draw a face Head Eyes Color Hair Age 5

6 Morphological analysis Morphological analysis: Design a new lamp List the variables about the subject that can be varied Or changed in some way. Select 2 to 6 significant variables to investigate further. Variables: Power supply Bulb type Light intensity Size Style Finish Material Cost 6

7 Morphological analysis - Lamp Power supply Bulb type Light intensity Size Style Finish Material Battery Halogen Low v. large modern black metal Solar Bulb Medium large antique white ceramic Generator Day light High Med. roman metallic Concrete Gas colored variable small ethnic natural Bone Oil Hand held industri al fabric Glass Wood Plastic Unstructured creativity methods Brainstorming 635 Method 7

8 Unstructured Search Encourage ideas, discourage criticism. Avoid groupthink. Use group techniques: Brainstorming Nominal group technique Groupware Brainstorming 1. Leader: State problem clearly. 2. Group: Make suggestions orally. 3. Leader: Reword and write down ideas. 4. Leader: Encourage participation. 5. Group: Evaluate/rank ideas. 8

9 Nominal Group Technique 1. Leader: State problem. 2. Individuals: Make suggestions in turn. 3. Leader: Display ideas. 4. Group: Vote for best ideas. 5. Leader: Record votes. 6. Group: Discuss top ideas further. Groupware Allows multiple computers to communicate simultaneously. Permits nominal groups to be at different locations. Makes information widely available. May cause information overload. 9

10 Videotape Analysis Operations are recorded so they can be viewed later. Multiple people can interact during viewing. Operator can explain video to team (auto-confrontation). Results of meetings may be potential solutions or indications for further analysis. Systematic Structured Search Identify management s perception of the problem See for yourself Obtain information from the operator Get information from the supervisor Measure light, noise, dimension, etc. 10

11 Structured Search: SCAMPER S Substitute components, materials, people. C Combine mix, combine with other assemblies or services, integrate. A Adapt alter, change function, use part of another element. M Modify increase or reduce in scale, change shape, modify attributes (e.g. color). P Put to another use. E Eliminate remove elements, simplify, reduce to core functionality. R Reverse turn inside out or upside down, or use Reversal. Structured Search: SEARCH S Simplify operations E Eliminate unnecessary work and material A Alter sequence R Requirements C Combine operations H How often 11

12 Simplify Operations Provide prepared, written information. Use jig and fixture designs to simplify machining. Shift from counting to sampling. Use forms, , phone calls. Generate less waste. Automate part of a process (e.g. cleaning). Eliminate Unnecessary Work and Material Eliminate unneeded work Eliminate unneeded work Use the exception principle Use self-service 12

13 Alter Sequence Simplify (or eliminate) other operations Reduce idle/delay time Do it now vs. do it later Inside machine time Simultaneous vs. sequential tasks Central vs. local storage Reduce material handling costs Group technology Bus vs. taxi transportation Requirements Quality (capability) costs Initial vs. continuing costs 13

14 Quality (Capability) Costs Determine if the level of quality is appropriate and worth the cost. Review design tolerances before release to production. Allow for concealed costs (unreported rework causes eddies in the river ). Pay attention to indirect materials, supplies, and utility costs. Consider selective assembly. Initial vs. Continuing Costs Minimize life-cycle costs, not just initial purchase cost. Identify maintenance, operating, and utility costs. Expect noneconomic behavior when cost is ignored. 14

15 Cost vs. Quality Curve Combine Operations Both general purpose and special purpose materials should be considered. Specialist job descriptions may be inefficient. Central departments allow economies of scale. Advances in communications can be used to centralize. Supervisors may resist consolidation. 15

16 How Often? Use economic lot size calculations. Trade off setup costs vs. inventory for make items Trade off purchasing cost vs. inventory for buy items Analyze maintenance, service, and inspection activities. Use red/yellow/green labels to concentrate resources where needed. Motivating Jobs Through Job Redesign Scientifically managed jobs: boring, repetitive, few skills utilized Job Enlargement: add more tasks of similar skill level to the job Horizontal Loading Job Enrichment: add more responsibility and autonomy to the job Vertical Loading 16

17 Design is just one of the four creative disciplines Design a new lamp Creativity 17

18 End of the Chapter 18