Prepared by: Assoc. Prof. Dr.

Adham MACKIEH

PROCESS ANALYSIS

The entire system or process of doing work should be studied before undertaking a
thorough investigation of a specific operation in the process. Such an over-all study
will ordinarily include an analysis of each step in the manufacturing process or
system.

Process Charts:

The process chart is a device for recording a process in a compact manner, as a

means of better understanding it and improving it.
The chart represents graphically the separate steps or events that occur during the
performance of a task or during a series of actions.
The chart usually begins with the raw material entering the factory and follows it
through every step, such as transportation to storage, inspection, machining
operations, and assembly, until it becomes either a finished unit itself or a part of a
subassembly.
The process chart might, of course, record the process through only one or a few
departments.

A careful study of such a chart, giving a graphic picture of every step in the
process through the factory, may suggest improvements.

It is frequently found that

- certain operations can be eliminated entirely or that a part of an operation
can be eliminated,
- that one operation can be combined with another,
- that better routes for the parts can be found,
- more economical machines used,
- delays between operations eliminated, and
- other improvements made,
all of which serve to produce a better product at a lower cost.

The process chart assist in showing the effects that changes in one part of the
process will have on other parts or elements.

Moreover, the chart may aid in discovering particular operations, in the process,
which should be subjected to more careful analysis.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

The process chart, like other methods of graphic representation, should be modified
to meet the particular situation. For example, it may show in sequence the activities
of a person, or the steps that the material goes through. The chart should be either
the man type or material type and the two types should not be combined.

Many years ago the Gilbreths devised a set of 40 symbols which they used in
making process charts.
The American Society of Mechanical Engineers has established as standard the five
symbols listed below. This set of symbols is a modification of the four most widely
used symbols of Gilbreths, in that the arrow replaces the small circle and a new
symbol has been added to denote a delay.

Operation: An operation occurs when an object is intentionally changed in

one or more of its characteristics. An operation represents a major step in
the process and usually occurs at a machine or work station.

Transportation: A transportation occurs when an object is moved

From one place to another, except when the movement is an integral
part of an operation or an inspection.

Inspection. An inspection occurs when an object is examined for

identification or is compared with a standard as to quantity or quality.

D Delay. A delay occurs when the immediate performance of the next planned
action does not take place.

Storage. A storage occurs when an object is kept under control such that its
withdrawal requires authorization.

Combined Symbols. Two symbols may be combined when activities are performed
at the same work place or when they are performed concurrently as one
activity.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Process Chart Example: Draw a Process chart, to show the binding activities listed below:

Activities DESCRIPTIONS
1 Carry printed sheets to Binding Shop
2 Place printed sheets on table-1
3 Wait for a while on table-1
4 Grasp the printed sheets
5 Carry printed sheets to table-3
6 Place printed sheets on Folding Machine
7 Fold printed sheets
8 Grasp the printed sheets
9 Carry printed sheets to table-2
10 Wait for a while on table-2
Grasp & Carry printed sheets to Stitching
11 Machine
12 Place printed sheets on Stitching Machine
13 Stitch the printed sheets
14 Grasp the printed sheets
15 Carry printed sheets to table-2
16 Place printed sheets on table-2
17 Wait for a while on table-2
18 Count the Stitched Booklets
19 Grasp the Stitched Booklets
Carry the Stitched Booklets to the Central
20 Storage
21 Place the Stitched Booklets on the shelves.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Process Chart Type: Man Type

Present Method
Proposed Method
Subject Charted Binding Process Date: 03-03-1993
Chart By: Mr. X
Chart No: 1010
Department Time study Sheet No: 1

Distance (m) Time (min) Operation Transportation Inspection Delay Storage DESCRIPTIONS
80 D Carry printed sheets to Binding Shop
D Place printed sheets on table-1
D Wait for a while on table-1
D Grasp the printed sheets
24 D Carry printed sheets to table-3
D Place printed sheets on Folding Machine
D Fold printed sheets
D Grasp the printed sheets
12 D Carry printed sheets to table-2
D Wait for a while on table-2
16 D Grasp & Carry printed sheets to Stitching Machine
D Place printed sheets on Stitching Machine
D Stitch the printed sheets
D Grasp the printed sheets
16 D Carry printed sheets to table-2
D Place printed sheets on table-2
D Wait for a while on table-2
D Count the Stitched Booklet
D Grasp the Stitched Booklet
90 D Carry the Stitched Booklet to the Central Storage
D Place the Stitched Booklet on the shelves.
D The Booklet on the shelve
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Process Chart Type: Material Type

Present Method
Proposed Method
Subject Charted Binding Process Date: 03-03-1993
Chart By: Mr. X
Chart No: 1010
Department Time study Sheet No: 1

Distance (m) Time (min) Operation Transportation Inspection Delay Storage DESCRIPTIONS
80 D Carry printed sheets to Binding Shop
D Place printed sheets on table-1
D Wait for a while on table-1
D Grasp the printed sheets
24 D Carry printed sheets to table-3
D Place printed sheets on Folding Machine
D Fold printed sheets
D Grasp the printed sheets
12 D Carry printed sheets to table-2
D Wait for a while on table-2
16 D Carry printed sheets to Stitching Machine
D Place printed sheets on Stitching Machine
D Stitch the printed sheets
D Grasp the printed sheets
16 D Carry printed sheets to table-2
D Place printed sheets on table-2
D Wait for a while on table-2
D Count the Stitched Booklet
D Grasp the Stitched Booklet
90 D Carry the Stitched Booklet to the Central Storage
D Place the Stitched Booklet on the shelves.
D The Booklet on the shelve

Flow Diagram

Sometimes a better picture of the process can be obtained by putting flow lines on
a plan drawing of the building or area in which the activity takes place. This is
called a flow diagram.

Sometimes, both a process chart and a flow diagram are needed to show the steps
in a manufacturing process, office procedure, or other activity.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Process Chart for an Office Procedure

In the office the process chart might show the flow of a time card, a material
requisition, a purchase order, or any other form, through the various steps.

The chart might begin with the first entry on the form and show all the steps until
the form is permanently filed or destroyed.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Assembly Process charts: A special type of process chart, sometimes called an

assembly process chart, is useful for showing such situations as the following:
1)- when several parts are processed separately and are then assembled and
processed together, 2)- when a product is disassembled and the component parts are
further processed, 3)- when it is necessary to show a division in the flow of work,
such as separate action on different copies of an office form.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Gang Process Charts: The gang process chart is an aid in studying the activities of
a group of people working together. This chart is a composite of individual member
process charts, arranged to permit thorough analysis. Those operations which are
performed simultaneously by gang members are indicated side by side.
The basic purpose of the chart is to analyze the activities of the group and then
compose the group so as to reduce to a minimum all waiting time and delays.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Construction( Gang Process Charts)

1- The same symbols are used as for ordinary process charts.
2- A process chart covers the cycle or routing followed by each member of the
gang. Member charts are placed side by side, with steps are performed
simultaneously shown on the same horizontal line.
3- Symbols of member charts may be placed close together, the various steps
are given code numbers rather than entering descriptions beside each symbol.
Numbers are entered in the center of each symbol and corresponding
explanations are placed at the side of the chart. This eliminates repetition of
the description when similar steps are repeated, and at the same time permits
the member charts to be placed close together.
4- Attention must be paid to entering simultaneous steps side by side. It may be
found that an operation performed by one member of the group continues
while another is performing more than one operation. In such instances, the
symbol is repeated at each step for the operation which occupies the larger
number of steps.
5- The chart should cover a complete cycle for the member performing the
largest number of steps. Other gang members usually repeat their cycles
during the largest member cycle.
6- Elements, which do not occur in every cycle, may be omitted from the chart.
This includes preparatory work, which is done before a cycle is started, such
as obtaining supplies for an entire shop. On the other hand, if an operational
step occurs at periodic intervals within the cycle, it should be included on the
chart. If such an operation occurs every two or three cycles, enough cycles
should be shown to include the operation.
7- Steps per unit before and after study are used in gang chart summaries. This
ratio is obtained by dividing the total steps on the chart by the total units
handled for the cycles represented on the chart.
8- A chart should not be constructed from observation of a single cycle. A
number of cycles should be observed, as the amount of waiting time may
vary from cycle to cycle. The average condition should be reflected by the
chart.
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

Analysis of the Gang Process Charts: Four steps are followed in analyzing a gang
process chart.
First, the six questions what, who, where, when, how, and why are asked of
the entire process.
Second, each operation and inspection is analyzed by utilizing the same six
questions.
Third, the remaining transportations and storage are studied.
Fourth, the how question should be applied in a new way after refinements
have been completed under step1, 2, and 3. This question is asked: “How should
the gang be composed to reduce waiting time to minimum?” The following will
assist the analyst to “balance” the gang under step 4:
1. Determine the class of operator having the largest amount of waiting time
per cycle, and the class having the least.
2. Adjust the gang by decreasing number of operators least busy and increasing
number of operators most busy. Generally, it is preferable to work toward a
smaller rather than a larger gang.

Steps to be Followed in Making a Process Chart and Flow Diagram

1. Determine the activity to be studied. Decide whether the subject to be

followed is a person, product, part, material, or printed form. Do not change
subjects during the construction of the process chart.
2. Choose a definite starting point and ending point in order to make certain
that you will cover the activity that you want to study.
3. Draw the process chart on a sheet of paper of sufficient size to allow space
for the heading, description, and summary. The heading should identify the
process being studied.The body of the process chart should contain a column
for Travel (distance in feet), Symbol, Description, and possible Time. The
five process chart symbols should be used. Every step in the process should
be shown if the analysis is to be of real value. Unnecessary steps and
inefficiencies in the work must first be “seen” before they can be eliminated.
4. Include on the process chart a tabular summary showing the number of
operations, number of moves of each kind, distance the part was moved,
number of inspections, and number of storages and delays. After
improvements have been made, a combined summary should be compiled
giving this information for the old method, the proposed method, and the
difference.
5. Obtain floor plans of the department or the plant, showing location of
machines and equipment used in making the part. It is frequently desirable to
mount the floor plans on a drawing board or table, cut out cardboard
Prepared by: Assoc. Prof. Dr. Adham MACKIEH

templates the size of the machines (Use a proper scale), and use these when
new arrangements for the equipment are suggested. Sometimes three-
dimensional scale models of machines and equipment are used instead of
templates.
6. Draw on the floor plans in pencil the path of the part through the plant,
noting the direction of travel by means of arrows. The flow diagram should
be made on location and not from memory at a desk. Distances should be
measured or paced off.