Unit 33: Workplace Study and Ergonomics Unit code: D/601/1472 QCF level: 5 Credit value: 15 Aim This unit will develop learners ability to identify and carry out productivity measurement and improvement, ergonomic and plant layout design and work measurement and method study. Unit abstract This unit provides an opportunity for learners to apply several lean manufacturing techniques commonly used to identify and eliminate waste. Learners should have the opportunity to see skills and techniques at work in real engineering/manufacturing environments. Learning outcomes On successful completion of this unit a learner will: 1 Understand productivity measurement techniques and the effect of a range of improvement methods 2 Understand the features of work measurement and method study techniques 3 Be able to assess the ergonomic and layout planning features of workstation and manufacturing operations design 4 Be able to select and apply appropriate industrial engineering techniques to a given engineering/manufacturing situation. 157
Unit content 1 Understand productivity measurement techniques and the effect of a range of improvement methods Productivity measurement: methods of measuring physical factors labour, materials and equipment; single factor and integrated productivity measurement, critical analysis techniques including cost benefit analysis and force field analysis; (evaluation may include graphical representations, statistical representations, fitness for purpose considerations and recognition of short-term and long-term effects); quality, cost, delivery (QCD) metrics, value stream mapping (VSM), process mapping Productivity improvement: reduction in unit cost of manufacture by labour, product, materials, production level or machine automation, uses of new technology, efficient manual operation use of work-study, job design, layout and ergonomic design, total quality management methods, waste of resources eg energy, human, materials; reduction/elimination of the 8 wastes ; standardised operations and their relevant forms, takt time analysis and production smoothing, change-over analysis (SMED) 2 Understand the features of work measurement and method study techniques Work measurement: direct work measurement time study and activity sampling; indirect work measurement synthetic timing; predetermined motion time systems (PMTS) methods time measurement (MTM); computer-based programs; primary standard data; analytical estimating Method study: job selection; recording methods and procedures; method description; development of improved method; definition of new method and installation and maintenance Work measurement and study: chart format; simple comparisons; critical analysis; ranking techniques; technique application description; fitness for purpose 158 BH023332 Edexcel BTEC Levels 4 and 5 Higher Nationals specification in Engineering
3 Bea able to assess the ergonomic and layout planning features of workstation and manufacturing operations design Ergonomic features: features of design including worker machine controls, environmental factors, anthropometrical data used in the design of workstations, special features for VDU operators, role of health and safety Layout planning features: features of design, including types of layout, operation sequence analysis, layout planning procedures and method, dedicated computer software, principles of motion economy Layout design: workstation design features such as characteristics of the operator, interaction between workspace and the operator eg posture, reach, desk/machine size, adjacent machinery, interaction between the environment and the operator Assess: develop criteria for good layout of workstation and manufacturing operations, consider flexibility, co-ordination, volume, visibility, accessibility, distance, handling, discomfort, safety, security, material flow, part identification, Poka yoke and Jidoka techniques 4 Be able to select and apply appropriate industrial engineering techniques to a given engineering/manufacturing situation Engineering/manufacturing situation: collect information and data on current company aims (eg current productivity, measurement, processes, process flow, scheduling, materials, equipment, labour, layout, ergonomic features of labour force and equipment operation); present evidence in a relevant form eg graphs, statistics, manuals, diagrams, recorded interviews, recorded observations, computer programs Engineering techniques: selection and application of techniques eg productivity measurement, productivity improvement, method study, work measurement, ergonomic design, layout planning; formulate a plan of action, appraise the feasibility of the techniques with reference to the engineering/manufacturing situation, make simple comparisons and use decision-making techniques eg consider fitness for purpose, long-term and short-term effects on the engineering/manufacturing situation; record and justify any changes to current engineering/manufacturing situation; present findings using relevant methods eg use of graphs, statistics, flow diagrams, layouts, computer programs, graphical techniques, video, file, written reports and discussion; use of appropriate lean manufacturing techniques eg use of QCD metrics, VSM, process mapping, takt time analysis, production smoothing, pull systems, SMED, visual management techniques 159
Learning outcomes and assessment criteria Learning outcomes On successful completion of this unit a learner will: LO1 Understand productivity measurement techniques and the effect of a range of improvement methods Assessment criteria for pass The learner can: 1.1 describe techniques of productivity measurement 1.2 analyse and evaluate the usefulness of the range of productivity measurement techniques 1.3 describe methods of productivity improvement 1.4 analyse and evaluate the effects of the range of productivity improvement methods LO2 Understand the features of work measurement and method study techniques 2.1 explain how work study comprises of work measurement and method study techniques 2.2 describe work measurement and method study techniques 2.3 analyse a range of work measurement and work study techniques used for a given situation LO3 Be able to assess the ergonomic and layout planning features of workstation and manufacturing operations design LO4 Be able to select and apply appropriate industrial engineering techniques to a given engineering/ manufacturing situation 3.1 describe ergonomic and layout planning features of workstation and manufacturing operations design 3.2 assess these features to develop criteria for good layout design 4.1 gather and present appropriate information from a given engineering/manufacturing situation 4.2 select industrial engineering techniques appropriate to a given engineering/manufacturing situation 4.3 apply industrial engineering techniques to a given engineering/manufacturing situation. 160 BH023332 Edexcel BTEC Levels 4 and 5 Higher Nationals specification in Engineering
Guidance Links This unit can be linked with a wide range of engineering/manufacturing specialist units including Unit 9: Manufacturing Planning and Scheduling Principles, Unit 10: Manufacturing Process, Unit 30: Quality Assurance and Management, Unit 20: Quality and Business Improvement and Unit 31: Value Management. Essential requirements Many of the techniques involved in industrial engineering use specialist software that may prove expensive. In such cases, centres will need to ensure that learners can view an industrial demonstration of such software at the least. Employer engagement and vocational contexts Industrial visits, work placements or employment could provide access to additional resource facilities and reinforce relevance. 161