Time and Motion Studies

VTA provides the engineering service of Time and Motion Studies. Existing operations are analyzed through the efficient and verifiable use of video tools. Future-state operations are analyzed using the Maynard Operation Sequence Technique (MOST®). VTA has certified MOST engineering.

The VTA Time and Motion Studies results and benefits:

• Determine accurate manufacturing costs

• Improve or validate productivity standards

• Identify non-value added activities and eliminate waste

• Improve planning, scheduling and throughput

• Support LEAN and Kaizen initiatives

• Support Line Balancing initiatives

LEAN Analysis and Initiatives

Through our LEAN Analysis and Initiatives VTA supports our clients in developing and continuing to expand their LEAN Process Improvements.

The VTA LEAN Analysis and Initiatives results and benefits:

• Identify activities that create value

• Define the Value Stream

• Reduce lead/cycle time

• Decrease work-in process

• Reduce cost

• Improve quality

• Reduce floor space

• Establish Takt time and implement “Pull” in the system

• Assist in establishing a continuing improvement mindset

Simulation Analysis

VTA engineering develops Simulation Models which produce a dynamic, virtual replica of the process or business operations.

The VTA Simulation Models results and benefits:

• Existing operation analysis

• Future state modeling

• Dynamic calculation of resource efficiency

• Identify inefficient operations

• Dynamic calculation of asset utilization

• Identify bottlenecks

• Value Stream Mapping

• Product mix analysis

• Reduce travel time of product and people

• Kanban Sizing

• Scenario and response “What-if” analysis

• Optimize factory layout

• Managers and operators training tool

• 2D and 3D Virtual Presentations

• Increase ROI on process improvement or capitalization spending

Plant and Production Process Layouts

• Existing assets 2D and 3D space documentation

• Exiting process utility documentation

• Future assets specification

• AutoCAD® 2D and 3D floor plans

• Coordination with A/E facility plan

• Transition planning

Operator Task Instruction Development

VTA provides Operator Task Instruction Development which deliver operators, maintenance, repair centers, end users and instructors with detailed, step-by-step, sequential work task descriptions. These can be displayed on terminals, distributed by CD/DVD, or provided in paper document formats.

VTA produced Video Shop Instructions are created in Adobe Acrobat Standard PDF and Windows Media Player files. The PDF contains hyperlinks to items within the Media Player files. The Media Player files provide a scripted, audio/visual demonstration of each work procedure.

Each individual Video Shop Instruction contains:

• Cover page

• Table of Contents

• A "How to Use Manual" page

• General Information

• Quality Requirements

• Transcript of the Work Procedures

• Parts List

• Expendable and Durable Items List

• Pictures and Video of each specific Work Station, Work Bay or Machine

• A list of the tools and or materials to be utilized by the operator

• Pictures and Video of the specific component, subassembly and assemblies

Information Technology Systems

VTA provides design, design–build and software programming of Information Technology (IT) Systems supporting industrial processes. Through the design and implementation of these IT systems the status of production rates, product quality, equipment parameters and production alarms are automatically reported from the plant floor to operators, supervisors and management.

The VTA Information Technology (IT) Systems results and benefits:

• Design, Build, Installation of industrial process State-of-the-Art system

• Operator Interface Terminals (OIT) with Touch screens

• Ethernet based communications

• Real-time data acquisition stored in a Microsoft Access® database

• RFID and bar code material tracking

• Production equipment and processes monitoring, analysis and control, to create a Pull "Customer-Supplier" relationship in the Value Stream

• Kanban management

• Support LEAN and Kaizen initiatives

• Quality measurement data

• SPC and Trending analysis

• Plant floor notification with Andons and Marquee

• Notification system (phone, pager, Intranet/Internet, e-mail)

• Rapid response escalation rules to operator through front office

• Data collection / Historical records

• Operator Work Task electronically displayed

Safety - Risk and Hazard Assessment

VTA provides the engineering services to provide production equipment Risk and Hazard Assessment which develops a comprehensive review and report of each machine to include: Documentation of observed hazards, Recommendations of hazard abatement and Cost estimate of the recommended abatement.

The Risk Assessment and Risk Reduction Plan provides the framework to identify the current use, task risks and hazards, as defined by applicable OSHA, ANSI, NFPA and NEC standards and to estimate, evaluate and document the risks and the methods to reduce the risks and methods of implementation. 

Excerpts from the Risk Assessment and Risk Reduction Plan 

1.  Production Equipment Identification
… Risk Reduction Implementation will first be performed on equipment identified at high-risk and then subsequently to the lower risk applications until all the identified equipment are at a tolerable risk level. 

2.  Information Collection
VTA will collect the pertinent information relating to the Production Equipment identified for a risk assessment. This information includes; the limits of the machine, its current use lifecycle requirements, energy sources …

3.  Consultation with Affected Personnel
VTA will gather input from individuals who have a vested interest in the risk reduction of the equipment. This may include operators, maintenance personnel, …
… VTA will document the level of training, experience or ability of the operators, helpers, maintenance, technicians and trainees.

4.  Observe the Production Equipment in Use
VTA will observe, photograph and video the Production Equipment in use. Although many machines are similar in design …

5.  Assess the limits of the Production Equipment
VTA will assess the limits of the Production Equipment by identifying:

Use Limits, Space Limits, Time Limits, Environmental Limits, Interface Limits

6.  Life Cycle Assessment
The total life cycle of Production Equipment includes; concept, design, construction, testing, installation, deployment, operation …

7.  Identify Hazards
VTA will identify each Production Equipment with a hazard and document the type of hazard. The technique based on observation of task/hazard …

8.  Identify the Risk Level
After the foreseeable task/hazard pairs have been identified, VTA will assign a risk level to each pair. Using consensus standards ANSI B11.TR3 and MIL-STD-882D which prescribe systems to assist in labeling risk levels, … Catastrophic, Serious, Moderate, Minor.

The probability of occurrence of harm is estimated by assessing the frequency, duration and extent of the exposure, …

9.  Evaluate the Risk Level
Based on the assessment of the severity of harm and the probability of occurrence of harm a Three Factor Risk Scoring System and Matrix will be applied to each hazard …

 10.   Risk Reduction System
        If a hazard Level of Risk is not initially tolerable, protective measures need
        to be applied that will effectively reduce the risk of a hazard …

Protective Measures will be considered in the following hierarchical order:

a)  Hazard elimination by design

b)  Implement safeguards & Implement the use of more reliable machine control techniques

c)  Implement awareness means

d)  Implement administrative controls

e)  Personal Protective Equipment

 11.  Estimate Risk and Hazard Reduction Costs
        VTA will provide costing for the recommended risk and hazard
        reductions. The cost will include the associated design, fabrication,
        procurement and installation labor and material costs.

 12.   Process Close-Out
        The final step is to complete the required documentation...

Referenced Standards

OSHA Manuals
National Fire Protection Association (NFPA)
National Institute of Occupational Safety and Health
Department of Defense
ANSI