In this blog post, we’ll explore how Scientific Management is applied to workstation design and factory layout to boost productivity and work efficiency.
The Beginnings of Scientific Management and Industrial Engineering
Industrial engineering is the discipline that studies efficiency. It investigates ways to make systems operate more efficiently, and historically, there have been two major trends in its development. The first is Operations Research, which emerged during World War II to efficiently manage the military and military supplies; the second is Scientific Management, which significantly influenced the growth of U.S. industry by improving the efficiency of production processes. While operations research developed primarily through a mathematical approach utilizing linear and probabilistic models, scientific management focused on minimizing waste in the production process and improving work methods. In this article, we will examine scientific management techniques applied to workstation design and factory layout.
The Relationship Between Workstation Design and Work Efficiency
A workstation is the space where an operator performs specific tasks in the production process. These tasks generally require a high level of concentration and often consist of multiple detailed steps. It is more comfortable for an operator to move only their forearm than to reach far with their hand, and movements using only the wrist are even more efficient. The workspace is divided into the Normal Work Area—the zone reachable by moving only the forearm—and the Maximum Work Area—the zone reachable by fully extending the arm. All materials and tools required for the task must be located within the Maximum Work Area, and it is desirable for as much of the work as possible to be performed within the Normal Work Area.
There are also various factors to consider for the worker’s comfort. Most notably, an appropriate chair must be provided; it should have sufficient cushioning and allow the worker to adjust the height and posture to suit their physical condition. Such a chair not only increases work efficiency but also reduces worker fatigue and provides a sense of psychological stability by allowing the worker to customize their work environment. Thus, not only the worker’s efficiency but also their health and psychological well-being are important considerations when designing the work environment.
The arrangement of tools and materials on the workbench is also crucial. It is advisable to place tools and materials close to where they are actually used and arrange them consistently according to the work sequence. By minimizing unnecessary movement and arranging items in the order they are used, workers can perform tasks more intuitively, and shorter movement paths significantly improve work efficiency. Additionally, appropriate lighting, the use of gravity, and maintaining a consistent work rhythm are also considered factors that enhance work efficiency. Such improvements in workbench design can, in some cases, significantly boost productivity while simultaneously increasing satisfaction with the work environment.
Factory Equipment Layout Based on Production Methods
When arranging factory equipment, it is essential to consider not only the efficiency of individual workers but also the overall workflow. The workflow varies depending on the characteristics of the products being manufactured.
In mass production of a limited number of product varieties with a consistent production process, products move along a conveyor belt while simple, repetitive tasks are performed at each process station. Organizing each process station to repeat the same task in this manner ensures high productivity; this type of equipment layout is called a “product-centered layout.” Since the conveyor belt moves at a constant speed, work must be allocated so that each worker can handle a workload that matches that speed.
In contrast, in high-mix, low-volume production, the production process is often complex, and the steps vary from product to product. Therefore, it is more efficient to organize work areas by process. Since products follow different paths depending on the item, it is more appropriate to arrange machinery around related processes rather than using a uniform conveyor system. This approach is called a process-centered layout.
In scientific management, interdependence charts are created to analyze the relationships between processes, and design principles are established to place highly interdependent processes close to one another.
In cases such as airplanes or ships, where products are very large and the manufacturing processes vary significantly from product to product, it is more efficient for workers to move with the equipment rather than moving the products themselves. This type of equipment layout is called a fixed-position layout.
Scientific Management Applied to Various Production Environments
Attempts are also being made to combine the advantages of basic facility layouts. A representative example is the cellular layout. This method arranges equipment along a single product flow, similar to a product-centered layout, but organizes the facilities in a cellular formation rather than a straight line, allowing products to move relatively freely between equipment, much like a process-centered layout. This enables more flexible production than product-centered layouts while offering higher efficiency than process-centered layouts. Depending on the characteristics of the products being manufactured, various hybrid layouts like this are utilized in addition to the three basic layout types.
These design principles can be viewed as a systematic compilation of the empirical knowledge possessed by skilled workers with long experience in factories. Workbench design aims to create an environment where workers can perform tasks more conveniently and intuitively; to this end, improvements are made, such as arranging tools and materials in the order of operations and placing them within easy reach. The layout of factory equipment is also a process of systematically designing the most efficient arrangement for producing goods. Scientific management is a management technique that increases productivity by systematically analyzing and standardizing such seemingly simple improvements.
Early research on scientific management included case studies reporting significant productivity gains achieved solely through improvements in work methods. A prime example is Frank Bunker Gilbreth’s motion study, which demonstrated how work efficiency was greatly enhanced by refining the motions involved in bricklaying and standardizing tool usage. However, the 7- to 10-fold productivity gains reported in early research were observed in specific work environments; today, it is more appropriate to view these figures not as typical outcomes but as historical examples illustrating the importance of work analysis and standardization.
Scientific management encompasses a wide variety of methodologies and has a broad scope of application. Its principles are utilized not only in factory design and workplace design but also in various fields such as improving office work processes, user interface (UI) design, and user experience (UX) design. Today, it continues to evolve through integration with automation, data analysis, ergonomics, and digital production systems, and will continue to play a vital role in identifying and eliminating hidden inefficiencies across diverse fields.
