Work Study – Method Study and Work Measurement

8/14/2019 Work Study Method Study and Work Measurement

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Work Study Method Study and Work Measurement

Work Study

Body of Knowledge [BoK] to improve the productivity of jobs:

-by better ways of doing jobs : analysis of work methods & equipment

used / design of optimum method / standardisation of proposed

method

-by better Control over the output of jobs

-by better standards with respect to time

-by obtaining cooperation between management and workers for

maximum mutual prosperity

Method Study Work Measurement-Systematic Recording of existing method

-Critical examination of existing method

-Developing improved / easier / cheaper /

more effective method

-Application of techniques designed

to establish the time for a qualified

worker to carry out a specified job at

a defined level of performance


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Work Study

Qualified Worker [ILO]:

-Necessary Physical Attributes

-Required intelligence

-Required Education

-Acquired necessary skill and knowledge

-Capable of carrying out the job with satisfactory level of safety standards,

quantity and quality

Foundation of work study:

Scientific ManagementFW Taylor, Frank Gilbreth & Lillian Gilbreth

Taylorism.The greatest production results when each worker is given a definite task to be

performed in a definite time in a definite manner.

What can be measured is controllable.


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Work Study

Objectives of Work Study

To analyse the present method of doing a job to better the method

-To measure the work content of a job by measuring the time required to do the jobby a qualified worker to establish a standard time

-To devise the most suitable method of doing the job by ensuring the best possible

use of human, machine and material resources to produce quality product at

optimum cost

-To improve operational efficiency

Benefits of Work Study

-Increased Productivity -Better Operational efficiency

-Reduced manufacturing cost -Better employee morale

-Better plant layout / working conditions -Better Job satisfaction

-Better planning -Better incentive schemes

-Improved work flow -Better labour efficiency standards


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Work Study

Method Study Work Measurement

Operation Process Chart

Flow Process Chart

Man-Machine Chart

Motion Study [Gilbreths]

Memomotion Study [Mundel]

Direct Time Study [Taylor]

Synthesis Method

Analytical Estimatimg

Pre-determined Motion

Time System [PMTS]

Work Sampling / Activity

Sampling / Ratio-Delay Analysis

Components and Methods / Techniques


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Work Design

Method Study /

Operations Analysis

Work

Measurement

Motion

Study

Time

StudyUsed to find

the fastest

motion

sequences

Used to

evaluate

alternatedesign /

methods

Developed by Gilbreths Developed by Taylor

Objective:Improve

Operations

Objective:Improve

Planning & Control

Relationship of Motion and Time Study to Work design

Work Study


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Work Study Procedure

-Selectthe job / process / operation

*High Operating Cost *Frequently repeated job *Very bad product quality

*Bottleneck to other jobs *Labour intensive *Safety hazard *Bad working conditions*Excessive material movements *High Return on Investment etc.

-Observe andRecord sequence / interrelationship / movement of activities

*Operation process chart *Flow process chart *Motion chart *SIMO *Man-Machine

Charts etc.

-Examinethe current method. Look for ways in which tasks can be eliminated, combined,rearranged, and simplified. 5W2H

-Developthe most practical, economic, and effective method. Obtain approval for the new

method

-Measurethe work content and establish the standard time

*Time study *Synthesis method *Analytical estimating method *PMTS *Worksampling

-Define the new / improved method. Tools / materials / operator skill / working conditions

-Install / implement the new method as standard practice

-Maintain the new / improved method by periodically checking it in use

Work Study


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Work Study

5W2H Typical Questions for Processes Improvement Questions

Who?

Who does this?

Who should be involved but is not?

Who is involved but shouldnt be?

Who has to approve?

Should someone else do it?

Could fewer people do it/

Could approvals be eliminated?

What?What is done?

What is essential?

Does every step have to be done?

Are steps omitted?

When?

When is this activity started?

When does it end?

When is it repeated?

Can it be done at a different time?

Can cycle time be shortened?

Can it be done less frequently?

Where? Where is this activity done? Can it be done elsewhere?

Why?Why do we do this? Can it be eliminated?

Can another group do it?

Can it be outsourced?

How/ How is this done? Is there a better way?

How

much/many?

How much does it cost? How much less could it cost?

5W2H Questions


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Work Study

Objectives of Method Study

-To study the existing / proposed method of doing any job

-To develop an improved method to improve productivity

-To reduce excessive material handling

-To improve utilisation of resources

-To eliminate wasteful and inefficient motions

-To standardise work methods or processes

Advantages of Method Study

*Work simplification * Improved method

*Better product quality * Better layout

* Improved work flow * Better material handling

* Shorter production cycle time * Higher job satisfaction

*Improved productivity


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Operation Process Chart


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Work Study

Recording Techniques in Method Study

Cast

Waits until

inspection

Inspect casting

To buffing section

Buffing / Polishing

Inspect

Store

Flow Process Chart

Left Hand Right Hand Machine

Pick-up

plate

0.05

Dip plate

0.03

Place

plate

0.03

Idle

Unload

machine

0.04

Idle

Pushbutton

0.01

Idle

Being

Unloaded

0.04

Idle

Punch

0.02

Return

0.02

Man-Machine Chart


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Work Study

Motion Study

It is the science of eliminating unwanted and or unnecessary motions in carrying

out any jobs. The objective of motion study is to identify and implement the scheme

of the least waste methods of labour. Micro Motion Study provides a valuabletechnique for making accurate analysis of operations.

Purpose of Motion Study:

-To study interrelationship among team members

-To study interrelationship between operator and machine

-To obtain the time of an operation

-To establish a permanent record of the method of doing a job

Micro Motion Study of operations is done by filming the operations and then

analysing the film to make SIMO charts. Very small time values (1/2000 minute)are used [micro-chronometer]. A job is divided into micro motions which are known

as Therbl igs.


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Work Study

Work Measurement

Objectives:

-Improved planning and control of jobs -Efficient manning of the plant-Reliable ideas for labour performance -Reliable basis for labour cost control

-Basis for sound incentive scheme

Benefits:

-Basis for comparing alternate methods -To prepare work accurate schedules

-To set labour performance standards -To compare actual& standardtimes

-To make labour cost estimation -To estimate tenders / price / delivery

Techniques:

-Direct e Study -Synthesis method

-Analytical Estimating -Pre-determined Motion Time Systems

-Work Sampling or Activity Sampling or Ratio Delay Method


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Work Study

Time Study

Time Study is concerned with the determination of the amount of time required to perform a

unit of work.

ILO defines it as: Time Study is a work measurement technique for recording the times andrates of working for the elements of a specified job carried out under specified conditions and

for analysing the data so as to obtain the time necessary for carrying out the job at a defined

level of performance.

Objectives:

-To determine the quantum work

-To establish the Standard time

-To furnish basis for comparison

-To set labour standard

-To determine standard costs

-To balance the work in assembly line

-To set piece rate incentives

-To set completion schedule

-To determine cycle time of job

Criteria for selection:

-New job for production

-Change in manufacturing method

-Design change

-Employee complaint about Standard

time

-Bottleneck operation-Highly labour intensive

-Job to be included in incentive

scheme -For new tooling and

fixtures


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Work Study

Work Sampling

It is a statistical sampling method to estimate the proportion of time devoted to a given type of

activity over a certain period of time by means of a large number of random spot

observations. Particularly useful to estimate the delays [ratio-delay analysis] such as:

Supply failures

Supply delays

Machine breakdowns

Manpower idling etc.

The larger the number of observations, the better the estimate (Accurate).

Uses of Work Sampling:

* To estimate time used by Operators and Machines

* To determine allowances to include in Standard times* To indicate the distribution of work among group members

* To provide basis for indirect labour time standards

* To determine productive and non-productive utilization of manpower

* To determine the standard time for repetitive operations as an alternative to time study


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Work Study

OT

PRF

PA

RA

CA

SA

PoA

NT / BT

ST

AT

Legend

OT -> Observed Time.

PRF -> Performance Rating Factor

NT / BT -> Natural / Basic Time

PA -> Process Allowance

RA -> Relaxation Allowance

CA -> Contingency Allowance

SA -> Special Allowance

*Interference Allowance

*Periodic Activity

Allowance

ST -> Standard TimePoA -> Policy Allowance

AT -> Allowed Time

Computation of Standard Time and Allowed Time


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Work Study

Exercise -01

Calculate the standard time per article produced from the following data

obtained by a work sampling study.

Total no of observations : 3000.

Working observations : 2500.

No of units produced during 100 hrs duration = 6000.

Proportion of manual labour = 75%. Proportion of machine time = 25%.

Observed rating factor for manual labour = 120%.

Total allowances = 15% of normal time.


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Work Study

Exercise - 02

Given below is the data regarding production of units:

Direct material price = Rs. 2.

Wage rate Rs 2000 per month consisting of 25 working days and 8 hours perday.

Overheads expressed as percentage of direct labour = 200%.

Time taken to manufacture 4 units each consisting of 4 elements a, b, c, d

during 4 cycles given below:

Element Cycle Cycle 2 Cycle 3 Cycle 4 ElementperformanceRatingabcd

1.20.71.40.5

1.30.61.30.5

1.30.651.30.6

1.40.751.20.4

851209070

Calculate standard time, labour cost, overhead cost, total production cost

per piece, given the personal, fatigue and delay allowances as 25%.


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Work Study

Exercise - 03

A 8 hours work measurement study in a plant reveals the following:

Units produced = 320 nos. Idle time 15%. Performance rating = 120%.Allowances = 12% of normal time. Determine the standard time per unit

produced.


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Work Study

Exercise - 04

The following data refers to the study conducted for an operation. Table shows

actual time for elements in minutes:

Cycle Elements 1 2 3 4 5

1 2.5 2.1 2.2 5.4 2.5

2 6.2 6.0 6.1 5.9 5.9

3 2.3 2.0 2.1 2.1 2.2

4 2.4 2.1 2.8 3.0 2.3

1) Element 2 is a machine element

2) Consider the observations as abnormal and delete the same if they are

more than 2% of the average time of that element.

3) Take performance rating as 120.

4) Allowances are

Personal30 minutes in a shift of 8 hours

Fatigue15%

Contingency2%

Estimate the standard time of operation and production per 8 hour shift.


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Work Study

Exercise - 05

A job has been divided into five elements 1,2,3,4&5. The element times for the

first 5 cycles along with performance rating are given in the following tables:

ElementCycle time in minutes Performanc

e(%)

Cycle-1 Cycle-2 Cycle-3 Cycle-4 Cycle-5

1 1.84 1.77 1.78 2.02 1.79 95

2 1.11 1.42 1.16 1.29 1.25 110

3 2.46 2.39 2.34 2.36 2.30 90

4 1.48 1.55 1.72 1.63 1.51 100

5 1.72 1.81 1.65 1.76 1.79 115

Determine the estimated normal time for the job.

Calculate the standard time if the permissible total allowance is 25% of

normal time.

Work Study – Method Study and Work Measurement

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