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METHOD STUDY
(AS A TECHNIQUE OF COSTREDUCTION)
ZAKIR A PATEL
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CONTENTS
Definition and Objectives of Method Study
Method study procedure
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Man, Machines, Materials, Money, Technology andTime are the main resources required to produce goodsand are to be deployed in the most effective manner
We have to select the best available combination ofthese resources at any point of time.
Method Study helps in analyzing the existingmethods and develop a more efficient method forfuture.
Method Study
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Method Study is the systematic recording and criticalexamination of existing and proposed ways of doing work,as a means of developing and applying easier and more
effective methods and reducing costs.
Definition And Objective of Method Study
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THE OBJECTIVES OF METHOD STUDY
Improvement of processes and procedures Improvement in the design of plant and equipment
Improvement of plant layout.
Improvement in the use of men, materials and machines.
Efficient materials handling
Improvement in the flow of production and process. Economy in human effort and the reduction of unnecessary
fatigue.
Method Standardization
Improvement in safety standards.
Development of a better physical working environment
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METHOD STUDY PROCEDURE
The basic approach to method study consists of the following
eight steps:
1. SELECT :- the work to be studied and define itsboundaries.
2. RECORD :the relevant facts about the job by directobservation and collect such additionaldata as may be needed from appropriatesources.
3.EXAMINE the way the job is being performed andchallenge its purpose, place, sequenceand method of performance.
4. DEVELOP the most practical, economic andeffective method.
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5.EVALUATE different alternatives to developing
a new improved method, and
compare the cost-effectiveness ofthe selected new method with the
current method of performance.
6.DEFINE the new method in a clear manner and present
it to those concerned, management, supervisors andworkers.
7.INSTALLthe new method as standard practice and trainthe persons involved in applying it.
8.MAINTAIN the new method & introduce controlprocedures to prevent a drawback to the previousmethod of work.
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These are the seven essential stages in theapplication of method study ; none can beexcluded. Strict adherence to the sequence, aswell as to their content, is essential for the
success of an investigation. They are showndiagrammatically on the chart.
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There are three factors that should be kept in mind when selecting ajob.
1. Economic or cost-effective considerations.
2. Technical considerations.
3. Human considerations.
1. Economic considerations:It is obviously a waste of time to start or continue a long
investigation if the economic importance of a job is small.
Questions that should always be asked
Will it pay to begin a method study of this job? Or
Will it pay to continue this study?
STEP 1: SELECTINGTHEWORKTOBESTUDIED
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Obvious choices for study are:
A. Key profit-generating or costly operations or ones with the largestScrap/waste rates.
B. Bottlenecks which are holding up other production operations, orlengthy operations that consume a great deal of time.
C. Operations involving repetitive work using a great deal of laborand ones that are likely to run for a long time.
D. Movements of material over long distances between workstations,
those involving the use of a relatively large proportion of labor orwhich require repeated handling of material.
One of the easiest techniques that can be used to identify keyoperations as listed in part (A) is the Pareto analysis (sometimesalso referred to as the ABC analysis of value analysis).
The same observation can be extended by saying that among all theoperations in a given plant a small number account for the largestshare of cost or of profit, or the largest percentage of waste.
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To illustrate the point we will consider the following example.
Let us assume that a certain enterprise produces 20 differentproducts.
Each of these products generates a certain profit.By listing the annual production and profit contribution oneobtains the results shown in table 6.
The next step consists of rearranging these items in descendingorder of importance according to profit. The result would thenappear like the one shown in table 7.
From table 7 it can be seen that three products only, listed asAitems, account for 60 per cent of the profit.
These are the most profitable and any improvement in methodsof producing these particular products would reflect highly onprofits. They would be a priority for study.
Products listed under B, which are seven in number,contribute 25 per cent of the profit. They could then assume a
second importance,while products C would command the last priority since theircontribution to profit is minimal.
The same type of analysis can be conducted to determine themost costly products or processes or the products or processesthat yield the highest waste.
Those would then become a priority for study by the work study
specialist.
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2. Technical or technological considerations:
One of the important considerations is the desire by management to
acquire more advanced technology, i.e. in equipment or in processes.
Therefore, management may want to computerize its office paperworkor its inventory system, or to introduce automation in the productionoperations.
Before such steps are taken, a method study can point out the most
important needs of the enterprise in this respect. The introduction of new technology should therefore constitute an
important factor in the choice of methods of work to be investigated.
3. Human considerations:
Certain operations are often a cause of dissatisfaction by workers.
They may bring on fatigue or monotony or may be unsafe to operate.
The level of satisfaction should point to a need for method study. In asimilar fashion, a choice of a particular job for study may lead to anxietyor ill feeling. The suggestion given here is to leave it alone.
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STEP 2: RECORDING THE FACTS
The next step in the basic procedure, after selecting the work to be studied,is to record all the facts relating to the existing method
The success of the whole procedure depends on the accuracy with which thefacts are recorded, because they will provide the basis of both the criticalexamination and the development of the improved method
Recording techniques known as CHARTS and DIAGRAMS Charts and diagrams broadly grouped as:
Charts Indicating Process Sequence
Charts Using Time Scale
Diagrams Indicating Movement
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PROCESS SEQUENCES includes the following CHARTS
OperationProcess Chart
Flow Process ChartMan , Material andEquipment Type Two Handed
Process Chart
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Process Chart Symbols
Indicates the main steps in a process, method or procedure.
Usually the part, material or product concerned is modified or
changed during the operation.
Inspection
Indicates an inspection for quality and / or check for quantity
Operation
Transport
Indicates the movement of workers, materials or equipment from place
to place
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Temporary Storage or Delay
Indicates a delay in the sequence of events : for example, work waiting
between consecutive operations, or any object laid aside temporarily without
record until required.
Permanent Storage
Indicates a controlled storage in which material is received into or issued
from a store under some form of authorization; or an item is retained for
reference purposes.
Process Chart Symbols
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The Outline Process Chart
An outline process chart is a process chart giving an overall picture byrecording in sequence only the main operations and inspections
It does not portray the details delays , movements, and storage
It does not go into the details of the details of the place of activity, theperson who performs it, or the physical means of achievement
In making an outline process chart we start with a vertical line downthe right hand side of the page to show the operations and inspectionsundergone.
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The Outline Process Chart- Example
For the purpose of illustration , the case of the repair of a bicycle is
taken.
In this example it is assumed that the bicycle had been involved in aminor accident and required restricted repairs to the front wheel, theleft pedal and the steering handle.
The Outline Process Chart would be
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FLOW PROCESS CHART (FPC)
It is a process chart setting out the sequence of the flow of a product orprocedure by recording all events under review using appropriateprocess chart symbols.
BENEFITS: In identifying ways of improving the process by eliminatingunnecessary idle time, minimizing the distances things must be movedor rearranging tasks for greater efficiency
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Three types of flow process charts
MAN TYPE:
Flow chart which shows the actions of a person
MATERIAL TYPE:
Flow chart which shows what happens to a product or item
EQUIPMENT TYPE:
Flow chart which shows how a tool or other piece of equipment isused
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Flow Process Charts- Material Type
An FPC (Matrl) sets out the sequence of flow of a product or a document ,recording all the events that affect the material or document beingprocessed.
Illustration : The process of charging of batteries by Umesh Motors(P)
Ltd. Is as follows. Customers deposit discharged automobile batteries at the ReceptionBay of the workshop, and obtain a receipt. After three days, they collect their respective batteries from the DeliveryBay of the workshop, on presentation of the receipt and payment ofservice charges.
The reception clerk marks each battery with a customer-identificationnumber.He stacks the batteries on a steel shelf.
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The chargeable batteries are collected twice a day from the Reception Bay bymazdoor Dharam. He transports the batteries on a stillage truck , and delivers them to thecharging shop, which is 50 meters away from the Reception Bay.
At the Charging Shop , the battery is tested, cell by cell , for voltage andspecific gravity. The cells are toppedup to the correct level. The battery is then moved to the charging bench, and placed on charge by
connecting the terminals to the bus bars. While on charge , it is tested every fourhours for specific gravity.On completion of charging, which is determined by the specific gravity of theelectrolyte , the connections to the bus bars are removed.The battery is tested for voltage of each individual cell.It is then placed on a stillage(small wooden platform with low legs)
Mazdoor Dharam collects a stillage of charged batteries and transports them, by astillage truck, to the delivery bay , which is 35 meters away from the charging shop. Here the Delivery Clerk takes over the batteries and places them on a steel rack.
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Flow Process Charts- Man Type
An FPC(Man), sets out the sequence of activities of an individual performing a
task under study .
Only four symbols are employed- operation , inspection, delay, transport
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TWO HANDED PROCESS CHARTS
Two handed process charts is a chart in which the activities of a workers hands
individually(or limbs) are recorded in the relationship to one another
SYMBOLS AND THEIR DESCRIPTIONS FOR TWO HANDED CHARTS
Operation
Is used for activities for grasp, position, use, release etc. of atool, component or material
Transport
To represent the movement of hand to or from thework, or a tool, or material
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Temporary Storage or Delay
Denotes time during which the hand being charted is idle(although the others may be in use)
HOLD
In two handed process chart , hold is used to represent the activity of
holding work , tool or material i.e when the hand being charted is
holding something
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MULTIPLE ACTIVITY CHART
A chart on which the activities of more than one
subject (worker, machine or equipment) are each
recorded on a common time scale to show their
interrelationship
Useful in organizing teams of operatives on mass
production workand also on maintenance workwhen
expensive plant cannot be allowed to remain idle
longer
Time (Hours) WORKER 1 WORKER 2 WORKER 3 WORKER 4
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Time (Hours) WORKER 1 WORKER 2 WORKER 3 WORKER 4
5
10
15
20
25
30
35
Disassembly of lathe Disassemble lathe. Head
stock, bed, fed and lead
screws, carriage and
tailstock
Disassemble head stock,
Remove main spindle,
speed change
mechanisms, and change
gears.
Idle
Inspection to determine
fault
Wash with thinner to
remover grease and
clean parts
Repair carriage bed and
lay out screw, nuts, etc.
Repair and assembly of
feed gear box
Repair carriage bed,
check and repair feed
screw and apron of the
carriage.
Repair and assemble
feed gear box
Grind lathe beds
Fit saddle to bed
Assemble tailstock
Assemble and mount bed
and headstock on stand
Repair carriage way and
lay out screw, nuts, etc.Assemble tailstock.
Idle
Fit cross slide and top
slide
Assemble cooling system
Repair and assembly of
apron
Install electric motor
Install feed gear box,
apron and feed rod
Installing feed gear box
apron and feed red
Mount electric motors
and fit reservoirs
Running in and finishing Run in and finish Run in and finish
Testing the lathe Test and calibrate
assembly
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MAN-MACHINE CHART
Variant of Multiple Activity Chart
Present a picture of the operations performedsimultaneously by a man and one or more machines
Useful for
1. Better coordination between man andmachine
2. Reduction / elimination of idle times of manand
machine to improve the utilization3. Exploration of alternative man-machine
arrangements suitable to the plant conditions
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TIME
Min.
Man Machine
2 Remove finished casting clean with compressed
air
Idle
4 Gauge depth on surface plate
5
6
Break sharp edge and clean with compressed air
8 Place in box obtain new casting
10 Clean machine with compressed air
12 Locate castig in fixture: start machine and
automatic feed
15 Idle Mill second face
20
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DIAGRAMSINDICATING
MOVEMENTS
String DiagramTravel Charts
Flow Diagrams
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STRING DIAGRAM
String diagram is a useful tool to record the distance
traveled by a worker in the working area. The string
diagram is a scale plan or model on which a thread is
used to trace and measure the distance traversed which
has to be minimum by
WORKERS
MATERIALOR
EQUIPMENT
during a specified sequence of events
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Observe the clusters of points, pins, turning points. Also observe the grid lines which represent a measure of the
distance between the points.
Red is the staring point and blue is the ending point
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CONSTRUCTIONOFA STRINGDIAGRAM
Step-1 Produce a scale map of the work area
Identifying all machines, furniture and other equipments in the diagramthat can be moved. These could be shaped as pieces of card that canbe pinned to the work area map
Step-2
Identify the points in the process where actions take place and alsoidentify the doorways, pillars etc that effect the path movements andmark the positions of these on the map with map pins and action
symbols. Step-3
Tie the end of a pieces of string to the pin where the process startsand then wrap it around each pin in turn, following the movementaround the process
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CONTINUE..
Step-4
Mark the string at the start and finish points, using a pen.
Step-5
Measuring between the pen marks, will give the totaldistance travelled during the process.
Step-6
Rearrange the movable items on the map, aiming toreduce the total distance
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Mobility:- Rearrange items and movements around fixed or
immovable items such as heavy machines.
Function:- Put machines or people together that perform the
same function. This is useful when varying loads may bebetween machines.
Product:- Put machines or people together that make thesame product. This works well when each machine is used for
only one product.
Strategies for deciding layouts include:
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TRAVELCHART
A travel chart is a tabular record for presenting
quantitative data about the movements of workers,
materials or equipment between any number of places
over any given period of time.
The travel chart also identifies movement, when
movements along complex paths are involved.
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WHY TRAVELCHART ?
Although the string diagram is a neat and effective way of recordthe movement of worker or material
o They take long time to construct ;
o Look increasingly like a complex maze with increasing
complexity of movement paths.
When the movement patterns are complex, the travel chart is
quicker and more manageable to record.
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Count of occurrence
Distance between places
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FLOW DIAGRAM
While the flow process chart describes the flow of a product orprocess, it is generally supplemented with a flow diagram.
While the flow process chart records travel distances and time
taken for various operations, the flow diagram is a plan , drawnto scale of the work area, correctly indicating the position ofmachines and working positions.
The example indicates the flow diagram of receiving,inspection, marking and storing materials.
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IMPROVED FD OF INSPECTIONAND MARKING
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Types of Jobs Examples Recording Technique
Complete Sequence of
manufacture
Manufacture of an electric motor from
raw material to dispatch;
Transformation of thread into cloth from
preparation to inspection;
Receipt, packing and dispatch of fruit
Outline process chart
Flow process chart
Flow diagram
Factory layout : movement of
materials
Movements of a diesel engine cylinder
head through all machining operations.
Movements of grain between milling
operations.
Outline process chart
Flow process chart material type
Flow diagram
Travel chart
Suitability of different recording techniques:-
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Types of Jobs Examples Recording Technique
Factory layout :
movement of
workers
Laborers servicing spinning machine
Cooks preparing meals in a restaurant kitchen
Flow process chart-man type
String diagram
Handling of
materials
Putting materials into and taking them out of
stores
Loading lorries with finished products.
Flow process chartmaterial type
Flow diagram
String diagram
Workplace layout Light assembly work on a bench
Typesetting by hand
Flow process chart-man type.
Two-handed process chart.
Multiple activity chart.
Continue..
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Types of Jobs Examples Recording Technique
Gang work or
automatic machine
operation
Assembly line
Operator looking after semi-automatic lathe
Multiple activity chart
Flow process chart-equipment
type
Movements of
operatives at work
Female operatives on short cycle repetition work
Operations demanding great manual dexterity
Multiple activity chart
Flow process chart
equipment
type
Continue..
EXAMINE
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EXAMINE
The questioning technique is the means by which the
critical examination is conducted, each activity being
subjected in turn to a systematic and progressive series of
questions.
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PRIMARY QUESTIONS
The PURPOSE for which
The PLACE at which
The SEQUENCE in which
The PERSON by whom
The MEANS by which
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THIS EXAMINATION SEEKS TO
the recorded activitiesIdentify possibility of
ELIMINIATING
COMBINING
REARRANGING
OR
SIMPLIFING
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THE SECONDARY QUESTIONS
Definition
The secondary questions cover the second stage of thequestioning technique, during which the answers to theprimary questions are subjected to further query to
determine whether possible alternatives to place,sequence, persons and/or means are practicable orpreferable as the means of improvement up on theexisting method
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Combining the two primary questions with the twosecondary questions under each of the headings
purpose, place, etc., yields the following list,which sets out the questioning technique in full:
PURPOSE: what is done?
why is it done?
what else might be done?what should be done?
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PLACE: where is it done?
Why is it done there?
Where else might it is done?
Where should it be done?
SEQUENCE: When is it done?
Why is it done?
When might it be done?
When should it be done?
PERSON: who does it?
Why does that person do it?
Who else might do it?
Who should do it?
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MEANS: How is it done?
Why is it done that way?
How else might it be done?
How should it be done ?
These questions, in the above sequence, must be asked
systematically every time a method study is undertaken.
They are the basis of successful method study.
Remember Rudyard Kipling's
I keep six honest serving men, They taught me all Iknew, Their names are What and Why and How andWhere and When and Who
DEFINING THE IMPROVED METHOD
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DEFINING THE IMPROVED METHOD
The report should show:1.
Relative costs in material, labour and overheadsof the two methods, and savings expected.
2.The cost of installing the new method, includingthe cost of new equipment and of re-layingout shops or working areas
3. Executive actions required to implement the newmethod.
It should also give details regarding :
1. The tools and equipment to be used2. A description of the method
3. A diagram of the work place layout, jigs/fixturesetc
I
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INSTALLATIONOFTHENEWMETHOD
The success of method study is realized when actual change is
made on ground.
The first part of installation is to define the new method bypreparing the written standard practice.
This method is perhaps the most difficult step ofmethod studyprocedure as it needs reassuring, retraining and supportingthrough acquisition of new skills.
New method involves gaining approval of following personnel for
the changes suggested:1. Concerned department supervision
2. Works and general management
3. Workers and their representatives
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The install Phase in some cases, will require a parallel running of
old and new systems.
While in other cases it may require the build up of buffer stocks.
It may also require changes in procedures, or minor addition ofequipment and process.
Thus, the successful introduction of new working methods isextremely important because very often there is only one chanceto make change.
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MAINTAINTHE NEWSTANDARD
After the introduction of new working methods, it is necessary to
check and verify that the new method is working and is it bringingthe desired results or not. This is the maintain phase.
Proper control procedures are used to ensure that new method ispracticed to achieve the benefits of method study and also to
achieve higher productivity.
One of the common problems of maintaining the new standard ismethod drift.
At last, installation is to be preceded by retraining the workers tooperate new methods. Close contact with the progress of the jobmust be maintained, till it is performed.
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FINAL EXAMPLE
Here I took an example of car manufacturingprocess.
As first step is to select the work to be studied,here, I select the process of car manufacturing.
Step-1 select, manufacturing process of car
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STEPSINCLUDEINMANUFACTURINGPROCESS
Parts are produced in various plantsStart with the frameInstalling the parts
Engine and Transmission InstalledBuilding the ShellFinal Body ComponentsInspection and WashingPaint
The Inner WorkingsThe Shell and the FrameTest the Car
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RECORDINGOFWORK
Suppose, here I used string diagram to record the work.
Plants
`
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EXAMINE
Here assume that total length of thread is 30cm andtherefore total distance has to covered within theprocess is 30*100= 3000 m. More distance meansmore time and more time mean more cost.
So improvement is required to reduced thedistance.
After considering all activities. It can be seen that allmachineries are movable. So here we rearrange all
machineries and after that will see the synergy.
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INSTALLATION MAINTANCE OF NEW
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INSTALLATION, MAINTANCE OF NEWSYSTEM
Before installation of new plan Length of thread
Distance
Time
Cost
Of the new model should be major and compare with theoriginal one
If profitable then install the new plan and maintain itthrough regular check on it
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