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.