METHOD STUDY (CONTINUED)

Methods Study Charting Techniques (c) Flow Diagram:- It is the plan view of a work to a certain scale and a line diagram which indicates the path followed by object under study. It shows the path followed by materials , man or machine. Flow process chart and flow diagrams are very simple and effective tools of methods study. They are very useful in establishing the overall sequence of operations and in determining the best layout. (d) Multiple Activity Chart (MAC): It is a graphic representation of the simultaneous activities of more than one man or machine on a common time scale to show their inter-relationship. These can be effective in analyzing situations in which at least two resources are employed within an operation. The objective is to group or arrange the sequence of events with respect to the resources employed so that a minimum unit production time is determined. MAC may be of the following types: One manone machine chart (Man-Machine Chart) Two menone machine chart One mentwo machine chart Two or more menone or more machine chart. A Man-Machine Chart is illustrated in Figure . The general approach in such analysis is to try to use the resources in optimal manner. The focus of the analysis is to minimize the cycle time of man or the operator. Based on this study, one can propose a better method. Efforts are directed to reduce the idle times of man and machine

(f ) String Diagram. For this diagram, a length of string is used to record the extent as well as the pattern of movement of a worker or piece of equipment within a limited area during a certain period of time. It is used to study where the journeys are irregular in distance and frequency. It is used in the following situations: When a group of operators is working. When a single operator is attending several machines. In process, where several sub-assemblies have to be moved to other assembly. Where processes require the operator to be moved from one work-place to another. For checking the relative value of various layout.

Micro-Motion Study In certain types of operations and particularly those with very short cycles which are repeated thousands of time, micro-motion study is carried out. This study is made with much more details to find out the possibility of saving movements and efforts and thereby developing the best possible pattern movement. Gilbreth divided the human activities into 17 fundamental motions called therbligs which are given below This method originally used a constant speed (1000 frames per minute) 16-mm industrial camera; therefore the time between successive frames was 0.001 minutes. By examining and counting successive frames, usually with the help of a frame counter attached to the projector, one could break down the detailed human activity. A SIMO (Simultaneous Motion) chart is used to display a micromotion study analysis. By filming various alternative ways of performing an operation and analyzing their respective charts, it is possible to devise combinations of motion sequences that minimize unit cycle times. The employee is than trained to perform the operation using a better method. Micromotion study can involve a considerable amount of film. Therefore, a technique known as memomotion study (similar to time-lapse photography) was developed, which employs a longer time interval between successive frames. It is often more feasible than micromotion study for medium- and long-cycle operations.

With the introduction video camera, it has become common practice to record the worker performance on videotape as part of the time-study process. (a) SIMO Chart SIMO stands for simultaneous motion cycle chart. It records simultaneously the various therbligs performed by different parts of the operators body of one or more operators on a common time scale. The term therbligs denote the fundamental motions of human activity. This was proposed by Frank Gilbreth and therbligs (Gilbreth spelled backwards) include activities like search, find, transport empty, preposition, grasp, etc. SIMO chart could be used as a tool for reducing the work cycle, and reducing the fatigue due to excessive work done by only one hand or one part of the body. (b) Cycle Graph Gilbreth used this initially for analysis of work. It is a photographic technique usually made by a process of double exposure.

 The first exposure is a normal snapshot in which the workplace and the worker are photographed. Special lights are then attached to the hands of the operator and the lights are allowed to burn continuously and the operator has to perform his work. The second exposure is a time exposure that lasts for one complete cycle. Only the light from these bulbs is recorded as s continuous line on the photographic film - the other lights are switched off. Such a picture is called a cyclegraph. This shows the workplace, the worker, his hands and a continuous line showing the motion patterns. Limitations:-In this cyclegraph, speed and direction of movement could not be determined from the continuous line of the light on the film. (c) Chronocycle Graph To overcome the limitations of the cyclegraph, Gilbreth used a relay circuit and made the lights attached to the operator to flicker (on and off). This caused on the film pear shaped dots from which the acceleration, deceleration and direction of movement by the increasing or decreasing length of the pear shaped dots and the direction of the tail formed by the moving light can be eliminated. The bulb is made slowly OFF and quickly ON and photograph is taken. The path of the bulb (path of mans movement) appears dotted, the dots taking pear shape. If the movement is fast, the dots are spaced far apart and they are closer if the speed is slow.

String Dia Work Study: The Pioneering Technique of Improving Value for Money and Productivity Work study, under the major discipline of industrial engineering, emerged as the earliest effectiveness and efficiency technique that even to date remains the basic to all other techniques that developed later. Work study was the sequel to Taylors famous scientific management. Work Study is defined as the systematic examination of the methods of carrying on activities so as to improve the effective use of resources and to set up standards of performance for the activities being carried out. Work study has two major branches: 1. Method study 2. Work measurement

Method Study Method study is the systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and more effective methods and reducing costs. It uses different sets of techniques to do so. Objectives of Method Study Improvement in use of all the inputs i.e. men, machines, material, money and also, time and information. Economy in human effort and reduction of unnecessary fatigue. Layout improvements. Improvement in design of plant and equipment. Improvement in safety standards and procedures. Development of better working environment. Seven Steps of Carrying Out Method Study: The Process 1. Define existing method. 2. Record existing method. 3. Examine existing method. 4. Develop new method. 5. Define new method. 6. Install new method. 7. Maintain new method. Different Recording Techniques Outline process charts Flow process chart: man type, material type, equipment type Two handed process chart Multiple activity chart: using time scale Simo chart: using time scale Flow diagrams String diagrams Cyclegraph Chronocyclegraph Travel Chart Some Details on Step 3 of the Process of Method Study i.e. Examine Examine step uses questioning technique. Each activity of the method under examination subjected to systematic and progressive series of questions. There are two types of questions asked: 1. Primary questions 2. Secondary questions Primary questions: Questions are asked and answers found out on: Purpose: for which activity is being done. Place: at which activity is being carried out. Sequence: in which activity is being performed. Person: by whom activity is being rendered. Means: by which activity is being accomplished. This primary examination is carried out with a view to Eliminate, Combine, Rearrange and/or

 Simplify the activities Secondary Questions During the secondary questions, answers to the primary questions are subjected to further query to determine whether possible alternatives of place, sequence, persons and means are practicable and preferred as a means of improvement upon the existing method. 1. Purpose: What is done? Why is it done? What else might be done? What should be done? 2. Place: Where is it done? Why is it done there? Where else might it is done? Where should it be done? 3. Sequence: When is it done? Why is it done? When might it be done? When should it be done? 4. Person: Who does it? Why does that person do it? Who else might do it? Who should do it? 5. Means: How is it done? Why is it done that way? How else might it be done? How should it be done ?