Work Study

Work Measurement

Method Study

Time Study

Predetermined Motion and Time Study

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Method Study
Method study is the systemic recording and critical examination of existing work and proposed ways of doing work as a means of developing and applying easier and more effective methods and thus reducing cost and time.

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Purpose of Method Study

1. To improve work method and procedure. 2. To determine the best sequence of doing work. 3. To improve labor efficiency. 4. To reduce fatigue/monotony in the work. 5. To reduce the manufacturing cost through cycle time reduction.

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Origin of Methods Engineering

Frank B Gilbreth first become interested in method analysis as an outgrowth of his observations of brick-laying. Gilbreth, who in 1885 was employed as an apprentice bricklayer, soon observed that a journeyman bricklayer used one set of motions when laying bricks slowly, another set when working at average speed, and still a different set when working at rapid speed. As a result of his observations, he invented an adjustable scaffold and developed a set of motions that greatly increased the number of bricks that could be laid in a day.

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Elements for Designing a system

Charles E. Geisel States that in order to design a system (method) thoroughly, eight elements must be considered. 1. Purpose: The function, mission, aim or need for the system (mainly what and why). 2. Input: The physical items those enter the system to be processed into the output (such as fabric, thread, accessories etc). 3. Output: That which the system produces to accomplish its purpose, such as finished garments.
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4. Sequence: The steps required to convert, transform, or process the input to the output. 5. Environment: The condition under which the system operates, including physical, attitudinal, organizational, contractual, cultural, political, and legal environment. 6. Human agents: The people who aid in the steps of the sequence without becoming a part of the output. 7. Physical catalysts: The equipment and physical resources that aid in the steps of the sequence without becoming part of the output. 8. Information aids: Knowledge and information resources that aid in the steps of the sequence without becoming part of the output.
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Steps involved in Method Study 1. Select The job to be analyzed.

2. 3. 4. 5. 6. 7. Record All relevant facts about present method. Examine The recorded facts critically. Develop Efficient, practical and economic methods. Define- the new method. Install The method as a standard practice. Maintain That standard practice.
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1. Selection of the job for method study

Work selected for method study may be an identified problem area or an identified opportunity. It may be identified through a systematic review of available data, normal monitoring of processes, high levels of dissatisfaction and complaint or as part of a change in management policy, practice or location.

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The job should be selected for the method study based upon the following considerations:
a) Economic Aspect
Bottleneck operations Operations involving excessive effort Job having inconsistent quality, Operations generating lot of alters and rejects Frequent complaints from workers regarding the job, More frequent of accidents

b)

Technical Aspect

c)

Human Aspect

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2. Recording Techniques
The Record stage of method study involves gathering sufficient data (in terms of both quality and quantity) to act as the basis of evaluation and examination. A wide range of techniques are available for recording; the choice depends on the nature of the investigation; the work being studied; and on the level of details required. Many of the techniques are simple charts and diagrams, but these may be supplemented by photographic and video recording, and by computer based techniques.
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Chart
A chart may be a diagram, a picture or a graph which gives an overall view of the situation say a process. It helps visualizing various possibilities of alteration or improvement. A chart representing a process may be called a PROCESS CHART. A process chart records graphically or diagrammatically in sequence, the operations connected with a process. The chart portrays the process with the help of a set of symbols and aids in better understanding and examining the process with a purpose to improve.
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Process Chart Symbols:

Operation
Inspection Transportation Delay Storage

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 Operation: Operation represents an action. Operation occurs when an object is internally changed in one or more of its characteristics (physically or chemically). Inspection: an inspection occurs when an object is examined and compared with standard for quality and quantity. Transportation: a transportation indicates the movement of workers, materials or equipments from one place to another.
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 Delay: a delay occurs when the immediate performance of the next planned thing does not take place. It is a temporary holt in the process. Storage: a storage occurs when an object is kept in an authorized custody and is protected against unauthorized removal.

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In addition to the basic symbols discussed above, there are symbols for combined activities also given below. The important event has the outer symbol.

Operation cum transportation

Inspection cum Operation

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Process charts are of three types: 1. Outline process chart. 2. Flow process chart. 3. Two handed process chart.

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Out line process chart

An outline process chart surveys and records an overall picture of the process and states only main events sequence wise. It considers only main operations and inspections. An outline process chart is the beginning of a detailed analysis.

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1. Marker Making

2. Fabric spreading

3. Placing marker on the lay 4. Fabric cutting

5. Numbering 6. 100% checking and parts replacing. 7. Sorting and bundling. 8. Input to sewing room
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Two handed process chart

A two handed process chart records the activities of the left hand and right hand of an operation as related to each other. The activities of two hands can be synchronized by providing a time scale on the chart. This is also known as operator activity chart. Such a chart is generally used for repetitive works of short duration.
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Two Handed Process Chart Old Method

N0 Left Hand Description Time in Sec

1
2 3 4 5 6 7 8 9

Take front on table

Unfold Front Idle put front on the machine table Idle Unfold pocket and take at position Reposition under needle Back stitch and stitch up to pocket mouth Realign

.
. . . .

1.3
2.9 1.0 1.5 2.0 2.8 5.5 8.1 1.9 16

1.3
2.9 1.0 1.5 2.0 2.8 5.5 8.1 1.9 16

. .
. . . . . . . .

Right Hand Description Idle Idle Take out Pocket put front on the machine table Take pocket near machine table Unfold pocket and take at position Reposition under needle Back stitch and stitch up to pocket mouth Realign Sewing

. .
. . . .

10 Sewing

11 Release

Idle

Total

45

45

Method Operations Transport Delays Inspection Storage Total

Operation Name - Front Pocket Attach Operative Name - A

Summary Present LH RH 5 3 4 5 2 3 0 0 0 0 11 11
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Two Handed Process Chart Improved Method

N0 Left Hand Description Time in Sec

1
2 3 4 5 6 7 8

Take front on machine Table

Idle Align and take pocket at position Position parts under needle Back stitch and stitch up to pocket mouth Realign Sewing Release

.
. . . . . . .

2.8
1.5 1.7 1.8 5.1 3.1 16 2

2.8
1.5 1.7 1.8 5.1 3.1 16 2

. . . .
. . .
.

Right Hand Description Take front on machine Table Take Pocket into work place Align and take pocket at position Position parts under needle Back stitch and stitch up to pocket mouth Realign Sewing Idle

Total

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Method Operations Transport Delays Inspection Storage Total

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Operation Name - Front Pocket Attach

Operative Name - A

Summary Present LH RH 5 3 4 5 2 3 0 0 0 0 11 11

Proposed LH RH 4 3 3 4 1 1 0 0 0 0 8 8

Current Method - 45 sec Improved Method 34 sec Difference 11 Method improvement 24.44%
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Flow process chart

A flow process chart is a detailed version of outline process chart and it records all the events. It, Sets out sequence of flow of operations. Records all the events in sequence using process chart symbols. Makes distances travelled and time taken for completing activity. Mention other important points , if any.

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SL NO 1 2 3 4 5 6

Activity Cutting store GSM checking Waiting Move to near cutting table Loading & Spreading Lay translation

Time Distance Remarks if (min) any

600 15 110 02 30 60 Trolley Iron rack GSM cutter

49
02

H6-V3
20

Garber spreader Perforated table & air pressure

Manual

7 8 9 10 11 12 13

Marker placing & attaching Cutting Waiting Sticker attaching & checking Bundling Waiting Reject part cutting

09

58
40 72

5 -

Cutter

Manual

59
40 40

3
10

Manual
Manual, Scissors Trolley, 23 Iron

14 Waiting 15Tuesday, April 23, 2013 Cutting Store

30
300

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Use of Film
In the past, the experienced method engineers found one of the most important aids which was the use of motion pictures with the help of film. There are many situations in which it is difficult to observe all of the actions taking place because of the high speed of activities or the complexity of the operation.

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Having observed slow-motion motion pictures, we are familiar with the facts that one can take motion pictures at normal speed and then, by projecting slow the action down. In using motion pictures, method engineers may have had several objectives in mind. First and foremost, they may have wanted a permanent record of the work as it was being performed. Or they may have wished to use the film for analysis purpose.

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Use of Video
Video recording provides a valuable technique for making minute analyses of those operations that are short in cycle, contain rapid movements, and involve high production over a long period of time. Thus it is very useful in analyzing operations such as the sewing of garments, assembly of small parts and similar activities.

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3. Examine
The recorded data are subjected to examination and analysis; formalized versions of this process are critical examination and systematic analysis. The aim is to identify, often through a structured questioning process, those points of the overall system of work that require improvements or offer opportunity for beneficial change.

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Examine the recorded events critically and in sequence. Critical examination involves answer to a number of questions. An activity can be eliminated, simplified and combines with another. The basic questions are:

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Purpose: what is done?

Why: why it is necessary. Alternative Ways of Doing: what else could be done. Best method of doing: what should be done.

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Person: who does it?

Why: why does he do it. Alternative Ways of Doing: who else could do it. Best method of doing: who should do it.

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Place: where it is done?

Why: why it is done there. Alternative Ways of Doing: where it could be done. Best method of doing: where it should be done

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Means: How is it done?

Why: why is it done by that method. Alternative Ways of Doing: how else it could be done. Best method of doing: how it should be done.

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Time: When it is done?

Why: why it is done at that time. Alternative Ways of Doing: when else it could be done. Best method of doing: when it should be done.

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Sequence: What order it is done?

Why: why it is done before/after some particular operation(s). Alternative Ways of Doing: what else the sequence could be. Best method of doing: what should be the sequence.
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4. Develop
The Examination stage merges into the Develop stage of the investigation as more thorough analysis leads automatically to identified areas of change. The aim here is to identify possible actions for improvement and to subject these to evaluation in order to develop a preferred solution. Sometimes it is necessary to identify short-term and long-term solutions so that improvements can be made (relatively) immediately, while longer-term changes are implemented and come to fruition.
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Develop the better methods as resulted from critical examination and record them. The developed method should be: Practical and feasible. Safe and effective. Economical. Accepted to design, production, quality control and sales department.
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5. Define
Define the new best method and related time and present it to all those concerned either verbally or in writing or using demonstration.

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6. Install
The success of any method study project is realized when actual change is made 'on the ground'. Making theoretical change is easy; making real change demands careful planning - and handling of the people involved in the situation under review. They may need retraining and supporting through the acquisition of new skills, incentives, salary increase, profit bonus etc.

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Installation involves three phases: 1. Planning 2. Arranging 3. Implementing

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During the planning and arranging stages the program of installation and a time table are planned and necessary arrangements of resources, equipments, tools and instructions to workers, overtime etc are made. The implementation or actual installation involves the introduction of developed method as a standard practice. Problem associated with the developed method should be carefully studied and remedied, if necessary. Installation phase is complete as soon as new method starts working smoothly and satisfactorily and gives encouraging results (like saving in time, alter-rejection reduction).
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7. Maintain
Some time after the smooth running of new working method, it is necessary to check that the new method is working well, that it is being properly followed, and that it is continuously bringing about the desired results. This is the Maintain phase. Method drift is common - when people either revert to old ways of working or introduce new changes without following systematic study. Some of these may be helpful and should formally be incorporated; others may be inefficient or unsafe. A method audit can be used to formally compare practiced method with the defined method and identify such irregularities.

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The purpose of checks and reviews is to find if the method being practiced is the same or it has deviated from the authorized one. Reasons for deviation if any, should be explored and the necessary changes should be made in the procedure being practiced so that it reverts to the authorized one. Views of workers, supervisors and other persons related with the authorized method can be of much help in exploring further improvements.

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Principles of Motion Economy

1. Uses of human body
The two hands should begin and complete their movements at the same time. The two hands should not be idle at the same time. Work should be arranged so that the eye movements are confined to a comfortable area.

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2. Arrangement of the work place

Tools and materials should be pre positioned to reduce searching. Tools, materials and controls should be located as near to the worker as possible. Materials and tools should be arranged to permit the best sequence of motions. Provision should be made for adequate lighting, chair and table height should be adjustable.

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Benefits of Work Study

It is a means of raising productivity of a plant or operating unit by reorganization of work, a method which normally involves little or no capital expenditure on facilities and equipments. It is systematic. This ensures that no factors affecting the efficiency of the operation is overlooked, whether in analyzing the original practices or in developing the new, and that all the factors about the operation are available. It is the most accurate means yet evolved of setting standards of performance, on which the effective planning and control of production depends.
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 It can contribute to the improvement of safety and working conditions at work by exposing hazardous operations and developing safer method of performing operations. The savings, resulting from the proper application of work study start at once and continue as long as the operation continues in the improved form. It is a tool which can be applied everywhere. It can be used with success wherever work is done or plant is operated, not only in the manufacturing shops but also in offices, stores, laboratories and service industries such as wholesale and retail distribution and restaurants and on firms.
It is relatively cheap and easy to apply.
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