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Method Study

3.ii Method Study


Man, Machines, Materials, Money, Technology and Time are the main resources required to produce goods and are to be deployed in the most effective manner We have to select the best available combination of these resources at any point of time. Method Study helps in analysing the existing methods and develop a more efficient method for future.

3.2.A Definition And Objective of 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.
The objectives of Method Study are : 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

Definition And Objective of Method Study

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

Procedure
The solution of any problem follows the following sequence of phases in that order : 1) 2) 3) 4) 5) 6) Define: The problem. Record: All the facts relevant to the problem. Examine: The facts critically but impartially. Consider: The courses of actions (possible solutions) and decide which to follow. Implement: The solution. Follow Up: The development. The basic procedure for the whole of work study, which embraces the procedures of both method study and work measurement. Contd

Procedure Steps and Procedure to conduct Method Study :


a) b) c) d) Select: the work to be studied. Record: all the relevant facts about the present method by direct observation. Examine: those facts critically and in an orderly sequence, using the techniques best suited to the purpose. Develop: the most practical, economic and effective method, having due regard to all contingent circumstances.

Procedure a) a)
a)

Define: the new method so that it can always be identified. Install: that methods as standard practice.
Maintain: that standard practice by regular routine checks.
These are the seven essential stages in the application of method study ; none can be excluded. Strict adherence to the sequence, as well as to their content, is essential for the success of an investigation. They are shown diagrammatically on the chart.

Method Study to improve methods of production

Select
Work which can be studied With economic advantage

Method Study
At Work Place By means of Charts

At Work Place By means of Charts

Define Scope of Study Record Outline Process ; Flow Process Man type , Material type ; Multiple Activity ; Travel Flow Diagrams ; String Diagrams ; Models Two handed ; Simo ; Multiple Activity Cycle Graphs ; Chronocycle Graphs ; Film Analysis ; Memotion Photography

Other Means

Other Means

Examine the facts critically Challenge PURPOSE PLACE SEQUENCE PERSON - MEANS Seek Alternatives

Find Pointers
Eliminate Combine or Change Develop A record of an improved method Planning and Control Materials Handling General Environment and Working Conditions Plant Layout Re - Examine that record to establish The Best Method under Prevailing Circumstances Define Install The Improved method Plan - Arrange - Implement Maintain Verify at regular intervals that The important method as defined is in fact in use
To achieve improved factory and work space layout Improved design of equipment Better working conditions Reduction of fatigue Resulting in improved use of material Plant and equipment manpower Mechanical Aids ; Manual Controls and Visual instruments Equipment design ; Jigs and fixtures Local Working Conditions

Simplify

Higher Productivity

The Field Of Choice


Types of Jobs Examples 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 Recording Technique

Complete Sequence of manufacture

Outline process chart Flow process chart Flow diagram

Movements of a diesel engine Factory layout : cylinder head through all machining movement of operations. Movements of grain between milling materials operations

Outline process chart Flow process chart material type Flow diagram Travel chart Models

The Field Of Choice


Types of Jobs Factory layout : movement of workers Examples Labourers servicing spinning machine with bobbins Cooks preparing meals in a restaurant kitchen Putting materials into and taking them out of stores Loading lorries with finished products. Recording Technique

Flow process chart-man type string diagram String diagram


Flow process chart material type Flow diagram String diagram Flow process chart-man type. Two-handed process chart. Multiple activity chart. Simo chart. Cyclegraph. Chronocyclegraph.

Handling of materials

Workplace layout

Light assembly work on a bench Typesetting by hand

The Field Of Choice


Types of Jobs
Gang work or automatic machine operation

Examples
Assembly line Operator looking after semiautomatic lathe

Recording Technique
Multiple activity chart Flow process chartequipment 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 Films Film analysis Simo chart Memotion photography Micromotion analysis

The Field Of Choice


When selecting a job for method study it will be found helpful to have a standerdised list of points to be covered as shown below :-

1. 2. 3. 4. 5.

Product and operation Person who proposes investigation Reason for proposal Suggested limits of investigation Particulars of the job a) How much is produced or handled per week?

Record, Examine, Develop The most commonly used method study charts and diagrams
A. Charts Indicating process SEQUENCE Outline Process Chart Flow Process Chart Man Type Flow Process Chart Material Type Flow Process Chart Equipment Type Two Handed Process Chart Using a TIME SCALE Multiple Activity Chart Simo Chart Indicating movement Flow Diagram String Diagram Cyclegraph Chromocyclegraph Travel Chart

B. Charts

C. Diagrams

Process Chart Symbols


Operation
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

Transport
Indicates the movement of workers, materials or equipment from place to place

Process Chart Symbols


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.

Combined Activities

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.

The Outline Process Chart

Example
Assembling a switch rotor

Switch Rotor Assembly


The operations and inspections carried out on the spindle made from 10mm steel rod are as follows O 1 Face, turn, undercut and part off on capstan lathe (0.025 hrs) O 2 Face opposite end on the same machine(0.010 hrs). Transport to inspn dept I 1Inspect for dimensions and finish (no time fixed). Transport to milling section O 3 mill four flats on end on a horizontal miller (0.020 hrs). Transport to work bench O 4 Remove burrs at the burring bench(0.020 hrs). Transport to inspn dept I2 Final inspn of machine (no time)

O5 Degreasing(0.0015 hrs) O6 Cadmium plating(.008 hrs) I3 Final check (no time) O7 Face on both sides, bore the cored hole and ream to size on a capstan lathe(0.080 hrs) O8 Drill cross-hole and burr on two-spindle drill press(0.022 hrs) I4 Final check dimensions and finish (no time) Transport to finished parts stores and await with-drawl for assembly. Note the numbering of operations and inspections

Outline process chart

3.ii.D

FLOW PROCESS CHART


Process activity symbols Operation Inspection Transport Temporary storage or Delay Permanent storage

3.ii.D Flow process chart

2/6

A FLOW PROCESS CHART records what the worker does. It is a chart setting out the frequency of flow of a product or procedure by recording all events under review using process chart symbols. there are different types of flow process charts. Purpose: To set out the sequence of the flow of a product or a procedure by recording all the events under review

Activities recorded in the flow chart


Those where some thing is happening to the work piece. Those where the work piece is not touched (stored or standstill)

Three types of flow process charts


Man type
Flow chart which records what the worker does

Material type
Flow chart which records how material is handled or treated

Equipment type
Flow chart which records how the equipment is used

FLOW PROCESS CHART FOR ENGINE Stripping Cleaning - Greasing

Critical Examination
The questioning technique is the critical means by which the critical examination is conducted each activity being subjected in turn to a systematic and progressive series of questions

OPERATIONS
Make Ready Do Put Away Make ready and put away operations can be represented by transport and inspection symbols DO operations can be shown by O

CRITICAL EXAMINATION - Primary questions


The Purpose The Place The sequence The person The means for which at which in which by which by which

the activities are undertaken

CRITICAL EXAMINATION - Primary questions


With a view to

Eliminating Combining Rearranging Simplifying


those Activities

PRIMARY QUESTIONS
PURPOSE PLACE SEQUENCE PERSON MEANS ELIMINATE COMBINE REARRANGE REARRANGE SIMPLIFY

EXAMPLE: ENGINE Stripping Cleaning - Degreasing

TOOLS USED FOR PREPARING PLANT LAYOUTS


1. 2. 3. 4.

String diagram Flow Process chart Travel Chart Flow diagram

5.
6.

Multiple activity chart


Template Models

3.ii.D.1 String diagram

1/6

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 Material or Equipment

during a specified sequence of events

Observe the clusters of points, pins, turning points. Also observe the grid lines which represent a measure of the distance between the points.

Example of a String diagram


Movement, Transport of tiles from Inspection to Storage

IMPROVED METHOD

Serving dinners in a hospital ward

FPC - Dinners in a hospital ward

Original Flow Diagram Inspn and Marking

Improved FD of Inspection and Marking

Travel chart

Original Flow Diagram Inspection and Marking

Improved FD of Inspection and Marking

MAC-Inspn of catalyst in a converteroriginal method

MAC-Inspn of catalyst in a converterImproved method

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