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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
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 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.
Select
Work which can be studied With economic advantage
Method Study
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
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
Handling of materials
Workplace layout
Examples
Assembly line Operator looking after semiautomatic lathe
Recording Technique
Multiple activity chart Flow process chartequipment type
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
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
Inspection
Indicates an inspection for quality and / or check for quantity
Transport
Indicates the movement of workers, materials or equipment from place to place
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.
Example
Assembling a switch rotor
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
3.ii.D
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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
Material type
Flow chart which records how material is handled or treated
Equipment type
Flow chart which records how the equipment is used
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
PRIMARY QUESTIONS
PURPOSE PLACE SEQUENCE PERSON MEANS ELIMINATE COMBINE REARRANGE REARRANGE SIMPLIFY
5.
6.
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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
Observe the clusters of points, pins, turning points. Also observe the grid lines which represent a measure of the distance between the points.
IMPROVED METHOD
Travel chart