METHOD STUDY

(AS A TECHNIQUE OF COST REDUCTION)

ZAKIR A PATEL

CONTENTS Definition and Objectives of Method Study Method study procedure

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 analyzing the existing methods and develop a more efficient method for future.

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

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 machines. Efficient materials handling 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

METHOD STUDY PROCEDURE

The basic approach to method study consists of the following eight steps:
1.

SELECT :- the work to be studied and define its boundaries.

2. RECORD :the relevant facts about the job by direct observation and collect such additional data as may be needed from appropriate sources. 3.EXAMINE the way the job is being performed and challenge its purpose, place, sequence and method of performance. 4. DEVELOP the most practical, economic and effective method.

5.EVALUATE different alternatives to developing a new improved method, and compare the cost-effectiveness of the selected new method with the current method of performance. 6.DEFINE the new method in a clear manner and present it to those concerned, management, supervisors and workers. 7.INSTALL the new method as standard practice and train the persons involved in applying it.

8.MAINTAIN the new method & introduce control procedures to prevent a drawback to the previous method of work.

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.

STEP 1: SELECTING THE WORK TO BE STUDIED

There are three factors that should be kept in mind when selecting a job. 1. Economic or cost-effective considerations. 2. Technical considerations. 3. Human considerations. 1. Economic considerations: It is obviously a waste of time to start or continue a long investigation if the economic importance of a job is small. Questions that should always be asked Will it pay to begin a method study of this job? Or Will it pay to continue this study?

Obvious choices for study are:

A. Key profit-generating or costly operations or ones with the largest Scrap/waste rates. B. Bottlenecks which are holding up other production operations, or lengthy operations that consume a great deal of time. C. Operations involving repetitive work using a great deal of labor and ones that are likely to run for a long time. D. Movements of material over long distances between workstations, those involving the use of a relatively large proportion of labor or which require repeated handling of material. One of the easiest techniques that can be used to identify key operations as listed in part (A) is the Pareto analysis (sometimes also referred to as the ABC analysis of value analysis). The same observation can be extended by saying that among all the operations in a given plant a small number account for the largest share of cost or of profit, or the largest percentage of waste.

To illustrate the point we will consider the following example. Let us assume that a certain enterprise produces 20 different products. Each of these products generates a certain profit. By listing the annual production and profit contribution one obtains the results shown in table 6. The next step consists of rearranging these items in descending order of importance according to profit. The result would then appear like the one shown in table 7. From table 7 it can be seen that three products only, listed as A items, account for 60 per cent of the profit. These are the most profitable and any improvement in methods of producing these particular products would reflect highly on profits. They would be a priority for study. Products listed under B, which are seven in number, contribute 25 per cent of the profit. They could then assume a second importance, while products C would command the last priority since their contribution to profit is minimal. The same type of analysis can be conducted to determine the most costly products or processes or the products or processes that yield the highest waste. Those would then become a priority for study by the work study specialist.

2.

Technical or technological considerations:

One of the important considerations is the desire by management to acquire more advanced technology, i.e. in equipment or in processes.

Therefore, management may want to computerize its office paperwork or its inventory system, or to introduce automation in the production operations. Before such steps are taken, a method study can point out the most important needs of the enterprise in this respect. The introduction of new technology should therefore constitute an important factor in the choice of methods of work to be investigated.

3. Human considerations:

Certain operations are often a cause of dissatisfaction by workers. They may bring on fatigue or monotony or may be unsafe to operate. The level of satisfaction should point to a need for method study. In a similar fashion, a choice of a particular job for study may lead to anxiety or ill feeling. The suggestion given here is to leave it alone.

STEP 2: RECORDING THE FACTS

The next step in the basic procedure, after selecting the work to be studied, is to record all the facts relating to the existing method The success of the whole procedure depends on the accuracy with which the facts are recorded, because they will provide the basis of both the critical examination and the development of the improved method Recording techniques known as CHARTS and DIAGRAMS Charts and diagrams broadly grouped as:

Charts Indicating Process Sequence

Charts Using Time Scale

Diagrams Indicating Movement

PROCESS SEQUENCES includes the following CHARTS

Operation Process Chart Flow Process Chart Man , Material and Equipment Type

Two Handed Process Chart

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.

The Outline Process Chart

An outline process chart is a process chart giving an overall picture by recording in sequence only the main operations and inspections

It does not portray the details delays , movements, and storage

It does not go into the details of the details of the place of activity, the person who performs it, or the physical means of achievement In making an outline process chart we start with a vertical line down the right hand side of the page to show the operations and inspections undergone.

The Outline Process Chart- Example

For the purpose of illustration , the case of the repair of a bicycle is taken.

In this example it is assumed that the bicycle had been involved in a minor accident and required restricted repairs to the front wheel, the left pedal and the steering handle.
The Outline Process Chart would be

FLOW PROCESS CHART (FPC)

It is a process chart setting out the sequence of the flow of a product or procedure by recording all events under review using appropriate process chart symbols.

BENEFITS: In identifying ways of improving the process by eliminating unnecessary idle time, minimizing the distances things must be moved or rearranging tasks for greater efficiency

Three types of flow process charts

MAN TYPE:

Flow chart which shows the actions of a person

MATERIAL TYPE:

Flow chart which shows what happens to a product or item

EQUIPMENT TYPE:

Flow chart which shows how a tool or other piece of equipment is used

Flow Process Charts- Material Type

An FPC (Matrl) sets out the sequence of flow of a product or a document , recording all the events that affect the material or document being processed.

Illustration : The process of charging of batteries by Umesh Motors(P) Ltd. Is as follows. Customers deposit discharged automobile batteries at the Reception Bay of the workshop, and obtain a receipt. After three days, they collect their respective batteries from the Delivery Bay of the workshop, on presentation of the receipt and payment of service charges. The reception clerk marks each battery with a customer-identification number. He stacks the batteries on a steel shelf.

The chargeable batteries are collected twice a day from the Reception Bay by mazdoor Dharam. He transports the batteries on a stillage truck , and delivers them to the charging shop, which is 50 meters away from the Reception Bay. At the Charging Shop , the battery is tested, cell by cell , for voltage and specific gravity. The cells are topped up to the correct level. The battery is then moved to the charging bench, and placed on charge by connecting the terminals to the bus bars. While on charge , it is tested every four hours for specific gravity. On completion of charging, which is determined by the specific gravity of the electrolyte , the connections to the bus bars are removed. The battery is tested for voltage of each individual cell. It is then placed on a stillage(small wooden platform with low legs)

Mazdoor Dharam collects a stillage of charged batteries and transports them, by a stillage truck, to the delivery bay , which is 35 meters away from the charging shop . Here the Delivery Clerk takes over the batteries and places them on a steel rack.

Flow Process Charts- Man Type

An FPC(Man), sets out the sequence of activities of an individual performing a task under study . Only four symbols are employed- operation , inspection, delay, transport

TWO HANDED PROCESS CHARTS

Two handed process charts is a chart in which the activities of a workers hands individually(or limbs) are recorded in the relationship to one another

SYMBOLS AND THEIR DESCRIPTIONS FOR TWO HANDED CHARTS

Operation
Is used for activities for grasp, position, use, release etc. of a tool, component or material

Transport
To represent the movement of hand to or from the work, or a tool, or material

Temporary Storage or Delay

Denotes time during which the hand being charted is idle (although the others may be in use)

HOLD

In two handed process chart , hold is used to represent the activity of holding work , tool or material i.e when the hand being charted is holding something

MULTIPLE ACTIVITY CHART

A chart on which the activities of more than one subject (worker, machine or equipment) are each recorded on a common time scale to show their interrelationship

Useful in organizing teams of operatives on mass production work and also on maintenance work when expensive plant cannot be allowed to remain idle longer

Time (Hours) 5

WORKER 1 Disassembly of lathe

WORKER 2 Disassemble lathe. Head stock, bed, fed and lead screws, carriage and tailstock

WORKER 3 Disassemble head stock, Remove main spindle, speed change mechanisms, and change gears. Wash with thinner to remover grease and clean parts Idle

WORKER 4

10 15

Inspection to determine fault

Repair carriage bed and lay out screw, nuts, etc.

Repair and assembly of feed gear box

20 25

Repair carriage bed, check and repair feed screw and apron of the carriage.
Fit saddle to bed

Repair and assemble feed gear box

Grind lathe beds

Assemble and mount bed and headstock on stand Assemble tailstock. Fit cross slide and top slide

Repair carriage way and lay out screw, nuts, etc.

30 Repair and assembly of apron 35 Installing feed gear box apron and feed red Running in and finishing Testing the lathe Run in and finish

Assemble cooling system

Install electric motor

Assemble tailstock

Install feed gear box, apron and feed rod Mount electric motors and fit reservoirs Run in and finish Test and calibrate assembly

Idle

MAN-MACHINE CHART
Variant of Multiple Activity Chart Present a picture of the operations performed simultaneously by a man and one or more machines Useful for 1. Better coordination between man and machine 2. Reduction / elimination of idle times of man and machine to improve the utilization 3. Exploration of alternative man-machine arrangements suitable to the plant conditions

TIME Min.
2 4

Man
Remove finished casting clean with compressed air Gauge depth on surface plate

Machine

5 6
8 10

Break sharp edge and clean with compressed air

Idle Place in box obtain new casting Clean machine with compressed air

12
15

Locate castig in fixture: start machine and automatic feed

Idle Mill second face

20

DIAGRAMS INDICATING
MOVEMENTS
String

Diagram Travel Charts Flow Diagrams

STRING DIAGRAM

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. Red is the staring point and blue is the ending point

CONSTRUCTION OF A STRING DIAGRAM

Step-1

Produce a scale map of the work area Identifying all machines, furniture and other equipments in the diagram that can be moved. These could be shaped as pieces of card that can be pinned to the work area map Identify the points in the process where actions take place and also identify the doorways, pillars etc that effect the path movements and mark the positions of these on the map with map pins and action symbols. Tie the end of a pieces of string to the pin where the process starts and then wrap it around each pin in turn, following the movement around the process

Step-2

Step-3

CONTINUE..

Step-4
Mark the string at the start and finish points, using a pen.

Step-5

Measuring between the pen marks, will give the total distance travelled during the process. Rearrange the movable items on the map, aiming to reduce the total distance

Step-6

Strategies for deciding layouts include:

Mobility:- Rearrange items and movements around fixed or immovable items such as heavy machines. Function:- Put machines or people together that perform the same function. This is useful when varying loads may be between machines. Product:- Put machines or people together that make the same product. This works well when each machine is used for only one product.

TRAVEL CHART

A travel chart is a tabular record for presenting quantitative data about the movements of workers, materials or equipment between any number of places over any given period of time.

The travel chart also identifies movement, when movements along complex paths are involved.

WHY TRAVEL CHART ?

Although the string diagram is a neat and effective way of record the movement of worker or material
o o

They take long time to construct ; Look increasingly like a complex maze with increasing complexity of movement paths.

When the movement patterns are complex, the travel chart is quicker and more manageable to record.

Count of occurrence Distance between places

FLOW DIAGRAM

While the flow process chart describes the flow of a product or process, it is generally supplemented with a flow diagram. While the flow process chart records travel distances and time taken for various operations, the flow diagram is a plan , drawn to scale of the work area, correctly indicating the position of machines and working positions. The example indicates the flow diagram of receiving, inspection, marking and storing materials.

IMPROVED FD OF INSPECTION AND MARKING

Suitability of different recording techniques:Types of Jobs Complete manufacture Sequence Examples Recording Technique of Manufacture of an electric motor from Outline process chart raw material to dispatch; Flow process chart Transformation of thread into cloth from Flow diagram preparation to inspection; Receipt, packing and dispatch of fruit

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

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

Continue..
Types of Jobs Factory layout : movement of workers Examples Laborers servicing spinning machine Cooks preparing meals in a restaurant kitchen Recording Technique Flow process chart-man type String diagram

Handling of materials

Putting materials into and taking them out of stores Loading lorries with finished products.

Flow process chart material type Flow diagram String diagram

Workplace layout

Light assembly work on a bench Typesetting by hand

Flow process chart-man type. Two-handed process chart. Multiple activity chart.

Continue..
Types of Jobs Gang work or automatic machine operation Movements of operatives at work Examples Assembly line Operator looking after semi-automatic lathe Female operatives on short cycle repetition work Operations demanding great manual dexterity Recording Technique Multiple activity chart Flow process chart-equipment type Multiple activity chart Flow process chart equipment type

EXAMINE

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

PRIMARY QUESTIONS
The
The The The The

PURPOSE
PLACE SEQUENCE PERSON MEANS

for which
at which in which by whom by which

THIS EXAMINATION SEEKS TO

ELIMINIATING COMBINING Identify possibility of

REARRANGING
OR SIMPLIFING the recorded activities

THE SECONDARY QUESTIONS

Definition The secondary questions cover the second stage of the questioning technique, during which the answers to the primary questions are subjected to further query to determine whether possible alternatives to place, sequence, persons and/or means are practicable or preferable as the means of improvement up on the existing method

Combining the two primary questions with the two secondary questions under each of the headings purpose, place, etc., yields the following list, which sets out the questioning technique in full:

PURPOSE:

what is done? why is it done? what else might be done?

what should be done?

PLACE:

where is it done?
Why is it done there? Where else might it is done?

Where should it be done?

SEQUENCE: When is it done? Why is it done?

When might it be done?

When should it be done? PERSON: who does it? Why does that person do it? Who else might do it? Who should do it?

MEANS:

How is it done?
Why is it done that way? How else might it be done?

How should it be done ?

These questions, in the above sequence, must be asked systematically every time a method study is undertaken. They are the basis of successful method study. Remember Rudyard Kipling's

I keep six honest serving men, They taught me all I knew, Their names are What and Why and How and Where and When and Who

DEFINING THE IMPROVED METHOD

The
1.

report should show:

Relative costs in material, labour and overheads of the two methods, and savings expected. 2.The cost of installing the new method, including the cost of new equipment and of re-laying out shops or working areas 3. Executive actions required to implement the new method.
It
1.

should also give details regarding :

The tools and equipment to be used 2. A description of the method 3. A diagram of the work place layout, jigs/fixtures etc

INSTALLATION

OF THE NEW METHOD

The success of method study is realized when actual change is made on ground.

The first part of installation is to define the new method by preparing the written standard practice.
This method is perhaps the most difficult step of method study procedure as it needs reassuring, retraining and supporting through acquisition of new skills. New method involves gaining approval of following personnel for the changes suggested:

1. 2. 3.

Concerned department supervision

Works and general management Workers and their representatives

The install Phase in some cases, will require a parallel running of old and new systems. While in other cases it may require the build up of buffer stocks. It may also require changes in procedures, or minor addition of equipment and process. Thus, the successful introduction of new working methods is extremely important because very often there is only one chance to make change.

MAINTAIN

THE

NEW

STANDARD

After the introduction of new working methods, it is necessary to check and verify that the new method is working and is it bringing the desired results or not. This is the maintain phase. Proper control procedures are used to ensure that new method is practiced to achieve the benefits of method study and also to achieve higher productivity. One of the common problems of maintaining the new standard is method drift. At last, installation is to be preceded by retraining the workers to operate new methods. Close contact with the progress of the job must be maintained, till it is performed.

FINAL EXAMPLE
Here I took an example of car manufacturing process. As first step is to select the work to be studied, here, I select the process of car manufacturing. Step-1 select, manufacturing process of car

STEPS INCLUDE IN MANUFACTURING PROCESS

Parts are produced in various plants Start with the frame Installing the parts Engine and Transmission Installed Building the Shell Final Body Components Inspection and Washing Paint The Inner Workings The Shell and the Frame Test the Car

RECORDING OF WORK

Suppose, here I used string diagram to record the work.

Plants

EXAMINE
Here assume that total length of thread is 30cm and therefore total distance has to covered within the process is 30*100= 3000 m. More distance means more time and more time mean more cost. So improvement is required to reduced the distance. After considering all activities. It can be seen that all machineries are movable. So here we rearrange all machineries and after that will see the synergy.

INSTALLATION, MAINTANCE OF NEW SYSTEM

Before installation of new plan

Length of thread Distance Time Cost

Of the new model should be major and compare with the original one

If profitable then install the new plan and maintain it through regular check on it