Work Study Method Study and Work Measurement

Work Study
Body of Knowledge [BoK] to improve the productivity of jobs: -by better ways of doing jobs : analysis of work methods & equipment used / design of optimum method / standardisation of proposed method -by better Control over the output of jobs -by better standards with respect to time -by obtaining cooperation between management and workers for maximum mutual prosperity

Method Study
-Systematic Recording of existing method

Work Measurement
-Application of techniques designed

-Critical examination of existing method

-Developing improved / easier / cheaper / more effective method

to establish the time for a qualified worker to carry out a specified job at a defined level of performance

Work Study Qualified Worker [ILO]: -Necessary Physical Attributes -Required intelligence -Required Education -Acquired necessary skill and knowledge -Capable of carrying out the job with satisfactory level of safety standards, quantity and quality

Foundation of work study: Scientific Management FW Taylor, Frank Gilbreth & Lillian Gilbreth Taylorism.

The greatest production results when each worker is given a definite task to be performed in a definite time in a definite manner.
What can be measured is controllable.

Work Study Objectives of Work Study To analyse the present method of doing a job to better the method -To measure the work content of a job by measuring the time required to do the job by a qualified worker to establish a standard time

-To devise the most suitable method of doing the job by ensuring the best possible use of human, machine and material resources to produce quality product at optimum cost
-To improve operational efficiency

Benefits of Work Study

-Increased Productivity -Reduced manufacturing cost -Better Operational efficiency -Better employee morale

-Better plant layout / working conditions -Better Job satisfaction -Better planning -Improved work flow -Better incentive schemes -Better labour efficiency standards

Components and Methods / Techniques

Work Study

Method Study
Operation Process Chart Flow Process Chart Man-Machine Chart Motion Study [Gilbreths] Memomotion Study [Mundel]

Work Measurement
Direct Time Study [Taylor] Synthesis Method Analytical Estimatimg Pre-determined Motion Time System [PMTS] Work Sampling / Activity Sampling / Ratio-Delay Analysis

Work Study Work Design

Objective: Improve Operations Objective: Improve Planning & Control

Method Study / Operations Analysis

Used to evaluate alternate design / methods

Work Measurement

Developed by Gilbreths

Developed by Taylor

Motion Study

Used to find the fastest motion sequences

Time Study

Relationship of Motion and Time Study to Work design

Work Study Method Study Work Study Work Measurement

Select

Select

Steps involved in Work Study

Record Record

Examine

Examine

Develop

Define Break-down

Define

Measure
Install & Maintain

Higher Productivity

Work Study Work Study Procedure -Select the job / process / operation
*High Operating Cost *Frequently repeated job *Very bad product quality *Bottleneck to other jobs *Labour intensive *Safety hazard *Bad working conditions *Excessive material movements *High Return on Investment etc. -Observe and Record sequence / interrelationship / movement of activities *Operation process chart *Flow process chart *Motion chart *SIMO *Man-Machine Charts etc. -Examine the current method. Look for ways in which tasks can be eliminated, combined, rearranged, and simplified. 5W2H -Develop the most practical, economic, and effective method. Obtain approval for the new method -Measure the work content and establish the standard time

*Time study *Synthesis method *Analytical estimating method *PMTS *Work sampling
-Define the new / improved method. Tools / materials / operator skill / working conditions -Install / implement the new method as standard practice -Maintain the new / improved method by periodically checking it in use

Work Study

5W2H Questions
5W2H Typical Questions for Processes Who does this? Who should be involved but is not? Who is involved but shouldnt be? Who has to approve? What is done? What is essential? When is this activity started? When does it end? When is it repeated? Where is this activity done? Why do we do this? Why? How is this done? How much does it cost? Improvement Questions Should someone else do it? Could fewer people do it/ Could approvals be eliminated? Does every step have to be done? Are steps omitted? Can it be done at a different time? Can cycle time be shortened? Can it be done less frequently? Can it be done elsewhere? Can it be eliminated? Can another group do it? Can it be outsourced? Is there a better way? How much less could it cost?

Who?

What?

When?

Where?

How/ How much/many?

Work Study Objectives of Method Study

-To study the existing / proposed method of doing any job -To develop an improved method to improve productivity -To reduce excessive material handling -To improve utilisation of resources -To eliminate wasteful and inefficient motions -To standardise work methods or processes

Advantages of Method Study

*Work simplification * Improved method

*Better product quality

* Improved work flow * Shorter production cycle time *Improved productivity

* Better layout
* Better material handling * Higher job satisfaction

Operation Process Chart

Work Study Recording Techniques in Method Study

Left Hand Right Hand
Unload machine 0.04

Machine
Being Unloaded 0.04

Cast

Waits until inspection

Pick-up plate 0.05

Inspect casting

Dip plate 0.03 Idle Idle

To buffing section

Place plate 0.03 Push button 0.01 Idle

Buffing / Polishing

Inspect

Idle

Punch 0.02 Return 0.02

Store Flow Process Chart Man-Machine Chart

Work Study Motion Study It is the science of eliminating unwanted and or unnecessary motions in carrying out any jobs. The objective of motion study is to identify and implement the scheme of the least waste methods of labour. Micro Motion Study provides a valuable technique for making accurate analysis of operations. Purpose of Motion Study: -To study interrelationship among team members -To study interrelationship between operator and machine

-To obtain the time of an operation

-To establish a permanent record of the method of doing a job Micro Motion Study of operations is done by filming the operations and then analysing the film to make SIMO charts. Very small time values (1/2000 minute) are used [micro-chronometer]. A job is divided into micro motions which are known as Therbligs.

Work Study Work Measurement Objectives: -Improved planning and control of jobs -Reliable ideas for labour performance -Basis for sound incentive scheme -Efficient manning of the plant -Reliable basis for labour cost control

Benefits:

-Basis for comparing alternate methods

-To set labour performance standards -To make labour cost estimation

-To prepare work accurate schedules

-To compare actual & standard times -To estimate tenders / price / delivery

Techniques: -Direct e Study -Analytical Estimating -Synthesis method -Pre-determined Motion Time Systems

-Work Sampling or Activity Sampling or Ratio Delay Method

Work Study Time Study

Time Study is concerned with the determination of the amount of time required to perform a unit of work. ILO defines it as: Time Study is a work measurement technique for recording the times and rates of working for the elements of a specified job carried out under specified conditions and for analysing the data so as to obtain the time necessary for carrying out the job at a defined level of performance.

Objectives: -To determine the quantum work -To establish the Standard time -To furnish basis for comparison -To set labour standard -To determine standard costs -To balance the work in assembly line -To set piece rate incentives -To set completion schedule -To determine cycle time of job

Criteria for selection:

-New job for production -Change in manufacturing method -Design change -Employee complaint about Standard time -Bottleneck operation -Highly labour intensive -Job to be included in incentive scheme -For new tooling and fixtures

Work Study Work Sampling

It is a statistical sampling method to estimate the proportion of time devoted to a given type of activity over a certain period of time by means of a large number of random spot observations. Particularly useful to estimate the delays [ratio-delay analysis] such as: Supply failures Supply delays Machine breakdowns Manpower idling etc. The larger the number of observations, the better the estimate (Accurate).

Uses of Work Sampling: * To estimate time used by Operators and Machines * To determine allowances to include in Standard times * To indicate the distribution of work among group members * To provide basis for indirect labour time standards * To determine productive and non-productive utilization of manpower * To determine the standard time for repetitive operations as an alternative to time study

Work Study

Computation of Standard Time and Allowed Time

Legend OT -> Observed Time. PRF -> Performance Rating Factor NT / BT -> Natural / Basic Time PA -> Process Allowance RA -> Relaxation Allowance AT ST CA -> Contingency Allowance SA -> Special Allowance *Interference Allowance *Periodic Activity Allowance ST -> Standard Time PoA -> Policy Allowance AT -> Allowed Time

PoA SA CA RA PA PRF

OT

NT / BT

Work Study Exercise -01 Calculate the standard time per article produced from the following data obtained by a work sampling study. Total no of observations : 3000. Working observations : 2500. No of units produced during 100 hrs duration = 6000. Proportion of manual labour = 75%. Proportion of machine time = 25%. Observed rating factor for manual labour = 120%. Total allowances = 15% of normal time.

Work Study Exercise - 02 Given below is the data regarding production of units: Direct material price = Rs. 2. Wage rate Rs 2000 per month consisting of 25 working days and 8 hours per day. Overheads expressed as percentage of direct labour = 200%. Time taken to manufacture 4 units each consisting of 4 elements a, b, c, d during 4 cycles given below:
Element Cycle 1 Cycle 2 Cycle 3 Cycle 4 Element performance Rating 85 120 90 70

a b c d

1.2 0.7 1.4 0.5

1.3 0.6 1.3 0.5

1.3 0.65 1.3 0.6

1.4 0.75 1.2 0.4

Calculate standard time, labour cost, overhead cost, total production cost per piece, given the personal, fatigue and delay allowances as 25%.

Work Study Exercise - 03 A 8 hours work measurement study in a plant reveals the following: Units produced = 320 nos. Idle time 15%. Performance rating = 120%. Allowances = 12% of normal time. Determine the standard time per unit produced.

Work Study Exercise - 04 The following data refers to the study conducted for an operation. Table shows actual time for elements in minutes:

Cycle Elements 1 2 3 4

1 2.5 6.2 2.3 2.4

2 2.1 6.0 2.0 2.1

3 2.2 6.1 2.1 2.8

4 5.4 5.9 2.1 3.0

5 2.5 5.9 2.2 2.3

1) Element 2 is a machine element 2) Consider the observations as abnormal and delete the same if they are more than 2% of the average time of that element. 3) Take performance rating as 120. 4) Allowances are Personal 30 minutes in a shift of 8 hours Fatigue 15% Contingency 2% Estimate the standard time of operation and production per 8 hour shift.

Work Study Exercise - 05 A job has been divided into five elements 1,2,3,4&5. The element times for the first 5 cycles along with performance rating are given in the following tables:
Cycle time in minutes Cycle-1 1.84 1.11 2.46 1.48 1.72 Cycle-2 Cycle-3 Cycle-4 Cycle-5 1.77 1.42 2.39 1.55 1.81 1.78 1.16 2.34 1.72 1.65 2.02 1.29 2.36 1.63 1.76 1.79 1.25 2.30 1.51 1.79 Performanc e (%) 95 110 90 100 115

Element 1 2 3 4 5

Determine the estimated normal time for the job. Calculate the standard time if the permissible total allowance is 25% of normal time.