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
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 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:
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

 OBSERVATIONS

After operation number 15, the next operation shown is number 23. Operations 16 to
22 are covered by the seven repetitions of operation 15. Similarly , the gap between
Inspection number 3 and 11 is accounted for by the seven repetitions of inspection 3.
 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 worker’s 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) WORKER 1 WORKER 2 WORKER 3 WORKER 4
Disassembly of lathe Disassemble lathe. Head Disassemble head stock, Idle
5 stock, bed, fed and lead Remove main spindle,
screws, carriage and speed change
tailstock mechanisms, and change
gears.
Inspection to determine Wash with thinner to Repair carriage bed and
10
fault remover grease and lay out screw, nuts, etc.
clean parts
15
Repair and assembly of Repair carriage bed, Repair and assemble Grind lathe beds
feed gear box check and repair feed feed gear box
screw and apron of the
20 carriage.
Fit saddle to bed Assemble and mount bed Repair carriage way and
25 and headstock on stand lay out screw, nuts, etc.
Assemble tailstock.
Fit cross slide and top
slide
30
Assemble cooling system
Repair and assembly of Install electric motor
apron
Assemble tailstock Install feed gear box, Idle
35 apron and feed rod
Installing feed gear box Mount electric motors
apron and feed red and fit reservoirs
Running in and finishing Run in and finish Run in and finish

Testing the lathe Test and calibrate

assembly
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 Man Machine
Min.
2 Remove finished casting clean with compressed
air
4 Gauge depth on surface plate

5 Break sharp edge and clean with compressed air

6
Idle
8 Place in box obtain new casting

10 Clean machine with compressed air

12 Locate castig in fixture: start machine and

automatic feed
15 Idle Mill second face

20
EXAMPLE
Draw a man – machine chart showing one man(the operator)
operating two semi-automatic lathes. The cycle consists of load M/C
, ½ min., Machine part , 1 min (the machine stops automatically at
the end of cut) and unload Machine, ¼ min. The two machines are
alike and each completes the machining operation and stops
automatically. The man-machine chart is to show the operator
starting the machines in the morning with both machines empty and
continues until each machine completes two cycles, i.e. it has
machined two pieces. The man-machine chart should have one
column for the man and a column each for machine 1 and machine
2.
CONTD..
DIAGRAMS INDICATING
MOVEMENTS

•String Diagram
•Travel Charts
•Flow Diagrams
STRING DIAGRAM
 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 yellow 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
 Step-2
 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.
 Step-3
 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
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.
 Step-6
 Rearrange the movable items on the map, aiming to reduce the
total distance
 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 They take long time to construct ;

o 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 shown 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 Examples Recording Technique

Complete Sequence of •Manufacture of an electric motor from Outline process chart

manufacture 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 Outline process chart
materials head through all machining operations. Flow process chart material type
•Movements of grain between milling Flow diagram
operations. Travel chart
 Continue…………………..
Types of Jobs Examples Recording Technique

Factory layout : Laborers servicing spinning machine with bobbins Flow process chart-man type
movement of String diagram
workers Cooks preparing meals in a restaurant kitchen

Handling of Putting materials into and taking them out of Flow process chart – material type
materials stores Flow diagram
Loading lorries with finished products. String diagram

Workplace layout Light assembly work on a bench Flow process chart-man type.
Typesetting by hand Two-handed process chart.
Multiple activity chart.
 Continue…………………..

Types of Jobs Examples Recording Technique

Gang work or Assembly line Multiple activity chart
automatic machine Operator looking after semi-automatic lathe Flow process chart-equipment
operation type
Movements of Female operatives on short – cycle repetition work Multiple activity chart
operatives at work Operations demanding great manual dexterity 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 PURPOSE for which

The PLACE at which

The SEQUENCE in which

The PERSON by whom

The MEANS by which

THIS EXAMINATION SEEKS TO

ELIMINIATING
COMBINING
REARRANGING
Identify possibility of the recorded activities
OR
SIMPLIFING
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. Concerned department supervision
2. Works and general management
3. 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 is 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 measure and compare with the original
one
 If profitable then install the new plan and maintain it
through regular check on it