Method Study

By
Kunal patel
 Method Study
To simplify job and develop more
economical methods of doing it

Work study
Work measurement
To determine how long it take
to carry out

HIGHER
PRODUCTIVITY
 Case
Vaibhav is making sandwiches for Hitesh. Hitesh is famished and screams, Vaibhav, cant you
hurry up? You are taking too long because of excess work content.
Vaibhav replies Excess work content? What are you talking about?
Hitesh explains:
Activity/Operation = Basic work content + Excess work content

Excess work content could be added in the following ways:

A]. Poor design or Product specifications or improper utilizations of materials

B]. Inefficient methods of manufacture or operation

C]. Excess work content due to human factor

Work-study reduces the excess work content or the ineffective time by using the techniques of
method study and work measurement.
 TOTAL WORK CONTENT
Basic work content
A.1 POOR DESIGN AND FREQUENT DESIGN CHANGES Work content added by poor
A.2 WASTE OF MATERIALS Product design or materials
A.3 INCORRECT QUALITY STANDARDS utilization

B.1 POOR LAYOUT AND UTILIZATION OF SPACE

B.2 INADEQUATE MATERIAL HANDLING
B.3 FREQUENT STOPPAGES AS PRODUCTION CHANGES Work content added by inefficient
FROM ONE PRODUCT TO OTHER Methods of manufacture or operation
B.4 INEFFECTIVE METHOD OF WORK
B.5 POOR PLANNING OF INVENTORY
B.6 FREQUENT BREAKDOWNS OF MACHINE

C.1 ABSENTEEISM AND LATENESS

Work content resulting mainly from
C.2 POOR WORKMANSHIP the contribution
C.3 ACCIDENTS AND OCCCUPATIONAL HAZARDS
 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.
 OBJECTIVES OF METHOD STUDY
Improvement of processes and procedures
Improvement in the design of plant and equipment
Improvement of layout
Improvement in the use of men, materials and machines
Economy in human effort and reduction of unnecessary fatigue
Improvement in safety standards
Development of better working environment
 METHOD STUDY PROCEDURE
1. Select the work to be studied
2. RECORD
3. EXAMINE
4. DEVELOP
5. DEFINE NEW METHOD
6. INSTALL
7. MAINTAIN
 Select the work to be studied

Select the job after considering three factors:

a) Economic considerations
b) Technical considerations
c) Human considerations

Records the fact

All facts related to the existing method should be recorded first as a rough sketch
and then in a more formal and accurate chart or diagram the standard symbol
used in charts and diagram are:
- Inspection
- Transport
- D-temporary storage and delay
- Permanent storage
- Combined activities

Commonly used charts are outline process charts, flow process charts and
multiple activity charts
 CASE
Fig shows the layout of the room allotted for the blood donation camp at Welingkar Institute

B E
Table containing
Needles and blood bag

C D

Outline Process chart: This gives an overall picture by recording in sequence only the main
operations and inspection
 FPC
The flow process chart shows the sequence of flow of a product/procedure by recording each and every
event in it, FPC can be of 3 types:
Man type- this records what operator does
Material type- this records how material is handled
Equipment type- this records how the equipment is used

Description Qty Dist. Time Remar

mt Sec. o D ks

Transport kit from van to center table 5 15

Carries needle and bag to bed A 1

Injects donor A -

Returns to central table -

Carries needle and bag to bed B 1

Injects donor B -

Returns to central table -

Continues till all donors are injected -

 Multiple activity Chart
This chart records the activities of more than one subject (i.e. worker, machine, etc.) on a common time scale to show their
interrelationship. For e.g. a multiple activity chart of Gajanan making a pizza will be as follows

Description Gajanan Oven Time

taken
Removes pizza from the oven Idle 5

Cuts the pizza Idle 5

Puts cheese on it Idle 5

Serves it Idle 5

Puts in pizza to be baked Idle 5

Pizza being baked idle 10

Thus Charts shows that the oven is idle for 25 min and Gajanan is idle for 10 mi. The total time needed for one pizza is 35 min.
Description Gajanan Oven Time
taken
Removes pizza from the oven Idle 5

Puts in another pizza to be baked Idle 5

Pizza being baked Doing other 10

work
Cuts the pizza (while other pizza is baking) Baking 5

Puts cheese on it (while other pizza is baking) Baking 5

Serves it Idle 5

Removes the pizza from the oven Idle 5

Now the oven is idle for 20 min. and idle time for Gajanan is zero
 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 ?
 SECONDARY QUESTIONS
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 of place, sequence, persons and means are practicable and preferred as a means of
improvement upon the existing method .

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 ?
 All activities recorded on the FPC fall into two categories:
Value adding activities: where some work is being done on the material.
Non value adding activities: storage and delays where no work is done on the material

Hence the first question a person should ask is Why is the table at the centre of the room? , where
should be the needles placed? How else can the activity be undertaken? Why should the table stand
still? Can it be moved ?
This led them to straight solution that must be adopted that doctor should use a trolley !

Troll
ey

B E
Troll
Troll
ey
ey

C D
Troll
Troll ey
ey
 Develop and evaluate the new improved
method
The report should show:
Relative costs in material, labor and overheads of the two methods, and savings expected.
The cost of installing the new method, including the cost of new equipment and of re-laying out shops
or working areas
Executive actions required to implement the new method.

It should also give details regarding :

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

Record the new method on a FPC and compare it with the original one
Changes incorporated in the new method may be
1. improved layout
2. Reduced material handling
3. Improved efficiency in handling
4. Better choice of equipment
5. Application of principles of motion economy
Classifications of Movements
Class of Change
 Define the new method clearly
Once the new method is decided the management and the operatives must be made
familiar with it.
A written standard practice report is prepared to explain the new method to the
management and to the operatives and to the future references

INSTALLING THE IMPROVED METHOD

Gaining acceptance of the change by the Management

Gaining acceptance of the change by the workers
Maintaining close contact with the progress of the job until satisfied that it is running
as intended
 THE PRINCIPLES OF MOTION
ECONOMY
A. Use of the human body
1. The two hands should begin and complete their movements at the same time
2. Motion of the arms shall be symmetrical and in opposite directions and should be made
simultaneously
3. Hands and body motions should be made at the lowest classification at which it is possible to do
the work satisfactorily
4. Rhythm is essential to the smooth and automatic performance of a repetitive operation.
5. Work should be arranged so that eye movements are confined to a comfortable area, without the
need for frequent changes of focus.

B. Arrangement of the work place

1. Definite and fixed stations should be provided for all tools and materials.
2. Gravity feed, bins and containers should be used to deliver the materials as close to the point of
use as possible.
3. Tools, materials and controls should be located within the maximum working area.
4. Materials and tools should be arranged to permit the best sequence of motion.
5. Provision should be made for adequate lighting.
6. The color of the workplace should contrast with that of the workplace to reduce eye fatigue.
 C. Design of tools and equipment
The hands should be relieved of all work of 'holding' the work piece where this can be done by
fixture etc.
Two or more tools should be combined wherever possible
Levers, cross bars and hand wheels should be so placed that the operative can use them with the
least change in body position and the greatest mechanical advantage.
 WORK MEASUREMENT
Work measurement is a technique used to establish the time for a qualified worker to carry out a task
at a defined rate of working. Work measurement serves 2 purposes;

1. It helps reveal the excess work content in any operation and take steps to reduce the ineffective
time.
2. It helps to set standard times for carrying out the work.

OTHER PURPOSE OF WORK MEASUREMENT

To set standard for output level
To evaluate worker's performance
To plan work force needs.
To determine available capacity
To compare work methods
To facilitate operations scheduling
To establish wage incentive schemes

THE TECHNIQUES OF WORK MEASUREMENT

Stop-watch time study
Work sampling
Predetermined time standards (PTS)
Standard Data
 Time study
Its the most widely used work measurement techniques, in Time study,
A) we record times of performing a certain job in specified condition
B) Analyze the data
C) obtain the time necessary for an operator to carry out job at a defined rate of performance

Basic Steps
a. Obtaining and recording all available information about the job, operator and the surrounding
conditions likely to affect the execution of the work
b. Recording the complete description of the method, breaking down the operation into 'elements'
c. Measuring with a stopwatch and recording the time taken by the operator to perform each 'element'
of the operation.
d. Assessing the rating
e. Extending observed time to 'basic times'
f. Determining the allowances to be made over and above the basic time for the operation
g. Determining the 'standard time' for the operation.
 Suppose a standard rating is denoted by 100 on a rating scale. If the work study person decides that the
observed speed is lower than that of a qualified average worker, a factor of less than 100 will be used,
say 80. if the observed time is 0.25 min , a basic time less than the observed time would be arrived at
using the rating factor as follows:
0.25 min. X 80/100=0.2 min.

The basic time represents the time that would be required to perform the elements if the operative was
working at the standard rate, instead of the slower one actually observed.

Determine the allowance to be made over and above the basic time, add them to the basic time and thus
determine the standard time for the operation.
Model for calculation of allowances

Observed time rating factor Allowances

Basic time

standard time
 Work Sampling

WORK SAMPLING METHOD WAS ORIGINAL DEVELOPED BY LEONARD HENRY CALEB

TIPPETT (1902-1985) IN BRITAIN IN 1934.

THE WORKERS ARE OBSERVED MANY TIMES AT RANDOM. IT IS DONE TO FIND OUT FOR
HOW MUCH TIME THE WORKER IS ACTUALLY ON THE JOB.

IT CHECKS HOW LONG HE IS WORKING AND HOW MUCH TIME HE IS NOT WORKING
(IDLE TIME).

WORK SAMPLING METHOD INVOLVES FOLLOWING THREE MAIN STEPS:

DECIDING WHAT ACTIVITIES ARE DEFINED AS WORKING. NON-WORKING ARE THOSE

ACTIVITIES WHICH ARE NOT DEFINED AS WORKING.
OBSERVE THE WORKER AT SELECTED INTERVALS AND RECORD (WRITE DOWN)
WHETHER HE IS WORKING OR NOT.
CALCULATE THE PORTION OF TIME (P), A WORKER IS WORKING.
 Predetermined time standards
Predetermined motion time system In Predetermined Motion Time System method or The normal
times are fixed for basic human motions.
These time values are used to fix the time required for doing a job.
Normally, three times are fixed for one job.
That is, one time is fixed for each level of performance.
The level of performance may be normal, fast and very-fast.
 Structured Estimation
Estimation is technique to predict past data using future values. This technique is normally used
where the required time values need not be in great detail

Analytical estimation: Analytical estimating method or technique is used for fixing the standard
time for jobs, which are very long and repetitive. The standard- time is fixed by using standard-
data. standard data is not available, then the standard time is fixed based on the experience of the
work-study engineer.

Comparative estimation: It relies on the identification and measurement of the benchmark jobs
of known work content against which all other jobs to be measured are compared
Thank you