WORK STUDY AND ERGONOMICS

K.C. Jain P.L. Verma Prabhat Kartikey

Authored by: Prof. K.C. Jain

Ex Professor and Head, Department of Mechanical Engineering, Samrat Ashok Technological Institute (Engg. College), Vidisha (MP). Ex Dean, Faculty of Industrial Technology, RGVP, Bhopal Ex Director, GSIMR, Indore

Prof. P.L. Verma

Associate Professor, Department of Mechanical Engineering, Samrat Ashok Technological Institute (Engg. College), Vidisha (MP).

Prof. Prabhat Kartikey

Engineer Graduated from Jabalpur Engineering College Jabalpur
Master of Engineering from S.G.S.I.T.S. Indore

Published By: Vijaya Publication

CH-72, Scheme No. 74-C, Vijay Nagar, Indore Email : kcjain44@gmail.com

All rights reserved. No part of this publication can be reproduced in any form without written permission of authors and publisher both.

First Edition 2013

Price Rs. 250/-

PREFACE
The contents of the syllabus of this subject of Work study and Ergonomics is so designed that there are very few books available on this subject in such a manner that all the topics are available in one textbook. With this objective we thought of preparing a manuscript on this subject in a most comprehensive manner. There are in all seventeen chapters covering all the five units of the syllabus. We must complement the designer of this subject that they have brought Work study and Ergonomics under one course of study. Work study as a subject has old gillereth, however, Ergonomics as a subject is quite new. The combination of these two subjects to form one course of study is complete subject of study on "Human Engineering". Generally there is no concern about the worker, during man - machine interface in work study. It is the use of mental and physical ability of the worker that make the task completed successfully effectively. The concern of Ergonomics along with work study is to enhance the these abilities through smooth and effective man - machine interface. Thus this course of study comprehense the study of work and workers mental and physical capabilities through machines used by workers to improve productive output. Chapter one deals with background of productivity, its importance, its measurements and methods of its enhancement. This chapter also deals with role of National Productivity Councils in India. Unit - 1 i.e. Method Study is covered in chapters two, three and four. Unit - 2 i.e. Work Measurement is covered in chapter five only. Unit - 3 i.e. Job Evaluation and Incentives schemes is covered in three chapters. i.e sixth, seventh and eight chapters. Unit - 4 i.e. Human Factor Engineering is covered through chapters nine, ten, eleven, twelve, thirteen, fourteen and fifteen. Unit - 5 i.e. Display Systems and Anthropometric Data is covered in chapters sixteen and seventeen. It is expected that the students and all others who read this book will be benefited with completion of subject and gaining knowledge about other topics which are rarely available.

July, 2013 K.C. Jain P.L. Verma Prabhat Kartikey

WORK STUDY AND ERGONOMICS

INTRODUCTION Chapter - 1 Productivity 1.1 Historical Background and Definition 1.2 Nature of Productivity 1.3 Importance of Productivity 1.4 Factors Affecting Industrial Productivity 1.5 Difficulties in Productivity Enhancement 1.6 Methods of Productivity Enhancement 1.7 Measurement of Productivity 1.8 Objective and Role of National Productivity Council 1.9 Management and Productivity 1.10 Review Questions UNIT - I METHOD STUDY Chapter - 2 Purpose and Objectives of Work Study 2.1 Introduction 2.2 History and Development of Work Study 2.3 Status of Work Study in U.S.A. Britain, India and the World 2.4 Human Factors in Work Study 2.5 Basic Principle of Work Study 2.6 Work Study and Ergonomics 2.7 Importance of Work Study in Present Context 2.8 Definition of Work Study 2.9 Work Study as a Means of Increasing Productivity 2.10 Review Questions Chapter - 3 Procedure and Application of Method Study 3.1 Introduction and Definition 3.2 Objectives and Scope of Method Study 3.3 Procedure of Method Study 3.3.1 Selection of Work for Method Study 3.3.2 Recording Techniques for Method Study 3.3.2.1 Process Chart 3.3.2.2 Outline Process Chart 3.3.2.3 Flow Process Chart 13-26 1-10

27-52

3.3.3 3.3.4 3.3.5 3.3.6 3.4 Motion Study 3.5 Micro Motion Study 3.6 Review Questions

3.3.2.4 Two Handed Process Chart 3.3.2.5 Multiple Activity Chart 3.3.2.6 Flow Diagram 3.3.2.7 String Diagram 3.3.2.8 Simo Chart Examin the Method Develop the Method Install the Method Maintain New Method

Chapter - 4 Memo and Micro Study 4.1 Introduction 4.2 Memo and Micro Motion Study 4.3 Principle of Memo and Micro Study 4.4 Simo Chart 4.5 Review Questions UNIT - II WORK MEASUREMENT

53-64

Chapter - 5 Work Measurement : Definition and Procedure 5.1 Introduction 5.2 Definition and Objective 5.3 Advantages of Work Measurement 5.4 Procedure of Work Measurement 5.5 Difference between Time Study and Work Measurement 5.6 Time Recording Techniques 5.6.1 Stop Watch Method 5.6.2 Motion Picture Camera Method 5.6.3 Other Techniques 5.7 Rating and its Classification 5.7.1 Speed Rating 5.7.2 Westing House System of Rating 5.7.3 Objective Rating 5.7.4 Performance Rating 5.8 Rating Factor and its Importance 5.9 Allowances and Types 5.10 Standard Times and their Uses 5.11 Methods of Work Measurement 5.11.1 Work Measurement Using Time Study 5.11.2 Work Measurement Using Work Sampling (Ratio-Delay Study)

67-92

5.11.3 Work Measurement Using Predetermined Motion Time System (PMTS) 5.11.4 Work Measurement by Analytical Estimating 5.12 Review Questions UNIT - III JOB EVALUATION AND INCENTIVE SCHEMES Chapter - 6 Job Evaluation and Merit Rating 6.1 Introduction 6.2 Job Evaluation 6.3 Merit Rating 6.4 Merit Rating Methods 6.5 Advantages and Disadvantages of Merit Rating 6.6 Review Questions Chapter - 7 Wages and Wage Incentive Plans 7.1 Introduction and Brief History of Compensation Wage 7.2 Factors Influencing Compensation 7.3 Characteristic of Good Compensation Methods 7.4 Form of Compensation System 7.5 Work Study Compensation and Productivity Incentives 7.6 Concept of Wage Incentive 7.7 Installation and Termination of Incentive Plan 7.8 Different Incentive Plan 7.9 Supplementary Incentive Plan 7.10 Review Questions. Chapter - 8 Standard Data System 8.1 Introduction 8.2 Predetermined Motion Times, Elimination & Non Elimination 8.3 Work Factor System 8.4 Methods Time Measurement (MTM) 8.5 MOST 8.6 Review Questions UNIT - IV HUMAN FACTOR ENGINEERING 153-174 95-107

108-124

125-150

Chapter - 9 Human Body Joint Function and Input Output System 9.1 Introduction 9.2 Connective Tissue and its General Properties 9.3 Synovial Fluids, Joint Lubrication and Extremities 9.4 Kinetic Chains 9.5 Human Skeleton and Function of Various Elements 9.6 Review Questions

Chapter - 10 Physical Activities and their Energy Cost 10.1 Introduction 10.2 Oxidation of Glucose and Release of Energy 10.3 Fuel of Human Energy 10.4 Estimations Energy Cost 10.5 Energy Cost for a Given Task 10.6 Review Questions Chapter - 11 Ergonomics: Fundamentals and Definition 11.1 Introduction and Background of the Subject 11.2 Definition of Ergonomics 11.3 Constituents of Ergonomics 11.4 Objectives of Ergonomics 11.5 Scope of Ergonomics 11.6 Anthropometric Measurement and their Applications in Product Design 11.7 Review Questions Chapter - 12 Ergonomics and Environmental Factors 12.1 Introduction 12.2 Ergonomics and Thermal Condition 12.3 Effect of Noise and Vibration on Human Health and Job Performance 12.4 Effect of Light and Illumination on Worker Efficiency 12.5 Effect of Hazardous on Working Condition 12.6 Review Questions Chapter - 13 Anthropometric Data Development and Application 13.1 Introduction 13.2 Historical Background and Application of Anthropometric Data 13.3 Status of Anthropometric Data in India 13.4 Development of Anthropometric Data 13.5 Mobility of Human Body Movements Around Joints 13.6 Review Questions Chapter - 14 Design of Work Place and Body Measurement 14.1 Introduction 14.2 Body Measurement 14.3 Posture and Movement 14.4 Hand and Arm Posture 14.5 Movements 14.6 Review Questions

175-184

185-192

193-205

206-221

222-240

Chapter - 15 Information System Design and Application 15.1 Introduction 15.2 Information Input and Transmission 15.3 Information Communication System 15.4 Review Questions

241-254

UNIT - V

DISPLAY SYSTEMS AND ANTHROPOMETRIC DATA 257-270

Chapter - 16 Design of Display and Man Machine System 16.1 Introduction 16.2 Principle of Display Design 16.3 Types of Display 16.4 Standardization of Safety Display Symbol 16.5 Importance of Display in Man Machine System 16.6 Review Questions Chapter - 17 Design of Controls, Selection and Use 17.1 Introduction 17.2 Control System 17.3 Manuel System 17.4 Principle of Design and Types of Control 17.5 Principle of Design for Control Display Compatibility 17.6 Fuzzy Control 17.7 Review Questions

271-280

UNIT - I