Sourabh Guha Assistant Professor (MBA)

UNIT IV
Work-study: Work Measurement: Time study, established of standard time, Rating of employees, allowances, work sampling, synthetic Data, Predetermined motion Time Analysis. Work Simplification: Method study objective scope, steps, selection of job for method Study Recording techniques, micro motion study WORK-STUDY Definitions According to the ILO Hand Book, it is a term used to embrace the techniques of method study and work measurement, which are employed to ensure the best possible use of human and material resources in carrying out a specified activity. According to the British Standards Institute, work study is a generic term for those techniques, particularly method study and work measurement, which are used in examination of human work in all its contexts and which lead systematically to the investigation of all factors which affect the efficiency and economy of the situation being renewed, in order to effect improvement. Work study is encompassed by two techniques, i.e., method study & time measurement as shown in figure. Method study is the systematic recording & critical examination of existing & proposed ways of doing work as a mean of developing & applying easier & more effective methods & reducing costs. Work measurement is the technique of establishment of time standards for a qualified worker to perform a specific job at a defined level of performance. There is a close link between method study & work measurement. Method study is concerned with the reduction of work content & establishing the one best way of doing the job where as work measurement is concerned with investigation & reduction of any ineffective time associated with the job & establishing time standards for an operation carried out as per the standard method. Objectives of Work Study
To assist the management to obtain the optimum use of the human and material resources available to the organization for the accomplishment of the work for which, it is engaged.

Work Study Procedure Work study is a procedure oriented & systematic study to establish the one best way (standard) method of doing an operation by investigation & analysis of all details regarding the job or operation carried out as per the established standard method.

Concept of Work Content Work content has two constituents: (a) Basic work content: Which is the minimum time theoretically required to do an operation or job. This cannot be reduced. Basic work content will result in the following conditions: (b) Excess work content: The actual time required completing an operation or job is more than the basic time in practical situations. This additional portion of the work content is called excess work content. Figure shows how manufacturing time is made up of.

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Sourabh Guha Assistant Professor (MBA)

METHOD STUDY Method study is the technique of systematic recording and critical examination of existing and proposed ways of doing work and developing an easier and economical method. Objectives of Method Study 1. To present & analyze true facts concerning the situation. 2. To examine those facts critically. 3. To develop the best answer possible under given circumstances based on critical examination of facts.. Steps in Method Study (SREDIM) 1. Select Select the work to be studied. It involves taking account of economic, technical and human considerations. 2. Record Record all the relevant facts of the present (or proposed) method by direct observation. 3. Examine Examine the facts critically in sequence, using special critical examination sheets. 4. Develop Develop the best method, i.e., the most practical, economic and effective method, under prevailing circumstances. 5. Install Install that method as standard practice. 6. Maintain Maintain that standard practice by regular routine checks. A. Select: While selecting a job for doing method study, the following factors are considered: i. Economical factors. ii. Human factors. iii. Technical factors. B. Record: All the details about the existing method are recorded. This is done by directly observing the work. Symbols are used to represent the activities like operation, inspection, transport, storage and delay. It is the phase of data collection. Data is relevant facts pertaining to the existing method which are collected and recorded to carry out the investigation. The place where this data is entered is called a record. Recording techniques depend on the type and nature of the data. The broad techniques are i. Charts for process and time records ii. Diagrams for path of movement of men or materials iii. Photographic aids 1. Charts: a) Outline process charts Principal operations and inspections of the processes. b) Flow process charts Activities of men, material or equipment are analyzed into five events of operation, inspection, transport, storage and delay. c) Two handed process charts Movements of two hands or limbs of the operator. d) Multiple activity charts Simultaneous / interrelated activities of operators and / or machines, on a common time scale. 2. Diagrams: a) Flow diagram Path of men, materials and equipments on a scale model. b) String diagram Same as above except for the variation that it uses a string to trace the path. 3. Photographic Aids:

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Sourabh Guha Assistant Professor (MBA)

a) Micro Motion Study Movement of body parts of the operator, expressed in terms of micro-motions (therbligs) 18 of them on a common time scale. b) SIMO chart c) Cyclograph & Chrono-cyclographs C. Examine: Critical examination is done by questioning technique. This step comes after the method is recorded by suitable charts and diagrams. The individual activity is examined by putting a number of questions. The following factors are questioned: 1. Purpose To eliminate the activity, if possible. 2. Place To combine or re-arrange the activities. 3. Sequence -do4. Person -do5. Means To simplify the activity. The following sequence of questions is used: 1. Purpose What is actually done? Why is it done? What else could be done? What should be done? 2. Place Where is it being done? Why is it done there? Where else could it be done? Where should it be done? 3. Sequence When is it done? Why is it done then? When could it be done? When should it be done? 4. Person Who is doing it? Why does that person do it? Who else could do it? Who should do it? 5. Means How is it done? Why is it done that way? How else could it be done? How should it be done? By answering these questions unwanted activities can be eliminated, number of activities can be combined or re-arranged & method can be simplified. All these will reduce production time. D. Develop: The answer to the questions given below will result in the development of a better method. 1. Purpose What should be done? 2. Place Where should it be done? 3. Sequence When should it be done? 4. Person Who should do it? 5. Means How should it be done? E. Define: Once a complete study of a job has been made and a new method is developed, it is necessary to obtain the approval of the management before installing it. The work study man should prepare a report giving details of the existing and proposed methods. F. Install: This step is the most difficult stage in method study. Here the active support of both management and trade union is required. Here the work study man requires skill in getting along with other people and winning their trust. Install stage consists of 1. Gaining acceptance of the change by supervisor. 2. Getting approval of management. 3. Gaining the acceptance of change by workers and trade unions. 4. Giving training to operators in the new method. 5. To be in close contact with the progress of the job until it is satisfactorily executed. G. Maintain: The work study man must see that the new method introduced is followed. The workers after some time may slip back to the old methods. This should not be allowed. The new method may have defects. There may be difficulties also. This should be rectified in time by the work study man. Periodical review is made. The reactions and suggestions from workers and supervisors are noted. This may lead to further improvement. The differences between the new written standard practice and the actual practice are found out. Reasons for variations are analyzed. Changes due to valid reasons are accepted. The instructions are suitably modified. RECORDING TECHNIQUES The recording techniques are designed to simplify & standardize the recording work. Graphical method of recording was originated by Gilberth. In order to make the presentation of the facts clearly, without any ambiguity & to enable to grasp them quickly & clearly, it is useful to use symbols instead of written description.

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Sourabh Guha Assistant Professor (MBA)

According to the nature of the job being studied & the purpose for which the record is required the techniques fall into following categories: Charts for process and time records Diagrams and models for path of movement of men or materials (not mutually exclusive) Photographic aids Charts:- There are four type of charts for recording, they are operation process chart, Flow Process Chart, TwoHanded Process Chart & multiple activity chart. (a) Operation Process Chart (outline Process Chart):An operation process chart is a graphic representation of the sequence of all operations and inspections taking place in a process. It is also known as outline process chart. It gives a birds eye view of the overall activities. Entry points of all material are noted in the chart. Operation process chart uses only two symbols, i.e. operation & inspection.

(A)

(b) Flow Process Chart: A flow process chart is a graphical representation of the sequence of all the activities (operation, inspection, transport, delay and storage) taking place in a process. Process chart symbols are used here to represent the activities. It is the amplification of the operation process chart in which operation; inspection, storage, delay & transportation are represented. There are three types of flow process charts. They are i. Man type flow process chart: This flow process chart records what the worker does. ii. Material type flow process chart: This flow process chart records how the material is handled or treated. iii. Equipment type flow process chart: This flow process chart records how the equipment or machine is used. Example: The activities of a stenographer in preparation of a letter are recorded in the operator type flow process chart shown in figure

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Sourabh Guha Assistant Professor (MBA)

(c) Two-Handed Process Chart (or) Right Hand, Left Hand Chart:It is the process chart in which the activities of two hands of the operator are recorded. It shows whether the two hands of the operator are idle or moving in relation to one another, in a timescale. It is generally used for repetitive operations. Operation: Represents the activities grasp, position, use, release etc. of a tool, component or material. Transport: Represents the movement of the hand or limb to or from the work or a tool or material. Delay: Refers to the time when the hand or limb is idle. Storage (Hold): The term hold is used here instead of storage. This refers to the time when the work is held by hand. The activity inspection by hand is considered as an operation. Hence, the symbol for inspection is not used in this chart. Two-handed process chart can be used for assembly, machining and clerical jobs.

(d) Multiple Activity Chart/ Man-Machine Chart: A man-machine chart is a chart in which the activities of more than one worker or machine are recorded. Activities are recorded on a common time scale to show the inter-relationship. It is also known as multiple activity charts. It is used when a worker operates a number of machines at a time. It is also used when a number of workers jointly do a job. .

(B) Diagrams: -

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Sourabh Guha Assistant Professor (MBA)

The flow process chart shows the sequence & nature of movement but it does not clearly show the path of movement but it does not clearly show the path of movements. In paths of movement, these are often undesirable features such as congestion, back tracking & unnecessary long movements. To record these unnecessary features two types of diagram can be used: Flow diagram & string diagram. (a) Flow Diagram: In any production shop, repair shop or any other department, there are movements of men and material from one place to another. Process charts indicate the sequence of activities. They do not show the frequent movements of men and material. If these movements are minimized, a lot of savings can be achieved in cost and effort. If the path of movement of material is not frequent and simple, a flow diagram is used for recording the movement. A flow diagram is a diagram which is drawn to scale. The relative positions of machineries, gang ways, material handling equipment etc. are drawn first. Then the path followed by men or material is marked on the diagram. Different movements can be marked in different colors. Process symbols are added to the diagram to identify the different activities at different work centers

(b) String Diagram: We make use of flow diagram for recording the movement of men or material when the movement is simple and the path is almost fixed. But when the paths are many and are repetitive, it may not be possible to record them in a flow diagram. Here a string diagram is used. String diagram is a scaled plan of the shop. Location of machines and various facilities are drawn to scale in a drawing sheet. Pins are fixed at the various work centers in the drawing sheet. A continuous colored thread or string is taken round the pins where the material or worker moves during the process.

B. Photographic Aids: There are three techniques of recording by photographic aids; they are micro motion study, SIMO chart & cycle graph & chrono cycle graph. a) Micro Motion Study:Micro-Motion study provides a technique for recording & timing an activity. Micro-Motion study is a set of techniques intended to divide the human activities in a group of movements or Micro Motion (called therblings) & the study of such movements helps to find for an operator one best pattern of movement that consumes less time & requires less efforts to accomplish the task.

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Sourabh Guha Assistant Professor (MBA)

b) SIMO Chart: Simultaneous motion cycle chart (SIMO Chart) is a recording technique for micro-motion study. A simo chart is a chart, based on the film analysis, used to record simultaneously on a common time scale the therbligs or a group of therbligs performed by different parts of the body of one or more operators It is a graphic representation of the sequence of the therbligs or group of therbligs performed by body members of operator. It is drawn on a common time scale. In other words, it is a two-hand process chart drawn in terms of therbligs and with a time scale.

(c) Cycle graph and Chronocycle graph These techniques of analyzing the paths of motion made by an operator were developed by the Gilbreths. These are used especially for those movements which are too fast to be traced by human eye. To make a cycle graph, a small electric bulb is attached to the finger, hand, or any other part of the body whose motion is to be recorded. By using still Photography, the path of light of bulb (in other words, that of the body member) as it moves through space for one complete cycle is photographed by keeping the working area relatively less illuminated. More than one camera may be used in different planes to get more details. The resulting picture (cycle graph) shows a permanent record of the motion pattern employed in the form of a closed loop of white continuous line with the working area in the background. A cycle graph does not indicate the direction or speed of motion.

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Sourabh Guha Assistant Professor (MBA)

ERGONOMICS
Ergons means work and Nomos means Natural laws. Ergonomics or its American equivalent Human Engineering may be defined as the scientific study of the relationship between man and his working environments. Objectives: The objective of the study of ergonomics is to optimize the integration of man and machine in order to increase work rate and accuracy. It involves 1. The design of a work place befitting the needs and requirements of the worker. 2. The design of equipment, machinery and controls in such a manner so as to minimize mental and physical strain on the worker thereby increasing the efficiency, and 3. The design of a conductive environment for executing the task most effectively. Both work study and Ergonomics are complementary and try to fit the job to the workers; however Ergonomics adequately takes care of factors governing physical and mental strains. Applications: In practice, ergonomics has been applied to working environments, the work place, and other areas of production as discussed below 1. Working environments 2. Work place layout 3. Other areas: -

WORK MEASUREMENT
Work Measurement is also called by the name Time Study. Work measurement is a technique to establish the time required for a qualified worker to carry out a specified job at a defined level of performance. It is the most widely used technique in work measurement. Objectives of work measurement 1. To reduce or eliminate non-productive time. 2. To fix the standard time for doing a job. 3. To develop standard data for future reference. 4. To improve methods. TECHNIQUES OF WORK MEASUREMENT 1. Stop watch technique (time study). 2. Work sampling or Ratio delay study. 3. Synthesis from standard data. 4. Analytical estimating. 5. Predetermined motion time system. 6. Production study. (A) Stop Watch Technique (Time Study): Stop watch time study is one of the techniques of work measurement commonly used. Here we make use of a stop watch for measuring the time. Procedure for conducting stop watch time study (B) Work sampling or Ratio delay study: Work sampling was originally developed by L.H.C. Tippett in Britain in1934 for the British Cotton Industry Research Board. Work sampling is a fact finding tool. Work Sampling has three main applications: Activity & delay sampling: To measure the activities & delay of workers or machine. E.g., the percentage of time in a day, a person is working & the percentage that a person is not working. Performance sampling: To measure working time & non-working time of a person on a manual work & to establish a performance index or performance level for a person during his working time.

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Sourabh Guha Assistant Professor (MBA)

Work measurement: Under certain circumstances, to measure a manual task, that is to establish a time standard for an operation. (C)Synthetic Data or Synthesis from standard data: Time study techniques are not suitable where direct observation is not convenient. Under such circumstances, we may estimate a standard time on the basis of previous experience of similar jobs. Time standards arrived at this way are called synthesis. Synthesis is a work measurement technique for building up the time for a job at a defined level of performance by totaling element times obtained previously from time studies on other jobs containing the elements concerned, from synthetic data. (D) Analytical estimating: A work measurement technique whereby the time required carrying out elements of a job at a defined level of performance is established from knowledge and practical experience of the elements concerned. Setting the time standards for long and non-repetitive operations by stop watch method are uneconomical. Analytical estimating technique determines the time values for such jobs either by using the synthetic data or on the basic of the past experience of the estimator when no synthetic or standard data is available. In order to produce accurate results the estimator must have sufficient experience of estimating, motion study, time study and the use of synthesized time standards.

(E) Predetermined motion time system (PMTS): APMTS consists of a set of time data & a systematic procedure which analyses & subdivides any manual operation of human task into motions, body motions or other elements of human performance & assign to each the appropriate time value. A predetermined motion time system (PMTS) may be defined as a procedure that analyzes any manual activity in terms of basic or fundamental motions required to performing it. Each of these motions is assigned a previously established standard time value in such a way that the timings for the individual motions can be synthesized to obtain the total time for the performance of the activity. Predetermined times are the tabulated values of normal times required to perform individual movements such as moving an arm from one position to another etc. The total times needed to perform the operation are the sum of the times needed for basic motions. By arranging the basic motions & aggregating associated times, an existing task can be analyzed or a proposed operation can be timed actually performing it. The main use of PMTS lies in the estimation of time for the performance of a task before it is performed. The procedure is particularly useful to some organizations because it does not require troublesome rating with each study. (F) Production study: Production study is a technique of work measurement to check accuracy of the original time study. This study is done to find the time delay due to occasional elements. These elements may occur at irregular intervals. Example: Tool grinding, setting tools etc. There are chances of missing these elements in the stop watch time study. Production study is conducted for a longer periodat least for half a day or one shift.

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