Module 3-Work Study

Module 3-WORK STUDY

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WORK STUDY: TIME AND METHOD STUDYDefinition of Russel M.Currie about

work study“The systematic objective and critical

examination of all factors governing the operation efficiency of any specified activity in order to effect improvement .”

Time study means the straight timing of work elements .The object of motion study , method study ,micro motion study is to device new and improved working methods.

Importance and scope of work study• It is essentially a practical one

dealing with human beings who have their own style and attitude

• The success of work study depends on the existence of good relations between management and workers.

• Work study involves changes in various kinds of working methods

VARIOUS MODELS• The layout Diagram• Flow Diagram• String Diagram

Implications on productivity• Productivity increase is the key factor

in raising the standard of living.• Work study indicates how resources

can be effectively utilized and helps realize this aim.

• The following steps need to be followed.

Select the work to be studied

• We should select to study the work that is likely to have the longest production run , offers the greatest scope for improvement, and promises the greatest financial saving for a given outlay.

Record Facts• It may be divided in to the following three

categories.Process and Time chartProcess chartsTravel charts

Advantages of work study• It helps uniformed and improved production flow• It helps higher production efficiency• Manufacturing costs are greatly reduced• It helps to secure proper performance• It helps in fixation of wages• It helps to introduce the methods and standards as

accepted routine practice• It helps in better employer employee relation• Job security and job satisfaction to workers is

ensured• It helps ensure the best possible and most

effective use of exciting and potential resources of the firm

Usefulness of the study

• To determine the std time for various operators

• Estimate the cost of product• Production control• Helps in predicting accurately• Operators efficiency in using

machine within the allotted time

Techniques of work study

• It consists of work study(motion study) and work measurement(or time study).

Uses• It is a direct means of raising

productivity.• It is systematic : no factor is

overlooked• It is a most accurate method• It is a most important tool of analysis• Everyone concerns with the industry

gets benefitted.

Definition of method study• Frank Gilberth defines method study

as “ the science of eliminating wastefulness resulting from ill –directed and inefficient motions .”

The purpose is to find out ways of least wastage of labour

Objectives of method study

• Improvement in manufacturing process• Improvement in working conditions• Improvement in plant layout and workspace

layout• Reducing the human effort and fatigue• Reducing health hazards• Reducing material handling• Improvement of plan and equipment design• Improvement in the utility of materials ,

machines and manpower• Ensuring safety

Flow chart of the Method procedure study

Selection of jobs

Recording of facts

Critical examination

Development and selection

Installation

Maintenance

1. Selection of jobs• Economic considerations• Technical considerations• Human considerations2. Recording of Facts• Operation• Transport• Inspection• Delay• storage

3. Critical examination• Purpose• Place• Sequence• Person• Means4. Development and Selection• Evaluation phase• Investigation phase• selection

5. Installation6.Maintanence • Performance appraisal

Therbligs Frank Gilberth developed a set of 17

elementary motions commonly found in manual operations and called them “Therbligs” which is his name in reverse.

• For the purpose of recording the motions , he split up the different motion of process into 17 fundamentals made by various parts of human body , and each event was allotted a symbol and abbreviations.

• the symbols are used for preparing motion study chart , which include the following:

1. Process charts• Outline process charts• Flow process charts• Two handed process charts

2. Flow Diagram3. String Diagram4. Time Study OBJECTIVES OF TIME STUDY

Production cost of any commodity is made up of three components:

• Raw material cost• Overheads• Labour cost

WORK MEASUREMETN AND WORK ENVIORNMENT

Work measurement:• Determines the time required to do a

job• Decides the man power required to

do a job• Provides info for effective production• Aids in calculating exact delivery

dates• Decides realistic labour budgeting• Provides for a sound incentives

scheme• Results in effective labour control

Procedure for work environment• The job is broken down into its elements• The observed time for each element is recorded.• Basic time is determined for those elements for which

data is not available• The values so determined for any of the elements

which could convincible secure another job are added to the records of basic times

• Determine the frequency determined for occurrence of each element in the job

• The proportion of the rest required is assessed• The addition of the relaxation allowance may be

made element by element.• Contingent delays- blanket allowances are

added .

Work environment

• Build trust• Maintain positive and open channels

of communication• Expect the best from each employee• Foster team spirit• Give credit• Be approachable• Positive physical work environment

Work sampling• Another technique for measuring an activity• It s similar to time study in that we observe

a portion or sample of the work activity• Inferences are made based on the findings

in this sample • And applied for every activity in general

Primary applications of work sampling• Activity time for personnel and machinery• Develop a performance index for workers• To fix time standars.

Predetermined motion time studies(PMTS)

• In which only motion patterns will be known • Alternatives may be evaluated prior to actually

trying them out • It is necessary to define a basic set of motions

into which any task can be split into.• It must be refined to account for various

degrees of difficulty.• It is necessary to apply micro-motion analysis to

such systems , these are often costly• most widely use is Methods Time

Measurement (MTM)

The basic elements use din MTM are:1. Reach2. Move3. Turn and apply pressure4. Grasp5. Position6. Release7. Disengage8. Eye travel time and eye focus9. Body, leg and foot motion10.Simultaneous motions

Industrial safetyThe Indian Factories Act , 1948 has the

following objectives :• To protect human beings from being subjected

to unduly long hours of bodily strains of manual labour

• Employees should work in healthy and sanitary conditions as far as the manufacturing process will allow and precautions should be taken for their safety and prevention of accidents.

• The terms accidents and injuries are often used interchangeably.

• An accident may be defined as an unintended occurrence arising out of employment that either causes personal injury or causes property damage or interference with production or other business activity under such circumstances that personal injury might have resulted.

• the prime purpose of accident prevention is to prevent personal injuries and death.

• Practically , every accident is caused by more than one factor :

• unsafe physical conditions are those factors , which are present due to defects in condition , errors in design , faulty planning or omission of essential safety requirements

Responsibility of accident prevention

• Emergency procedures• Investigation of accidents• Care in the use of material and equipment• First aid

Cost associated with accidents

Companies could not admit huge losses from accident because:

• The info could effect the valuation of the company on the stock market

• The disclosure could give an edge to its competitors

• The info could create concern among the customers about the likely impact on cost of the product.

Safety organization• The safety department is usually

located within the personal department

• The safety personnel should preferably report to someone senior in the organization

• He may report work to the production manager

• This can help in proper implementation of major safety programs , as operations and production are areas more prone to accidents.

Risk assessment

• It is an essential part of safety operations

• There should be an ongoing program for assessing the reliability of process equipment

• There should be comprehensive risk analysis plan to indicate the impact of specific practiced emergency procedures.

• Safety induction and periodical refresher training for the regular employees and contract workmen should be given.

Value Analysis

“Prepare an assignment on value analysis”

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