Work study

PRODUCTION AND OPERATIONS

MANAGEMENT

Chapter 10DESIGN OF WORK SYSTEMS

Design of Work Systems

Work Study-Method Study and Work Measurement

• Methods engineering includes work simplification, job design, value analysis and the like.

• Work study method was developed to improve performance of a given work.

• Work study is the body of knowledge concerned with analysis of the work methods, and the standard of proposed work methods.

• Objective of work study is to improve operational efficiency.

• The purpose of work study is to determine the best or most effective method of accomplishing a necessary operation.

Design of Work Systems

Relationship of Time and Motion Study to Work Study

• Time study and motion study are results of practices developed by F.W. Taylor, Frank and Lillian Gilbreth.

• Time study: Exercising control over the output in respect of a job by setting standards for performance.

• Time study may be used to compare the effectiveness of alternative work methods.

Design of Work SystemsSteps Involved in Work Study

Design of Work Systems

Method Study or Methods Analysis

• Method study is also known as methods improvement.

• Prime objectives of method study is to eliminate wasteful and inefficient motions.

• It is a scientific technique of observing, recording and critically examining the present method of performing a task or job or operation with the aim of improving the present method and developing a new and cheaper method.

• It encompasses study of work processes, working conditions and equipment. tools used to carry out the job.

Design of Work Systems

Objectives of Method Study

• To study existing proposed method of doing a job.

• To develop an improved method to improve productivity and reduce operating cost.

• To reduce excessive material handling or movement so reduce fatigue to workmen.

• To improve utilization of resources.

• To eliminate wasteful and inefficient motions.

• To standardize work method, processes, working conditions, machinery, tools etc.

Design of Work Systems

Method Study Procedure Method study procedure involves six steps.

• Select: select the job and define the objective for selecting this particular job for study.

• Record: all relevant information.• Examine: recorded fact critically examined.• Develop: generating several alternatives and selecting the

best method in terms of cost of implementation, expected savings in time and cost, feasibility, productivity, acceptance to design, ppc, quality control and sales departments etc.

• Reaction of employees for new method.• Short term or long term implication of alternatives.• Install: in 3 phases- planning, Arranging and

implementation.• Maintain: ensure the installed method functioning well.

Design of Work Systems

Recording Techniques Used in Method Study

Process Charts used in Method Study1. Outline process chart2. Operation process chart3. Flow process charts4. Two handed process chart5. Multiple activity chart6. The man machine chart or worker-machine chart 7. Flow diagram8. String diagram9. SIMO chart

Design of Work Systems

Qualified Worker

"A qualified worker is one who is accepted as having the necessary physical attributes, possessing the required intelligence and education and having acquired the necessary skill and knowledge to carry out the work in hand to satisfactory standards of safety, quantity and quality"

Design of Work Systems

Work Measurement

• Measuring the work content of any activity under this study.

• Work measurement is defined as the application of techniques designed to establish the work content of specified task by determining the time required for carrying out the task at a defined standard of performance by qualified worker.

• According to ILO-it is defined as the technique applied to determine the amount of time necessary for a qualified worker to perform a particular task.

Design of Work Systems

• Standard time: is the amount of time a qualified worker working at a normal rate of sped, will require to perform the specified task.

Design of Work Systems

Techniques of Work Measurement

The main techniques used to measure work are:

1. Direct Time Study.

2. Synthesis Method.

3. Analytical Estimating.

4. Pre determined Motion Time System (PMTS).

5. Work sampling or Activity Sampling or Ratio Delay Method.

Design of Work Systems

Steps in Work Measurement Work measurement involves seven steps.1. Break the job into elements2. Record the observed time for each element by means of either time

study, synthesis or analytical estimating.3. Establish elemental time values by extending observed time into

normal time for each element by applying a rating factor.4. Assess relaxation allowance for personal needs and physical and

mental fatigue involved in carrying out each element.5. Add the relaxation allowance time to the normal time for each

element to arrive at the work content.6. Determine the frequency of occurrences of each element in the job,

multiply the work content of each element by its frequency (i.e., number of time the element occurs in the job) and add up the times to arrive at the work content for the job.

7. Add contingency allowance if any to arrive at the standard time to do the job.

Design of Work Systems

1. TIME STUDY

• Time study is concerned with the determination of the amount of time required to perform a unit of work.

• Objective of time study is to establish the standard time.

• Time study by stop watch: The steps involved are

1. Select the job to be studied

2. Select the worker to be studied

3. Conducting stop watch time study

Design of Work Systems

2. SYNTHESIS METHODSynthesis Method: Building up the time required to do a job at a defined level of performance.

3. ANALYTICAL ESTIMATINGAnalytical Estimating: Used to determine the time values for jobs having long and non-repetitive operations.

4. PREDETERMINED MOTION TIME SYSTEM (PMTS) PMTS: Normal times are established for basic human motions.

5. WORK SAMPLING OR ACTIVITY SAMPLING OR RATIO-DELAY METHODWork sampling helps determine allowances for inclusion in standard times.

Design of Work Systems

The work sampling study consists of essentially the following steps:1. Determine the objective of the study, including definitions of the

states of activity to be observed.2. Plan the sampling procedure including:

(a) An estimate of the percentage of time being devoted to each phase of the activity.

(b) The setting of accuracy limits.(c) An estimation of the number of observations required.(d) The selection of the length of the study period and the

programming of the number of readings over this period.(e) The establishment of the mechanics of making the

observations, the route to follow and the recording of data.3. Collect the data as planned.4. Process the data and present the results.

Design of Work Systems

Motion Study

Motion study is the science of eliminating wastefulness resulting from using unnecessary; ill-directed and inefficient motion. The aim of motion study is to find and perpetuate the scheme of least waste methods of labour.

Micro motion study provides a valuable technique for making minute analysis of those operations that are short in cycle, contain rapid movements and involve high production over a long period of time.

Micro-motions are also known as ‘Therbligs’.

Design of Work Systems

Examples of Therbligs

1. Search (Sr) 2. Select (St) 3. Grasp (G)4. Transport empty

(TE)5. Transport loaded

(TL)6. Hold (H)7. Release load (RL) 8. Position (P)9. Pre-position (PP)10. Inspect (I)

11. Assemble (A)

12. Disassemble (DA)

13. Use (U)

14. Unavoidable delay (UD)

15. Avoidable delay (AD)

16. Plan (Pn)

17. Rest for overcoming fatigue (R)

18. Find (F)

Design of Work Systems

Principles of Motion Economy

Principles of motion economy are divided into three groups.

a. Effective use of the operator

b. Arrangement of the workplace

c. Tools and equipment

Design of Work Systems

Techniques of Work Measurement

The main techniques used to measure work are:

1. Direct Time Study.

2. Synthesis Method.

3. Analytical Estimating.

4. Pre determined Motion Time System (PMTS).

5. Work sampling or Activity Sampling or Ratio Delay Method.

Design of Work Systems

Steps in Work Measurement Work measurement involves seven steps.1. Break the job into elements2. Record the observed time for each element by means of either time

study, synthesis or analytical estimating.3. Establish elemental time values by extending observed time into

normal time for each element by applying a rating factor.4. Assess relaxation allowance for personal needs and physical and

mental fatigue involved in carrying out each element.5. Add the relaxation allowance time to the normal time for each

element to arrive at the work content.6. Determine the frequency of occurrences of each element in the job,

multiply the work content of each element by its frequency (i.e., number of time the element occurs in the job) and add up the times to arrive at the work content for the job.

7. Add contingency allowance if any to arrive at the standard time to do the job.

Design of Work Systems

1. TIME STUDY

• Time study is concerned with the determination of the amount of time required to perform a unit of work.

• Objective of time study is to establish the standard time.

• Time study by stop watch: The steps involved are

1. Select the job to be studied

2. Select the worker to be studied

3. Conducting stop watch time study

Design of Work Systems

2. SYNTHESIS METHODSynthesis Method: Building up the time required to do a job at a defined level of performance.

3. ANALYTICAL ESTIMATINGAnalytical Estimating: Used to determine the time values for jobs having long and non-repetitive operations.

4. PREDETERMINED MOTION TIME SYSTEM (PMTS) PMTS: Normal times are established for basic human motions.

5. WORK SAMPLING OR ACTIVITY SAMPLING OR RATIO-DELAY METHODWork sampling helps determine allowances for inclusion in standard times.

Design of Work Systems

The work sampling study consists of essentially the following steps:1. Determine the objective of the study, including definitions of the

states of activity to be observed.2. Plan the sampling procedure including:

(a) An estimate of the percentage of time being devoted to each phase of the activity.

(b) The setting of accuracy limits.(c) An estimation of the number of observations required.(d) The selection of the length of the study period and the

programming of the number of readings over this period.(e) The establishment of the mechanics of making the

observations, the route to follow and the recording of data.3. Collect the data as planned.4. Process the data and present the results.

Design of Work Systems

Productivity and Employees

• Production refers to the total output.

• Productivity: The amount of goods and services produced with resources used.

Design of Work Systems

Output in a given period

• Partial productivity: Output in a given period divided by labors hours used in the period.

Labour hours used in the periodPartial productivity =

Total productivity = Output in a given period

Labour + Capital + Materials + Energy used in the same period

Design of Work Systems

• Labour ProductivityThere are three ways of measuring labour productivity.

• Ways of Improving ProductivityUnderstanding the factors that influence the relationship between output and input.