Work study - production and operations management

Apurb Sinha Vibha Garg

Executive PGDM (2010-11)

Organizational objective

• VFM for customers

• Improve overall productivity

Q : Quality S : Service R : Customer relationship P : Price L : Lead time

Output : Good or services

Input : Man, Machine, Material, Information, Capital

Technique of improving◦VFM◦Productivity

Major discipline of Industrial engineering

The systematic examination of the method of carrying on activities so as to improve the effective use of resources and to set up standards of performance for the activities being carried out.

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 cost

Select job/process to be examined & observe current performance • high process cost, bottlenecks, tortuous route, low

productivity, erratic quality Record & document facts

• activities performed• operators involved - how etc• equipment and tools used• materials processed or moved

Apply critical examination - challenge job components & necessity (purpose, place, sequence, method).

Develop alternative methods & present proposals Document as base for new work system Install, monitor (slippage) & maintain

Improvement in use of all inputs Economy in human effort Layout improvement Improvement in design of plant and machinery Improvement in safety standards and

procedures Better working environment

Outline process chart Flow process chart Travel chart Multiple activity chart Data flow diagrams

High operating cost High wastage & scrap Excessive movement of materials and workmen Excessive production bottlenecks Excessive rejections and rework Complaints about quality Complaints about poor working condition Increasing number of accidents Excessive use of overtime

The application of technique designed to establish time for a qualified worker to carry out a task at a defined rate of working at a defined level of performance

Fair Day’s work

Why define/measure work?◦standard, reliable methods◦control performance & quality◦obtain predictability◦defined labour costs & performance◦set pay rates & provide data for effort-reward

relationship Why set standard times

◦assumptions about competent, motivated workers◦be clear about "allowances" & fatigue

Finding ineffective time in an activity Setting standards (norms) for output level Performance evaluation – capability management Capacity management Comparing work methods Scheduling – facility operations Establishing wage incentives schemes

Stop – watch time study Work sampling Predetermined times standards Standard data

Techniques to establish the time for a qualified, motivated worker to carry out a task at a defined rate of working

Example – Cricket pitch curator

One of the most common types of work measurement is time study

For example - PurposeAn international coffee shop chain may want to find out how long a barista should take to make a specific coffee drink. Some of the stated condition may include using cold milk that needs to be steamed, rather thanalready steamed milk.

Observations◦ A qualified practitioner should observe the employee using a time

measurement device. The observer should also assess the quality of work

Observed Person◦ The observed person in the time study must be fully trained in the

measured task

Employees are your company's life. Providing incentives for employees can boost productivity and confidence in the workplace, especially in a poor economy

Customers place pizzas orders A single order may contain several pizzas Each customer is in one of many service areas Each customer is serviced by one of 6 outlets Each customer is allocated an outlet depending on

their area location All pizzas are made at all outlets

All work is different - idiographic vs/ nomothetic

Large firm/employer and large engineered systems only

Work study is obsolete

It is exploitative of workers

It has never been and never will be accepted here

Increased productivity and increased efficiency Reduced manufacturing costs Improved work place layout Better manpower planning and capacity planning Fair wages to employees Better working conditions for employees Improved workflow Reduced material handling costs Better industrial relations and employee morale Provides better job satisfaction to employees

Human capital managers Capability managers Capacity managers Project managers Consultants Leaders

F W Taylor(1856 – 1915)

◦Father of scientific measurements and IE

◦Criticism

Raising standards