Professional Documents
Culture Documents
UNIT-2
METHOD STUDY
Syllabus:-
Work Study: Definition, objective and scope of work-study, human factors in work-study.
Method Study: Definition, objective and scope of method study, work content, activity recording and exam aids.
Charts to record movements: Operation process charts, flow process charts, travel chart, two-handed chart and
multiple activity charts. Principles of motion economy, classification of movements, SIMO chart, and micro
motion study.
Definition and installation of the improved method, brief concept about synthetic motion studies. Introduction to
Value Engineering and Value Analysis.
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Work Study
Definition: Work study may be defined as the analysis of a job for the purpose of finding the preferred
method of doing it and also determining the standard time to perform it by the preferred (or given)
method. Work study, therefore, comprises of two areas of study: method study (motion study) and time
study (work measurement).
(1) It helps in the optimum use of plant, equipment, manpower and material.
(4) It helps in establishing the most efficient and effective utilization of human effort.
(8) It helps in the elimination of wasteful efforts, useless material handling, etc.
(10) It is helpful in developing plant safety schemes, plant layout, and conducive
work environment.
5. To utilize facilities such as man, machine and materials most effectively, and
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· Record from direct observation everything that happens in order to obtain data for analysis.
· Examine the recorded facts critically and challenge everything that is done, considering in turn: the
purpose of the activity, the place where it is performed; the sequence in which the elements are
performed; the person who is doing it; the means by which it is done.
· Develop the most economic methods, taking into account all the circumstances.
· Measure the amount of work involved in the method used and calculate “standard time” for doing it.
Method Study
Method study, aims to achieve the better method of doing work, and for this reason method study is
sometimes called Work Method Design.
Definition: Method study can be defined as the procedure for systematic recording, analysis and critical
examination of existing or proposed method of doing work for the purpose of development and
application of easier and more effective method.
Method study scope lies in improving work methods through process and operation analysis, such as:
3. To smoothen material flow with minimum of back tracking and to improve layout.
Method study has two levels of its application. (a) Motion study, and (b) Micro-motion study
Motion Study
This is more detailed investigation of individual operation or operator and layout of materials, parts or
tools around a working bench or machine, use of jigs, fixtures and consumables to perform the job
effectively. The study of environment, body postures, gestures, the noise level, the temperature, the
pressure, the humidity around the work place are the major concerns of motion study which are now
known as 'ergonomics'.
Micro-motion Study
This is the most detailed investigation of the movements of hands, arms, limbs, legs, head, etc. while
performing the job. Motion pictures, cameras, filmed records, etc. are a few tools used to study the micro-
motions of a specified job.
Method Study Procedure
4. Develop the most practical, economical and effective method by considering real limitations of the
situation.
7. Install the new method as a standard practice and train the persons involved in applying it.
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8 Maintain the new method and introduce control procedures to prevent a drifting back to the
previous method of work.
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Considerations may be given to the following factors while selecting a job for method study
• Economic Factors
• Technical Factors
• Human Factors
Economic Factors:
If the economic importance of a job is small, it is not wise to start or continue a long study. Priorities
should be given to those types of job which offer greater potential for cost reduction. Such jobs are easily
identifiable, as they have
Human Factors: Emotional reaction of the workers to the method study and changes in method are
important considerations. If the study of a particular job is suspected to cause unrest or ill feeling, it
should not be undertaken, however useful it may be from the economic point of view. It is always better
to take up first those jobs which are considered ‘dirty', unsafe, unpleasant, boring, or highly fatiguing, and
improvements brought about as a result of method study. This would possibly ensure cooperative from
the workers for the other jobs as well.
After it is recognized that a problem exists, the first step is to properly formulate it. From the general
statements like “Costs are too high“, “Increase the production”, “Reduce shop floor accidents”, it is
necessary to determine just what the real problem is. After it is ascertained that the problem merits
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consideration, it is decided whether this is the proper time to solve it, and how much time can be spent in
solving it. The problem may then be defined broadly giving minimum constraints at this stage, as it will
permit the use of imagination and creativity in finding a solution. It may sometimes be desirable to divide
the complete problem into a couple of small problems and solve them.
RECORD
The accuracy of data about the method study problem is important for the development of improved
method. The following techniques are used for the collection of information / data about the task under
consideration. These are not exclusive of each other, and for any particular method study problem, some
or all the techniques may be employed.
• Observation. It is a common technique used for collecting information about the present method or the
existing problem. The method study person visits the site where the work is currently being done and
observes various steps in the method being followed. There are many instances where all the data needed
is obtained by only observing the work or work site.
• Discussion. Discussion with those who do or who supervise the work can frequently provide information
not obtainable by observation. The discussion technique is commonly used where irregular work is
involved or where one is trying to analyze past work in order to improve efficiency of work to be done in
future.
Even where observation by itself may accomplish the data collection task, discussion may be used for
developing good human relations.
• Records. Valuable information can be obtained from past records concerning production, cost, time,
inventory and sub-contracts. For certain type of information concerning the past practice, sometimes this
is the only way to obtain authentic data.
• Motion Pictures or video Films. Accurate and most detailed information can be obtained by taking
motion pictures or video film. Information obtained by this procedure can easily be transmitted /
forwarded to all levels in the organization and if needed, can be used directly for training purposes. The
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film can be used to focus attention at particular point or motion in an operation. For obtaining information
concerning those types of work that involve large crew size, it is probably the only procedure.
It is also called outline process chart. An operation process chart gives the bird’s eye view of the whole
process by recording only the major activities and inspections involved in the process. Operation process
chart uses only two symbols, i.e., operation and inspection. Operation, process chart is helpful to:
a. Visualize the complete sequence of the operations and inspections in the process.
b. Know where the operation selected for detailed study fits into the entire process.
c. In operation process chart, the graphic representation of the points at which materials are
introduced into the process and what operations and inspections are carried on them are shown.
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Example:-1
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Example:-2
Flow Process Chart:-It gives the sequence of flow of work of a product or any part of it through the work
centre or the department recording the events using appropriate symbols. It is the amplification of the
operation process chart in which operations; inspection, storage, delay and transportation are
represented. However, process charts are of three types:
a. Material type— which shows the events that occur to the materials.
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Like operation process chart, flow process chart is constructed by placing symbols one below another as
per the occurrence of the activities and are joined by a vertical line. A brief description of the activity is
written on the right hand side of the activity symbol and time or distance is given on the left hand side.
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Example:-1
Example:-2
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It is a chart where activities of more than subject (worker or equipment) are each recorded on a common
time scale to show their inter-relationship. Multiple activity chart is made:
1. To detect the idle time enforced on men and machines and thereby rearranging the work cycle in
order to reduce the same.
2. To establish the number of machines that may be conveniently manned by an operator
3. To reallocate the activities among the workers in order to achieve optimal work distribution
4. To combine or eliminate some of the work elements if observed unnecessary.
Principles of motion economy:- The principles of motion economy form a set of rules and suggestions to
improve the manual work in manufacturing and reduce fatigue and unnecessary movements by the
worker, which can lead to the reduction in the work related trauma.
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The two hands should not be idle at the same time except during rest periods.
Motions of the arms should be made in opposite and symmetrical directions and should be made
simultaneously
Momentum should be employed to assist the worker whenever possible, and it should be reduced
to a minimum if it must be overcome by muscular effort.
Smooth continuous motions of the hands are preferable to zigzag motions or straight-line motions
involving sudden and sharp changes in direction.
Ballistic (i.e. free swinging) movements are faster, easier and more accurate than restricted or
controlled movements.
Hand motions should be confined to the lowest classification with which it is possible to perform
the work satisfactorily:
Finger motions
Wrist motions
Forearm motions
Shoulder motions
There should be a definite and fixed place for all tools and materials.
Tools, materials, and controls should be located close in and directly in front of the operator.
Materials and tools should be located to permit the best sequence of motions.
Arrange the height of the workplace and chair for alternate sitting and standing, when possible.
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Where each finger performs some specific movement, the load should be distributed in
accordance with the inherent capacities of the fingers.
Momentum should be used to help the worker in doing their task not to increase their task.
Time Conservation
Machine should not run idle, it is not desirable that a lathe machine is running and its job is
rotating but no cut is being taken.
Two or more jobs should be worked upon at the same time or two or more operations should be
carried out on a job simultaneously if possible.
Micro-Motion Study
• It is a technique for recording and timing an activity. It consists of taking motion pictures of the
operation with a clock in the picture (or with a video camera running at a known speed.
• The film is a permanent record of the method and the time and is always ready to be examined when
needed.
2. A large number of operators can see the procedure at any time even after the completion of motion
study work.
3. Films can easily reveal the difference between the present and the proposed technique.
5. It provides very accurate time for each operation or motion in comparison to stop watch time study.
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Methods
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.
SIMO Chart
A video film or a motion picture film is shot of the operation as it is carried out by the operator. The film is
analyzed frame by frame. For the left hand, the sequence of therbligs (or group of therbligs) with their
time values are recorded on the column corresponding to the left hand. The symbols are added against
the length of column representing the duration of the group of therbligs. The procedure is repeated for
the right hand and other body members (if any) involved in carrying out the operation.
The movements are recorded against time which is measured in “Winks” (1 wink= 1/2000 minute). The
recording is done by a “Wink Counter” positioned in such a location that it can be seen rotating during
filming process. The figure above shows SIMO chart of an operator performing assembly of clamp with
nut and bolt.
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2. String Diagram: The string diagram is a scale layout drawing on which, length of a string is used to record
the extent as well as the pattern of movement of a worker working within a limited area during a certain
period of time. The primary function of a string diagram is to produce a record of a existing set of conditions so
that the job of seeing what is actually taking place is made as simple as possible.
The main advantage of string diagram compared to flow diagram is that respective movements between work
stations which are difficult to be traced on the flow diagram can be conveniently shown on string diagram.
Following are the procedures to draw string diagram:
1. A layout of the work place of factory is drawn to scale on the soft board.
2. Pins are fixed into boards to mark the locations of work stations, pins are also driven at the turning
points of the routes.
3. A measured length of the thread is taken to trace the movements (path).
4. The distance covered by the object is obtained by measuring the remaining part of the thread and
subtracting it from original length.
Travel Chart::A chart that represents the quantitative data regarding the movement of workers, materials or
equipment between different stations in a tabular form during a given period of time is called a travel chart. It
can be used instead of string diagrams, as it’s much easier to construct and takes less time as compared. It
becomes very easy to record complex movements with the help of travel charts.
Travel chart usually consist of a square, which further consists a number of smaller squares. Each small
sequence in the square represents a work station. A diagonal line is drawn from top left to bottom right.
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This travel chart shows that total movement for the load between B and C is 700. This 700 shows that 200
load moved from B to C and 500 moved from C to B. Further, it gives that 200 load moved from A to B, 100
from A to C, 500 from B to D and 100 from C to D.
From this; it can be concluded that from materials handling point of view shops B and C be adjacent. Also shop
D should be located close to shop B. It comparatively is less important that shops A and B, A and C, and C and D
be adjacent.
With this information the planning departments proceed to locate individual work stations on the drawing.
Much planning and rearranging still may be needed at the final stage of layout planning.
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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 – -do-
4. Person – -do-
5. 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
doing this questioning Unwanted activities can be eliminated Number of activities can be combined or re-
arranged Method can be simplified. All these will reduce production time.
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?
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. He should give his reasons for the changes
INSTALL
The success of any method study project is realized when actual change is made 'on the ground' - change
that meets the originally specified terms of reference for the project. Thus, the Install phase is very
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important. Making theoretical change is easy; making real change demands careful planning - and
handling of the people involved in the situation under review. They may need reassuring, retraining and
supporting through the acquisition of new skills. Install, in some cases, will require a parallel running of
old and new systems, in others; it may need the build-up of buffer stocks, and other planning to manage
the change. What matters is that the introduction of new working methods is successful. There is often
only one chance to make change!
MAINTAIN
Sometime after the introduction of new working methods, it is necessary to check that the new method is
working, that it is being properly followed, and that it has brought about the desired results. This is the
Maintain phase. Method drift is common - when people either revert to old ways of working, or introduce
new changes. Some of these may be helpful and should formally be incorporated; others may be
inefficient or unsafe. A methods audit can be used to formally compare practice with the defined method
and identify such irregularities.
Introduction to Value Engineering and Value Analysis.
Exchange Value – is the price a customer is prepared to pay for the product, or service
Synthetic Rating
This method of rating has two main advantages over other methods. These are (i) it does not rely on the
judgment of time study person and (ii) it gives consistent results.
The time study is made as usual. Some manually controlled elements of the work cycle are selected. Using
a PMT system (Pre-determined motion time system), the times for these selected elements are
determined. The times of these elements as determined are compared with the actual observed times
and the performance factor is estimated for each of the selected elements.
The overall rating factor is the mean of rating factors determined for the selected elements. This is applied
uniformly to all the manually controlled elements of the work cycle.
The average actual time for 6 elements of a task were measured and tabulated below. The Predetermined Motion
Time for two elements is also given. Calculate the performance rating factor. Also find the normal times for all the
elements on the basis of average rating.
Element No. 1 2 3 4 5 6
Value Engineering
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Definition: Value Engineering is where the value of all the components used in the construction of a
product from design to final delivery stage are completely analyzed and pursued.
Value Engineering (VE) is concerned with new products. It is applied during product development. The
focus is on reducing costs, improving function or both, by way of teamwork-based product evaluation and
analysis. This takes place before any capital is invested in tooling, plant or equipment.
This is very significant, because according to many reports, up to 80% of a product’s costs (throughout the
rest of its life-cycle), are locked in at the design development stage. This is understandable when you
consider the design of any product determines many factors, such as tooling, plant and equipment, labor
and skills, training costs, materials, shipping, installation, maintenance, as well as decommissioning and
recycle costs.
ix. It is not a mere criticism of existing system, method, design or process but an appraisal of practical
alternatives.
Value Analysis
Definition: VA is a step by step approach to identify the functions of a product, process, system or service;
to establish a monetary value for that function and then provide the desired function at an overall
minimum cost without affecting any of the existing parameters like Quality, Maintainability, Productivity,
Safety and other Performance characteristics.
Value Analysis (VA) is concerned with existing products. It involves a current product being analyzed and
evaluated by a team, to reduce costs, improve product function or both.
A significant part of VA is a technique called Functional Analysis, where the product is broken down and
reviewed as a number of assemblies. Here, the function is identified and defined for each product
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assembly. Costs are also assigned to each one. This is assisted by designing and viewing products as
assemblies (or modules). As with VE, VA is a group activity that involves brainstorming improvements and
alternatives to improve the value of the product, particular to the customer.
1. Can a different (cheaper) material be used that is better than the material currently used?
3. Can the use of material components be standardized to facilitate longer production runs if
manufactured internally, or gain benefits from bulk buying if purchased
1. VA reduces costs (in all areas such as materials, parts and production), as well as improving product
function. Therefore, the value of the product is increased to the customer.
2. Reducing the cost of products increases revenue and profit per product. Therefore, giving your
company the option of reducing price to sell more or investing in R&D.
3. VA enables improvements to be made to the product in a variety of areas, such as design and
engineering, material selection, testing, manufacturing, assembly, shipping, installation, use by the
customer, service, maintenance and recycling.
4. A VA project enables your business to take commercial advantage of the constantly falling price of some
technologies, as well as source alternative components and materials.
5. The prestige value of the product increases, therefore making ownership more desirable, which should
help product sales (and indeed the process of marketing and selling it).
6. A customer who perceives the value of the product as being more prestigious is more willing to pay a
premium for it or choose it over rival products if it is priced the same.
7. An all-round better quality product is easier and less costly to produce, assemble, ship, install, use,
service and recycle. The result is to reduce all associated costs throughout the product lifecycle
(importantly, including ownership costs for the customer).
Examples:-
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1. An engineer in a motor manufacturer does a Value Analysis on the motor casing and the process used
to build it. He finds three different sizes of nuts and bolts used, with significant time taken to insert and
tighten them. A redesign of the casing changes this to use one size of bolt with threaded bolt holes, which
removes the need for nuts. The result is a savings in both material costs and assembly time.
2. A marketing manager for a washing-up liquid analyzed the liquid bottle and its use. She discovered that
the bottle became slippery when liquid dribbled down the side of the bottle. The shape of the bottle and
the spout were both changed to improve grip and reduce dribble. Without any additional advertising,
sales of the product subsequently went up by 2%.
3. A product manager at a company that produced nails had received several requests from customers
that the nail loose grip of wood. Identifying this 'improved nail' as a possible new product line, he decided
to do a Value Analysis to help identify costs and values.
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