WORK STUDY:

Definition: Work study is a general term for the techniques of method study and work
measurement.
These techniques are used in the examination of human work in all its contexts. They help in
investigation of all the factors which affect the efficiency and economy at the work place in order
to affect improvement
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. Improvement of manufacturing processes and procedures.
2. Improvement of working conditions.
3. Improvement of plant layout and work place layout.
4. Reducing the human effort and fatigue.
5. Reducing material handling
6. Improvement of plant and equipment design.
7. Improvement in the utility of material, machines and manpower.
8. Standardization of method.
9. Improvement in safety standard.
Method Study Procedure:
This procedure involves seven basic steps as follows:
1. SELECT : the work to be studied
2. RECORD : all the relevant facts about the present method
3. EXAMINE: the facts critically and in ordered sequences, using the techniques best
suited to the purpose.
4. DEVELOP: the most practical, economic and effective method having due regard to all
contingent circumstances.
5. DEFINE : the new method so that it can always be identified
6. INSTALL. : the method as standard practice
7. MAINTAIN: the method by regular routine checks.
Recording Techniques:
It is the second important step in Method Study. The facts collected about the existing method
are subsequently subjected to a thorough examination with a view to evolving improved
methods. Hence, a clear and precise record is necessary, if method study is to be effective.
The advantages of such a form of recording are,
(i)
It helps in presenting the necessary information in a precise and clear manner and
facilitates further analysis.
(ii)
It is easily understandable and can be .clearly visualized,
(iii)
Often presentation of the existing method or procedure, in a graphic form itself shows
obvious improvements.

Charts and Diagrams used in Method Study:

The following charts and diagrams are used in method study.
1. Operation process chart (or) Outline process chart.
2. Flow process chart.
(a) Material type
(b) Man type
(c) Equipment type
3. Two-handed process chart. (or) Left hand-Right hand chart
4. Multiple activity charts.
5. Flow diagram.
6. String diagram
Charting Symbols:
All activities can be broken down into five basic types of events and each is represented by a
symbol. Following are the five standard symbols used in charting.
(a) An operation- O -occurs, when there is a change in the physical or chemical characteristics
of an object or material. Assembling and dis-assembling, making ready for the activity or putting
away after another activity are also classified as operation. Mental activities such as giving or
receiving information or calculating, etc., are included in operation.
Example: Turning a rod on a lathe, joining two components by welding, a chemical reaction,
dismantling of a steam pipe.
(b) An inspection- - occurs when an object is checked for either quantity or quality.
Example: Checking by counting, dimensional check, visual inspection of welding, checks a
letter.
(c) A transport- -occurs whenever there is any movement either by the material or the man.
Example: Movement of material on a trolley, man walking.
(d) A delay-D-occurs when conditions do not permit the performance of'. the next activity
immediately. Various delays and interruptions are denoted by this symbol.
Example: Material waiting near a machine for an operation and operator waiting for a tool near
the tool crib.
(e) A storage- -occurs when an object is kept and protected against unauthorized removal.
Example: Materials in 'tore, a letter in a file.
OPERATION PROCESS CHART
Operations Process Chart is a graphic representation of the sequence of all the operations and
inspections involved in a process or procedure. It provides a bird's eye view of the whole process
or activity. In an operations process chart all the operations and inspections involved are
recorded. The chart does not indicate where the work takes place or who performs it. The delays,
transport and storages are not indicated. But the entry points of materials are indicated.

Such a chart will serve as a starting point for the critical examination. This is a very useful chart
for initial analysis. Where the process is long and complicated, this chart provides an overall
picture and gives adequate information for critical examination. This chart is particularly useful
for recording maintenance and other indirect work.
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. There are three types of flow process charts. They are
1. Man type flow process chart
This flow process chart records what the worker does.
2. Material type flow process chart
This flow process chart records how the material is handled or treated.
3. Equipment type flow process chart
This flow process chart records how the equipment or machine is used.
General guidelines for making a flow process chart:
1. The details must be obtained by direct observationcharts must not be based on memory.
2. All the facts must be correctly recorded.
3. No assumptions should be made.
4. Make it easy for future reference.
5. All charts must have the following details:
(a) Name of the product, material or equipment that is observed.
(b) Starting point and ending point.
(c) The location where the activities take place.
(d) The chart reference number, sheet number and number of total sheets.
(e) Key to the symbols used must be stated.
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.
General guidelines for preparing the chart:
1. Provide all information about the job in the chart.
2. Study the operation cycle a few times before starting to record.
3. Record one hand at a time.
4. First record the activities of the hand which starts the work first.
5. Do not combine the different activities like operations, transport etc
MAN-MACHINE CHART (MULTIPLE ACTIVITY 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. Activities of workers or
machines are recorded in separate vertical columns (bars) with a horizontal time scale.
The chart shows the idle time of the worker or machine during the process. By carefully
analyzing the chart, we can rearrange the activities. Work load is evenly distributed among the

workers or machines by this the idle time of worker or machine is reduced. Multiple activity
chart is very useful in planning team work in production or maintenance. Using the chart we can
find out the correct number of machines that a worker can operate at a time. We can also find out
the exact number of workers needed to do a job jointly. To record the time, ordinary wrist watch
or stop watch is used. High accuracy is not needed.
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 position of machineries, gang
ways, material handling equipment etc. is drawn first. Then the path followed by men or material
is marked on the diagram. Different movements can be marked in different colours. Process
symbols are added to the diagram to identify the different activities at different work centres.
The flow diagram is used for the following purposes:
1. To remove unwanted material movement.
2. To remove back tracking.
3. To avoid traffic congestion.
4. To improve the plant layout.
Conventions adopted are:
1. Heading and description of the process should be given at the top of the diagram.
2. Other information like location, name of the shop, name of the person drawing the
diagram are also given.
3. The path followed by the material is shown by a flow line.
4. Direction of movement is shown by small arrows along the flow lines.
5. The different activities are represented by the symbols on the flow lines. (Same symbols
used in flow process chart are used here).
6. If more than one product is to be shown in the diagram different colours are used for each
path.
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 centres in the drawing sheet. A
continuous coloured thread or string is taken round the pins where the material or worker moves
during the process.
Construction procedure of string diagram:
1. Draw the layout of the shop to scale in a drawing sheet.

2.
3.
4.
5.

Mark the various work centres like machines, stores, work bench etc. in the diagram.
Hold the drawing sheet on a soft board and fix pins at the work centres.
Tie one end of a coloured string to the work centre from which the movement starts.
Follow the path of the worker to different work centre and accordingly take the thread to
different points on the drawing board.
6. At the end of the session note down the number of movements from one work centre to
another.
7. Remove the string and measure the total length of the string. Multiply by the scale and
get the actual distance of movement.
Applications of string diagram
1. It is used for recording the complex movements of material or men.
2. Back tracking, congestion, bottlenecks, underutilized paths are easily found out.
3. It is used to check whether the work station is correctly located.
4. Used to record irregular movements.
5. Used to find out the most economical route.

TWO HANDED PROCESS CHART (Example: Assembly of washer and nut to a bolt)

The assembly of a nut and washer over a bolt is recorded. The work place layout is shown in the right
hand corner. The activities of left hand are recorded at left half of the chart. The activities of the right
hand are recorded at the right half of the chart. The horizontal lines represent the time scale.
Activities of left hand and right hand shown in the same line occur at the same moment.
Summary of the number of each activity can be tabulated at the bottom of the chart. The chart is first
drawn for the existing method. This chart is analyzed and if it is found that one hand is over loaded
than the other, modification are done in the layout of the workplace or in the sequence of activities.
Then a new chart is made for the proposed cycle.

MAN-MACHINE CHART (MULTIPLE ACTIVITY CHART):

Here one operator operates two semi-automatic machines simultaneously. The activities of the
operator are recorded in a separate vertical column. The activities of the two machines are recorded
in two separate vertical columns. The different activities like loading, machining and unloading are
represented by different symbols. Blank space shows the idle time.

FLOW DIAGRAM

STRING DIAGRAM

OPERATION PROCESS CHART

OPERATION PROCESS CHART (MANUFACTURE OF PLYWOOD)

FLOW PROCESS CHART