Industrial Engineering

Laboratory
Manual
 INDUSTRIAL ENGINEERING LAB

Introduction to Work study

Production: It is a process of transformation of set of input elements such as men, materials,

capital, information and energy into a specified set of output elements like, finished products
and services in proper quantity and quality, thus achieving the objectives of an enterprise.
Productivity:
Productivity refers to only the efficiency of any production system i.e. a ratio of output to
input.
Productivity P= Output of the system (O) / Input of the system (I)
P= Output/Input

Work-study: Work study is a general term for those techniques, particularly method study
and work measurement, which are used in the examination of human work in all its contexts
and which lead systematically, to the investigation of all the factors which affects the
efficiency and economy of the situation being revised, in order to effect improvement.
Method study:
Method study is the 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

Work Measurement: A qualified worker at a defined level of performance may define Work
measurement as the application of different techniques to measure and establish the time
required completing the job.

Applications of Work study:

Industries (production, operations research and development)
Marketing, Sales and Distribution
Offices store and Warehouse.
Material handling
Design
Building and other Construction
Transport
Hospital
Army and
Agricultural etc.

Advantages of Work Study:

Uniform and improved production flow
Higher productivity, efficiency
Reduced manufacturing cost
Fast employee, Employer relations
Fast and accurate delivery rate
 1. Recording Techniques
The next step in the basic procedure ,after selecting the work to be studied, is to recorded by
"Recording Techniques". These Recording Techniques were classified as foolows:

1. Out Lines Process chart

2. Flow Process chart
3. Flow Diagram.
4. Multiple Activity Chart.
5. String Diagram,
6. Simo Chart,
7. Two Handed Chart.

The most commonly used of these recording techniques are Chart and Diagrams.
Chart:
Indicating Process SEQUEENCE:
 Out Lines Process chart
 Flow Process chart
 Flow Diagram.
 Two Handed Chart.

Indicating Process with TIME SCALE::

 Multiple Activity Chart.
 Simo Chart,

Diagrame:

Indicating Process MOVEMENT:

 Flow Diagram.
 String Diagram,

The recording of facts about a job or operation on a process chartis made much easier
by the use of a set of five standard symbols,These are represented by the following
symbols:
 O OPERATION
Indicates the main steps in a process, method or procedure. Usually the part, material
or product concerned is modified or changed during the operation.

INSPECTION

Indicates an inspection for quality and/or check for quality.

TRANSPORT

Indicates the movement of worker,materials or equipment from place to place.

D TEMPORARY STORAGE OR DELAY

Indicates a delay in the sequence of events: for example work waiting between
consecutive operations,or any object laid aside temporarily without record until
required.

 PERMANENT STORAGE
Indicates a controlled storage in which material is received into or issued from a
store under some from of authorization, or an itemsis retained for reference purpose.
 Out Lines Process chart
Introduction : An Out line Process Chart is a Process chart giving an overal
picture by recording in sequence only the main operation and inspections.

Aim: Study of out line chart by Re- assembling the refill of a ballpoint pen..
Components: Ballpoint pen, Working Table, Tray.
Procedure:
1. Unscrew cap
2. Unscrew neck
3. Remove the old refill
4. Assembly the spring on new refill
5. Place the refill in the bared
6. Screw the neck
7. Check if the ball pen writes.
8. Screw the cap.

1 Unscrew cap

2 Unscrew neck

3 Remove the old refill

Assembly the spring on new refill

4
4

5 Place the refill in the bared

6 Screw the neck

7 Check if the ball pen writes.

8 Screw the cap.

 Flow Process Chart
Introduction : A flow process chart is a process chart setting out the sequence of the flow of
a product or a procedure by recording all events under review using the appropriate process
chart symbols.
They are classified as follows
Worker type : A flow process chart which records what the operate does
Material type: A flow process chart which records how material is handled or treated
Equipment type: A flow process chart which records how the equipment is used

Aim: To study the flow process chart by repairing and wiring of a three pin socket.
Apparatus: Three pin Socket, Screw Diver, Multi MeterTester,Normal working table, Stop
Watch.
Procedures:
Flow Process Chart: Worker/Material/Equipment type
Chart No: Sheet No: Summary
Subject Charted: Activity Present Propose Saving
d
Activity: Operation----O
Transport---
Delay---------D
Inspection__

Storage-----

Distance(m)
Time(Min)
Location: Cost
Labour
Material
Operative
Charted By: Date:

Description Qty Distance Time Symbol Remarks

O D 

Description Qty Distance Time Symbol Remarks

 Flow Diagram. 12
2 7
Introduction : A flow diagram is a Plan of diagram on which1 to trace and
measure the path of worker, material or equipment during a specified sequence
of events.
3 8 13
Aim:
2
Components:
4 9
Procedure:
14 In
5 10 3

6 11 15
4
 1

Out

MULTIPLE ACTIVITY CHART

Introduction : A multiple activity chart is a chart on which the activities of

more than one subject (worker, machine or item of equipment )are each
recorded on a common time scale to show their interrelationship.
Aim:
Components:
Procedure:

Multiple activity chart on

____________________________________________________________

Chart No. Sheet No. Summary

Product Present Proposed Saving
Drawing No. Cycle Time (min)
Process Worker
Machines Machine
Working
Worker
Operative Machine
Idle
Worker
Charted by Date Machine
Utilization
Worker
Machine
Time Worker Machine Time

Two Handed Process chart

Aim:To assembly the nut, bolt and washer to draw a Two handed process chart.

Components: Nut, bolt, and washer.

Theory:
In two handed process chart.
Activities of workers hands or limbs are recorded and also relationship between two hands is
recorded.
Producing a time scale can synchronize the activities of two hands.
For analysis of relative jobs for short duration and assembly work.

Procedure:
Present Method:
In the present method the left hand is moved to the bolt, the bolts are then grasped and held
in position. During this time the right hand is moved towards the washer no.1 grasped and
assembled with the bolt.
In similar way the washer no.2 can be assembled and then the nut is assembled. During the
time the left hand is in the idle position.

Improved Method:
In the present method the right hand is initialized. Starting the motion of both the hands,
together can save time. Also to washer 1 and washer2 can be picked up at the same time and
then nut is picked and assembled.

TWO HANDED PROCESS CHART

Drawing
Chart No: Sheet No:
Work lay out:
Drawing & Part:
Operation:
Location:
Operative
Charted By: Date:

Left Hand
Description
O  D ▼ O  D ▼ Right Hand
Description
Summary

Method Present Proposed

L.H. R.H. L.H. R.H.
Operation
Transport
Delay’s
Holds
Inspections
Totals

Application of Principle of Motion Economy.

Introduction: There are a number of "Principles" concerning the economy of movements
which have been developed as a result of experience and which from a good basis for the
development of improved methods at the work place. They may be grouped under three
headings.
A. Use of the human body.
B. Arrangement of the workplace.
C. Design of tool and equipment.

Experiment No. Date :

Aim: Developing a better method through analysis of hands movement

(Using of the Human Body) and to study application of motion economy..

Apparatus: Pin board, wooden pins, decimal stop watch and work table.
Procedure:
Take a pin board and wooden pins and place it the table.
Take another man who should handle the stopwatch.
Start placing the pins in the wooden board by placing the pins near to the board and
determine the time required using one hand.
Repeat this method for another two times.

Then change the method place by keeping the board apart and use both hands for placing
pins in holes.

Determine the time using stopwatch.

Like this different methods are used so as to find the best method.

Method 1:
At first while working, place the board on the table and place the pins in the plate.
Pick up the pins by right hand and at that time, the left hand is idle .put the pin in the board.

Method 2:
In this method pick the pin by left and right hand at the same time and place in the board.

Measurement of Effect of Work on Human Body

Pulse Recovery time
Experiment No. Date :

Aim:To determine the pulse recovery time.

Apparatus:Stop watch , ergnometer

Theory:
Physical work result in changes in oxygen consumption, heart beat, pulmonary ventilation,
body temperature and lactic and concentration in the blood. Although some of these factors
are only slightly affected by muscular activities. There is linear correlation between heart
beat rate, oxygen consumption and physical work performed by and individual. The heart
beat rate and oxygen consumption is most widely used for measuring the physiological cost
human work.
The performance of physical work required the use of group of muscle, some muscles are
needed for maintain the body posture while other performance the task.
Davis and Miller have classified physical efforts into three types.
Full bodywork uses 2/3 or 3/4 of body's total muscle.
Localized muscular work few muscles are used.
Static muscular work muscle are used to exert force
The total physiological cost of a task but also the energy expenditure above the resting rate
during the recovery period that is until recovery is complete muscle constitute 45% of the
human body weight. The most important characteristics of muscles tissue is it ability to
contract to the extent of its half-length and contacts with a certain force.
The maximum muscular force in man amounts to about 4 kg/cm 2 (cross section of muscle).
The greatest force is exerted at the beginning of the contraction. When the muscle length is
still that of its relaxed state. At the muscle shorten force declines. These factors are important
in the physiology of work. The mechanical energy developed in muscular contraction is
created from the muscles, chemical energy resource and glucose and high-energy phosphate
compound and thus oxygen becomes of muscular system. Glucose and oxygen are stored in
only limited amount in the muscle and the continues supply if glucose and oxygen to
muscular system is maintained by the blood. So the supply of the blood to the working
muscle can limit muscle performance i.e. therefore as the work is done there is change in
oxygen consumption and heart beat rate.
There are two kinds of muscular activity:
Dynamic muscle work or rhythmic work and
Static muscular work of postural work.
In the, dynamic work tension and relaxation of muscle remain in a state of contraction for
each time the heart beats., a small electric potential is generated. By placing electrodes in
either side of chart. This potential cab be picked up and transmitted by wide or by
transmitted to a receiver.

Procedure:
Select the operator who is healthy and fit for condition experiments.
Record the normal pulse rate per minutes using demonstrates watch. Note down is as normal
and standard pulse
Ergonometer should be set for zero load. Then the operator is told to ride or pedal the meter
at a constant speed at 30 km/hr for 3 minutes.
And one of the other member should watch pulse ratio for every 30 seconds by holding
wrist of the operator by sensing the nerve pulse.
Like this, for every 30 second pulse rate should be noted down for 3 minutes.
The operator should take rest, while taking rest number of pulse for every 30 seconds should
be noted down by the help if other observer.
This should be continued until the pulse rate becomes normal.
Continue the same procedure for another two persons for same load and note down the pulse
rate.
Then changing the load and speed repeat the same procedure.
After comparing all readings draw a graph of pulse rating v/s standard time of pedaling.

Sl No Time in Pulse Rate Pulse Rate

Second (Working) (Rest)
1 0
2 30
3 60
4 90
5 120
6 150
7 180
8 210
9 240
10 270
11 300
12 330
13 360
14 390
15 420
 Recovery time for Blood pressure
Experiment No. Date :

Aim: To determine the recovery time for blood pressure operator.

Apparatus: Sphygmomanometer, ergonometer, stethoscope and stopwatch.

Theory:
Physical work results in changes in oxygen conception heartbeat, blood pressure and body
temperature. The force exerted by the muscle depends on the number of activities controlling
muscle fiber. The presence of oxygen is necessary for the regeneration of glucose and high
energy phosphate compound and thus oxygen becomes the second most important substance
in the energetic and of the muscular system. Glucose and oxygen are stored in only limited
amount in the muscle and the continuos supply of glucose and oxygen to the muscular
system is maintained by the blood. So the supply of blood to the working muscle can limit
muscular performance. Sue to this when an individual done the work the blood pressure and
heart beat increases. In some cases stressed to the brain can also increase the blood pressure
here we consider only physical work.
PROCEDURE:
Choose an operator who is healthy and fir for conducting experiment.
By using sphygmomanometer find out his normal blood pressure.
Then ergonometer should be set for zero inclination and the operator is told to walk on it
making speed to 3 km/hr.
After every 30 seconds check the blood pressure of the operator for 3 minute.
Take reading for every 30 seconds. After 3 minutes, stop the machine and ask the operator to
take rest and relax.
Now check his blood pressure for every 30 seconds until his blood pressure comes to normal,
this gives recovery period.
Carry out same procedure for another operator and thus, change the speed and note the
reading.

Rating Exercises
Theory:
" Rating is an assessment of the workers rate of working relative for observers concept of the
rate corresponding relative to standard place." Rating is comparison of rate of working
observed by the work study person with a picture of some standard level in mind. This
standard level is the average rate at which qualified workers will naturally work at a job,
when using the current method and when motivated to apply themselves to their work. This
rate of working corresponds to the term standard rating and is denoted by 100 on the rating
scale recommended. If the standard place is maintained and the approximate relation is taken
a worker will achieve standard performance over the working day or shift.Operations
involving mental activities (judgement of finish for example in inspection of work) are most
difficult to access.
The study person should be careful not to rate too highly when:
The worker is hurried or looks hurried
The worker id obviously being over careful
The job difficult to study person
The study person is working very fast, as when recording a short element study.
Conversely, there is a danger of rating too low when-workers makes the job look easy.The
worker is using smooth rhythmic movements.The worker does not pause to think when the
study persons expect this.The worker is performing heavy manual job.The study person is
tired rating is very much easier if a good method study has been made first in which the
activities calling for special skill or effort have been reduced to a minimum.
Scales of Rating:
There are several scales of rating in use, the most common of which are those designated the
60-80, 75-100 and 100 - 133 scales and the British standard scale used is 0-10
Observed time x Rating = a constant
Observed time x Rating/standard rating = Basic Time

Recording the Rating:

Each element of activity must be rated during its performance before the time recorded,
without the regard to previous or succeeding element. No consideration should be given to
the aspect of fatigue, since the allowance for recovery from fatigue will be assessed
separately

Dealing cards
Experiment No. 01 Date:
Aim:To conduct rating study of dealing cards.
Apparatus:Decimal stopwatch cards, rating room.
Place:
Select a room large enough to accommodate the group of people who will participate in the
study.
Procedure:
Make someone as (operator) to practice to distribute cards in four equal areas (piles) exactly
in 21 sec. This exact speed can be attained by little practice.
Keep the tabular column ready and the operator then distributes the cards into four files in 21
sec. This is the normal speed of rating of 100%. Let the operator take two or three trial at this
speed.
The operator then distributes the cards for this speed at random. The observer rates the
operator for every trial. one person records the actual time with the help of the decimal
stopwatch for distribution of the cards.
The rating can be carried out in two methods:
Without feedback
With feedback
Without feed back method:
In this method distribute the cards in four equal piles for ten times at different speed. After
every trial observed rate with by this judgement of speed.One person is noting the actual
time. After completion of 10 times the observer are told the actual time and form that the
actual performance is calculated and compared with observed rating.
 With immediate feed back method:
In this method actual time taken by the operator to distribute the cards is told to the observer
after rating at the end of each trial. This gives an idea of rating under or over for observer,
which can be taken care for the next trial. This feed back helps in judging the actual speed by
operator.

Actual rating = Standard Time X 100

Actual Time
Observed time X Rating
Standard rating =Basic time

Standard Time:

Ex=> 1 2 3 4 5 6 7 8 9 10
Observed
Actual
% of error

Walking Practice
Experiment No. Date:

Aim:To conduct rating study of walking.

Equipment Required: Decimal minute stopwatch, chalk tape. A room with smooth level
floor.

Working place: A room with smooth level floor.

Procedure:
Measure 15 meter of unobstructed floor space, making a starting line and stamping line on
the floor and following additional space at either end for the operator to stop.
Have someone (this person will be called operator) practice walking 15 minute, at exactly
4.8 km/hr. This practice should take place before the group assembly. The operator should
take 11.25 seconds to walk the 15 meters. After little practice. It will not be difficult for the
operator to walk 15 meters.
Provide each person a data sheer and graph for plotting. Let him fill the name and data
No stop watch or clock is used while observing the activities.

The rating exercise is to carry out in two ways.

Without feed back
 With feed back

Without Feed Back:

The operator walk at 4.8 km/hr and group is tools that this speed represented a rating of
100%.
Two or three trial are made this speed
The operator times himself. and
If he takes more or less than 11.25 sec, to walk 15 m. We inform the group of that part and
compute the actual speed in % which gives to the groups. The group of course make no
record of this primary trial.
The operator then walk 15m, at 10 different times called trial varies his speed at a random. At
the end of each trial he records on his sheets the actual time taken to walk, and the
corresponding rating announced through the group.
Each person watches the operator walking 15m and ratio him using 100% =4.8 km/hr as
normal speed. in this method announcement of current reading is not to be made the group
take observation without any feed back to the group and he is liable to make each overrating
or underrating the performance.

With Feed back Method:

This part of experiment is modified slightly to give feedback to estimate error in each of the
demonstration.
These may leave to the quicker process of learning as every one of the group is known his
tendency to over rate or under rate may subsequently improve his rating.
In this method after demonstration first time every one records his reading in a slight time
gap demonstration annoyance the actual taken by him. Then taking this time one can judge,
how much out of estimated he is which helps him to rate subsequent events.
Then some another walking activities is made of varying speed and at the end of each event
actual time taken by the worker is announced.

Actual rating = Standard Time X 100

Actual Time
Observed time X Rating
Standard rating =Basic time

Standard Time:

Ex=> 1 2 3 4 5 6 7 8 9 10
Observed
Actual
% of error

Determining the standard time for simple

operating using stop watches and PMTS.
Traditional Method

SHORT CYCLE TIME STUDY FRORM

Operation:________________ Date: ____________ Sheet No:
Studied By:_______________ Checked by:________ Time on:
Operator:_________________ Clock No:____________ Time off:
TimeObserved

:
Elements Description: Ball pen Asseble
Average ST
Cycles

Cap

Total Cycle Time

Bottom Led

Refill

Upper Led
Barrel

ST OT ST OT ST OT ST OT ST OT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ST= Subtracted Time Foreign Elements 1Cycle Time for the
OT= Observed Time Job___________
Remarks by Observer 2 Allowance Factor for
the job:____________
3 Standard Time for the
Job:_____________

New -Method

SHORT CYCLE TIME STUDY FRORM

Operation:________________ Date: ____________ Sheet No:
Studied By:_______________ Checked by:________ Time on:
Operator:_________________ Clock No:____________ Time off:
Elapsed Time:
Elements Description
Total ST
FactorRating

Average ST
Cycles

Normal Time
Refill
Spring

Button
Barrel

ST OT ST OT ST OT ST OT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ST= Subtracted Time Foreign Elements 1 Normal Cycle Time
OT= Observed Time for the Job___________
Remarks by Observer 2 Allowance Factor for
the job:____________
3 Standard Time for the
Job:_____________

Multiple Activity chart

Multiple activity chart on
____________________________________________________________

Chart No. Sheet No. Summary

Product Present Proposed Saving
Drawing No. Cycle Time (min)
Process Worker
Machines Machine
Working
Worker
Operative Machine
Idle
Worker
Charted by Date Machine
Utilization
Worker
Machine
Time Worker Machine Time
 Flow Process Chart
Flow Process Chart: Worker/Material/Equipment type
Chart No: Sheet No: Summary
Subject Charted: Activity Present Propose Saving
d
Activity: Operation----O
Transport---
Delay---------D
Inspection__

Storage-----

Distance(m)
Time(Min)
Location: Cost
Labour
Material
Operative
Charted By: Date:
 Flow Process Chart
Flow Process Chart: Worker/Material/Equipment type
Chart No: Sheet No: Summary
Subject Charted: Activity Present Propose Saving
d
Activity: Operation----O
Transport---
Delay---------D
Inspection__

Storage-----

Distance(m)
Time(Min)
Location: Cost
Labour
Material
Operative
Charted By: Date:

Description Qty Distance Time Symbol Remarks

O D 
Description Qty Distance Time Symbol Remarks
Activity Distance Time