DEPARTMENT OF INDUSTRIAL ENGINEERING

COURSETITTLE: WORK STUDY AND METHOD ENGINEERING

UNIT THREE: METHODS ENGINEERING
PREPARED BY
DEREJE KEBEDE
ID NO:SGSR/0312/13 AND
AMEN MELAKU
ID NO:SGSR/0308/13
SUBMITTED TO INSTRUCTOR : DR. KASSU JILCHA SILEYEW
(Assistant Professor of Industrial Engineering, Director, Students
Career Development)
 METHODS ENGINEERING

UNIT THREE

METHODS

ENGINEERING

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Contents
3.1 Methods engineering definition & objectives ......................................................................................... 1
3.1.1 Methods engineering definition ................................................................................................... 1
3.1.2 A systematic procedure to develop a work center in method engineering................................... 3
3.1.6 Areas of application of method study .......................................................................................... 8
3.1.7 Objective of Method Study .......................................................................................................... 8
3.1.8 Objectives in Methods Engineering ............................................................................................. 9
3.2 Operations Analysis, Methods Analysis, Methods Design ................................................................. 9
3.2.1 Operation Analysis....................................................................................................................... 9
3.2.2 METHODS ANALYSIS............................................................................................................ 14
3.2.3 Methods design .......................................................................................................................... 15
3.3 Techniques of Methods Engineering ................................................................................................ 15
3.3.1 Techniques of work study and their relationship ....................................................................... 15
3.3.2 classification of work study ....................................................................................................... 17
3.4 Charting and diagramming techniques ............................................................................................. 18
3.4.1 Commonly used recording techniques ....................................................................................... 18
3.5 Motion Study and Work Design ....................................................................................................... 18
3.5.1 Motion Study ............................................................................................................................. 18
3.5.2 Principles of Motion study ......................................................................................................... 18
3.5.3 An Example of Application of Motion Economy Principles ..................................................... 20
3.5.4 Recording Techniques of Motion Study .................................................................................... 21
3.5.4 Work design ............................................................................................................................... 21
3.6 Objectives of Charts and Diagrams .................................................................................................. 21
3.7 Charts and Diagrams ......................................................................................................................... 21
3.7.1 Process charts ............................................................................................................................. 21
3.7.2 Outline (Operation) process chart .............................................................................................. 26
3.7.3 Two handed process chart .......................................................................................................... 29
3.7.4 Multiple activity charts .............................................................................................................. 33
3.7.5 TRAVEL CHARTS .................................................................................................................. 37
3.7.6 SIMO (SIMULTANEOVS - MOTION- CYCLE CHART) ...................................................... 39
3.7.7 String diagram ............................................................................................................................ 40
3.8.0 Flow Diagram ................................................................................................................................ 42
3.9 BASIC MOTIONS............................................................................................................................ 43
3.9.1Effective Therblings .................................................................................................................... 43
3.9.2 Ineffective Therblings ................................................................................................................ 44

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3.9.3 Analysis of Motion..................................................................................................................... 45

3.9.4 17 Therblings ............................................................................................................................. 46
3.9.5 Micro-motion Study ................................................................................................................... 49
3.9.6 Memo Motion Study .................................................................................................................. 53
3.10 Solved exercises .............................................................................................................................. 55
3.11 Case studies in context of Ethiopia ................................................................................................. 57
References ................................................................................................................................................... 62

List of figures

Figure 1.shows Steps of methods engineering .............................................................................................. 7

Figure 2. Operation chart for the present method of assembling nut and bolts. ......................................... 11
Figure 3. operation chart for the proposed method of assembling nuts and bolts....................................... 12
Figure 4.Basic procedure of work study 5 .................................................................................................. 16
Figure 5.Classification of work study [4] ................................................................................................... 17
Figure 6.Non-standard process chart symbols [18]..................................................................................... 23
Figure 7.Operation process chart [4]........................................................................................................... 28
Figure 8. Outline process chart for nut, bolt and washer assembly.7 ......................................................... 29
Figure 9.Symbols used in two hand process chart ...................................................................................... 31
Figure 10.Two hand process chart for knurling wheel assembly [18] ........................................................ 32
Figure 11.Multiple activity chart (man machine chart) [6] ......................................................................... 35
Figure 12.Man-Machine Chart [19]. ........................................................................................................... 36
Figure 13. Right-Hand/Left-Hand Activity Chart....................................................................................... 37
Figure 14.Travel Chart 38 .......................................................................................................................... 38
Figure 15. Flow diagram 36 ....................................................................................................................... 41
Figure 16.Flow diagram [6] ...................................................................................................................... 42
Figure 17.shows the 17 therblings [4] ......................................................................................................... 47
Figure 18.Procedure for micro motion study. ............................................................................................. 51
Figure 19. Chrono cycle graph and cycle graph [5] .................................................................................... 54
Figure 20.Shows spur gear for flexible factory gate ................................................................................... 58
Figure 21.Shows spur gear for flexible factory gate ................................................................................... 59
Figure 22.Shows design of spur gear for flexible factory gate ................................................................... 59
Figure 23.Shows milling process spur gear for flexible factory gate.......................................................... 60
Figure 24.Shows flow process chart spur gear for flexible factory gate ..................................................... 61
List of tables

Table 1.The ASME standard set of process chart symbols ......................................................................... 22

Table 2.therblings their symbols, color and codes ...................................................................................... 48

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3.1 Methods engineering definition & objectives

3.1.1 Methods engineering definition
The terms "Methods Engineering" or "Work Study" are used to describe a collection of analysis
techniques used to improve the effectiveness of men and machines. It enables the industrial
engineer or manager to subject each phase of an operation to systematic analysis. Methods
Engineering or Work Study engineering is a combination of industrial engineering work
measurement, method study, human factor, and management techniques combined with system
engineering function analysis, synthesis, evaluation, decision-making, and design techniques.

It was developed to simultaneously apply the advantages of industrial and system engineering
techniques to the efficient and effective design and improvement of systems in which functions
are performed by men and equipment. Its basic approach is to collect meaningful data on complex
systems and to arrange the data in a form whereby evaluation, innovation, and implementation are
more easily performed.[32]

Methods engineering includes designing, creating, and selecting the best manufacturing methods,
processes, tools, equipment, and skills to manufacture a product based on the specifications that
have been developed by the product engineering section. When the best method interfaces with
the best skills available, an efficient worker–machine relationship exists. [29]

It is the systematic examination of the methods 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. It then aims at examining the way an activity is being carried out, simplifying or modifying
the method of operation to reduce unnecessary or excess work, or the wasteful use of resources,
and setting up a time standard for performing that activity. [1]

Methods engineering or work study is a branch of industrial engineering specializing in the

analysis of methods and the improvement and standardization of methods, equipment, and working
conditions. Methods engineering is the term for those techniques viz., method study and work
measurement which are used in the examination of human work. Work study is aimed at the
investigation of all the factors which affect the efficiency and economy of the situation being
reviewed, in order to effect improvement. Work study is a means of enhancing the production
efficiency (productivity) of the firm by elimination of waste and unnecessary' operations. It is a

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technique to identify non-value adding operations by investigation of all the factors affecting the
job. It is the only accurate and systematic procedure oriented technique to establish time standards.
It is going to contribute to the profit as the savings will start immediately and continue throughout
the life of the product. [5]

Work study can conveniently be defined as an important tool in the hands of management for
achieving higher production efficiency of an organization. Industrial engineers are using more and
more of this vital technique to solve the problems of varied complexities challenging the very-
existence of engineering industries. Some of these problems, in the solution of which work studs
can play an important role, may be mentioned as follows. [4]

Work study is the study of human work with a view to increase the effectiveness with which the
work is done. As per IS-6363, 1972 work study is defined as “a modern discipline which analyses
and evaluates all aspects of a work system in order to enhance effectiveness and functional
efficiency”.

As per International Labor organization, (I.L.O., Geneva, Switzerland) work study is defined as
“a generic 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 leads systematically to the
investigation of all the factors which affect the efficiency and economy of the situation being
reviewed, in order to affect improvements”.

In simple terms work study may be defined as the analytical investigation of methods, conditions
and effectiveness of work and thereby the determination of the ways in which human effort may
be applied most economically. It is a method used to increase productivity.

Work study embraces two distinct but interdependent techniques, i.e., method study and work
measurement.

Method study may be defined as the detailed analysis of existing or proposed method of doing the
work for the purpose of effecting improvements. Work measurement may be defined as the
determination of time allowed for the effective performance of a specified volume of work
performed in a specified manner. [7]

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In summary, methods engineering is the systematic close scrutiny of all direct and indirect
operations to find improvements that make work easier to perform, in terms of worker health and
safety, and also allow work to be done in less time with less investment per unit (i.e., greater
profitability).

3.1.2 A systematic procedure to develop a work center in method engineering

Methods engineers use a systematic procedure to develop a work center, produce a product, or
provide a service as seen in figure below.

1. Select the project.

Typically, the projects selected represent either new products or existing products that have a high
cost of manufacture and a low profit. Also, products that are currently experiencing difficulties in
maintaining quality and are having problems meeting competition are logical projects for methods
engineering. [29]

There are three factors that should be kept in mind when selecting a job.

1. Economic or cost-effective considerations.

2. Technical considerations.
3. Human considerations
1) Economic considerations

It is obviously a waste of time to start or to continue a long investigation if the economic

importance of a job is small, or if it is one that is not expected to run for long. Questions that should
always be asked are: "Will it pay to begin a method study of this job?" or "Will it pay to continue
this study?" Obvious choices for study are:

A. Key profit-generating or costly operations, or ones with the largest scrap/waste rates.
B. Bottlenecks which are holding up other production operations, or lengthy operations that
consume a great deal of time.
C. Operations involving repetitive work using a great deal of labor and ones that are likely to
run for a long time.
D. Movements of material over long distances between workstations, those involving the use
of a relatively large proportion of labor or which require repeated handling of material.

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2) Technical or technological considerations

One of the important considerations is the desire by management to acquire more advanced
technology, whether in equipment or in processes. Thus management may want to computerize its
office paperwork or its inventory system, or to introduce automation in the production operations.
Before such steps are taken, a method study can point out the most important needs of the
enterprise in this respect.

3) Human considerations

Certain operations are often a cause of dissatisfaction by workers. They may induce fatigue or
monotony or may be unsafe or clumsy to operate. The level of satisfaction should point to a need
for method study. Thus an operation which may be perceived as effective by management may,
on the other hand, generate a great deal of resentment by the workforce.

In a similar vein, a choice of a particular job for study may lead to unrest or ill-feeling. The advice
given here is to leave it alone, however promising it may be from the economic point of view. If
other jobs are tackled successfully and the study can be seen to benefit the people working on
them, opinions will change and it will be possible, in time, to revert back to the original choice.
[5]

2. Get and present the data.

Assemble all the important facts relating to the product or service. These include drawings and
specifications, quantity requirements, delivery requirements, and projections of the anticipated
life of the product or service. Once all important information has been acquired, record it in an
orderly form for study and analysis. The development of process charts at this point is very
helpful.

3. Analyze the data.

Utilize the primary approaches to operations analysis to decide which alternative will result in the
best product or service. These primary approaches include purpose of operation, design of part,
tolerances and specifications, materials, process of manufacture, setup and tools, working
conditions, material handling, plant layout, and work design.

4. Develop the ideal method.

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Select the best procedure for each operation, inspection, and transportation by considering the
various constraints associated with each alternative, including productivity, ergonomics, and
health and safety implications.

5. Present and install the method.

Explain the proposed method in detail to those responsible for its operation and maintenance.
Consider all details of the work center, to ensure that the proposed method will provide the results
anticipated.

6. Develop a job evaluation.

Conduct a job analysis of the installed method to ensure that the operators are adequately selected,
trained, and rewarded.

7. Establish time standards

Establish a fair and equitable standard for the installed method.

8. Follow up the method

At regular intervals, audit the installed method to determine if the anticipated productivity and
quality are being realized, whether costs were correctly projected, and whether further
improvements can be made.

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1. Select Project
 New plants and plant expansion
 New products, new methods
 Products with high cost/low profit
 Products unable to meet competition
 Manufacturing difficulties
 Bottleneck operations/exploratory tools
2. Get and Present Data

 Obtain production requirements

 Procure engineering data
 Procure manufacturing and cost data
 Develop description and sketches of workstation and tools
 Construct operation process charts
 Construct flow process chart for individual item
Systematic Procedure for Methods and Work Measurement

3. Analyze the data.

 Obtain production requirements

 Procure engineering data
 Procure manufacturing and cost data
 Develop description and sketches of workstation and
tools
 Construct operation process charts
 Construct flow process chart for individual item
4. Develop the ideal method.

Use 9 primary approaches to operation analysis

Question every detail
Use: why, where, what, who, when, how

5. Present and install the method.

 Use decision-making tools

 Develop written and oral presentation
 Overcome resistance
 Sell method to operator, supervisor, and management
 Put method to work
6. Develop a job evaluation.
 Job analysis
 Job descriptions
 Accommodation of differently abled workers

7. Establish time standards

 Stopwatch time study
 Work sampling
 Standard data
 Formulas
 Predetermined time systems

8. Follow up the method

 Verify savings
 Assure that installation is correct
 Keep everyone sold
 Repeat methods procedure [29]

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Figure 1.shows Steps of methods engineering

3.1.4 Method study

Method study (often called motion study, method analysis or methods engineering) is the
systematic recording and critical examination of existing and proposed ways of doing work in
order to develop and apply easier and more effective methods and to reduce costs. It is used to
improve processes and procedures, plant layout, design of plant and equipment; to reduce human
effort.

3.1.5 Work study

Work study is a combination of two groups of techniques, method study and work measurement,
which are used to examine people’s work and indicate the factors which affect efficiency. Work
study is normally used in an attempt to increase output from a given quantity of resources with
little or no further capital investment. This is achieved by systematically analyzing existing
operations, processes and work methods. [20]

Work study deals with the techniques of method study and work measurement, which are
employed to ensure the best possible use of human, machine and material resources in carrying
out a specified activity.

Objective

Work study is concerned with finding better ways of doing work and avoiding waste in all its
forms. As such the objective of work study is to assist management to obtain the optimum use of
the human, machine and material resources available to the organization for the accomplishment
of the work upon which it is engaged.

The objective has three aspects:

• The most effective use of plant and equipment

• The most effective use of human effort

•The evaluation of human work.

Work study has two broad areas viz., method study and time study.

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METHOD STUDY

It is the systematic recording, analysis and critical examination of existing and proposed ways of
doing work and the development and application of easier and new production methods.

3.1.6 Areas of application of method study

It can be applied to any field of work, but the most important areas where it plays a major role in
improving productivity arc as follows.

 Improved layout of office, working areas of factories.

 Improved design of plant and equipment.
 Improved use of materials, plant, equipment and manpower.
 Most effective handling of materials.
 Improved flow of work.
 Standardization of methods and procedures.
 Improved safely standards.
 Better working conditions.[22]

3.1.7 Objective of Method Study

a. To study the existing/proposed method of doing any job, operation or activity.
b. To develop an improved method to improve productivity and to reduce operating costs.
c. To reduce excessive materials handling or movement and thereby reduce fatigue of
workman.
d. To improve the utilization of resources.
e. To eliminate wasteful and inefficient motions.

To standardize work methods or processes, working conditions machinery, equipment and took.

Factor facilitating Method Study

1) High operating cost 5) Complaints about quality

2) High wastage and scrap 6) Complaints about poor working
3) Excessive movement of material and conditions
workmen 7) Increasing number of accidents.[23]
4) Excessive production bottlenecks

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3.1.8 Objectives in Methods Engineering

 Increase productivity and efficiency
 Reduce cycle time
 Reduce product cost
 Reduce labor content
Other Objectives
 Improve customer satisfaction
 Improve product and/or service quality
 Reduce lead times and improve work flow
 Increase flexibility of work system
 Improve worker safety
 Apply more ergonomic work methods
 Enhance the environment (both inside and outside the facility) [31].

3.2 Operations Analysis, Methods Analysis, Methods Design

3.2.1 Operation Analysis
Operations analysis comprises all procedures involved in designing or improving operations. It
makes use of studies and analyses of entire processes or systems, methods, motions, materials,
tools, and equipment to determine the one best way. It also includes the use of work measurement
to perform quantitative analyses [10].

Operation Analysis is a detailed study of different operations involved in doing a work. Operation
analysis becomes necessary in order to investigate the shortcomings of the existing method and to
develop an improved procedure. Operation analysis suggests, whether some elements, should be
eliminated or combined or their sequence should be altered in order to obtain effective utilization
of existing manpower and machinery with the minimum fatigue incurred by the workers. The
analysis mainly considers the movements of the limbs and aims at finding a simpler and
economical method of doing the job.

Before the procedural steps of a task are analyzed and the motions (of an operator) are studied or
eliminated, an operation chart is constructed. Figure 2 shows an operation chart of the existing
method of assembling nuts and bolts. The chart of figure 3 the existing method is tested as per the
rules of motion economy and the following points are noted:

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1. The distribution of work between the two hands is not balanced. Right hand is overloaded.

2. The two hands do not follow opposite motions.

3. Gravity has not been utilized for delivering the material to its destination, etc.

Besides assessing the present method as per the principles of motion economy, it is also subjected
to following questions (whichever are applicable) with regard to

a. Worker

1. Is he mentally and physically fit?

2. Does he incur unnecessary fatigue?

3. Does he need training to improve?

4. Does he get suitable salary?

b. Set-up.
1. Are tools and other equipment’s readily available?
2. Can the set-up be modified or can the number of set-ups be decreased?
c. Material
1. Is material of the proper specifications, re., composition, diameter, width, thickness or
weight?
2. Can be substituted by a less costly material?

3. Can scrap be minimized?

d. Material handling

Can materials be transferred in big (unit) lots, thereby reducing the number of handlings?

2. Is it possible to avoid back tracking of the material?

3. Can the distances, by which the material is moved, be cut short?

d. Operations

1. Can some operations be eliminated?

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Operation: Nut & Boll assembly. Name of the worker.— workplace layout
Location: ……………. B I N S
Method : Present/Proposed 1 2 3

left Hand Description symbol Right Hand Description

Idle Goes to bin-1

Grasps a bolt

Carries to left hand

Grasps and holds the bolt Releases to left hand

Goes to bin-2

Grasps a nut

Carries to left hand

Screws nut on the bolt

Releases nut-bolt Grasps the assembly

Assembly
Idle Transfers assembly to bin-3

Figure 2. Operation chart for the present method of assembling nut and bolts.

2. Can some operations be made automatic?

3. How, re-sequencing of the operations will effect?

4. Is it possible to combine some operations?

e. Tools and Fixtures. 1. Are they available in good condition?

2. Are they suitably located and prepositioned?

3. Is it advantageous to modify existing jigs and fixtures for better productivity?

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(g) Working Conditions.

1. Is light and ventilation adequate?

2. Are the operations and working conditions safe?

3. Are facilities of wash rooms, etc. available?

Considering the existing method in the light of motion economy principles and questions
mentioned above, a proposed method for the same task is as follows (Figure 3) [17].

workplace layout
(3) It is a cavity in the work
Operation : Nut and
table, under which runs a
B I N S
Bolt Assembly Name of the worker…… conveyor to take each
1 2 3 assembly at its destination.
Location…………..
Method : Present/Proposed

left Hand Description symbol Right Hand Description

Goes to bin-1 Goes to bin-2

Grasps a bolt Grasps a nut

Brings over the cavity or space cut
in the work table (3) Bring over cavity-3

Holds and grasps the bolt Screws the nut

Releases the assembly to drop on a Releases the assembly to drop on a

conveyor through cavity-3 conveyor through cavity-3

Figure 3. Operation chart for the proposed method of assembling nuts and bolts
The important analysis approaches include:

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1. Operation Purpose: It questions the existence of operations. If necessary thinks the possibility
of either simplifying or combining. The rule is eliminating if possible, if not combine or simplify.

2. Part Design: Good method engineer should be in a position to review every design for possible
improvement changes in design should be made for possible improvement. The concept like design
for manufacturing and assembly standard digestion and simplification will help to reduce the part
counts, process and assembly time and bring down the cost.

3. Tolerances and Specifications: This is a quality aspect of operation it is always the tendency of
the designer to incorporate more stringent specification then it is called for maybe because of lack
of influence this is on the cost of manufacture. Only the tolerances and specifications that need for
effective function be incorporated method analyst should be well versed in the details of cost and
should have an in-depth knowledge of close tolerance and rejects and its impact on the selling
price.

4. Material: Choice of material plays an important role in operation analysis and an analyst should
think of recommend the material which is economical and at the same time will not affect the
function.

The methods analyst should consider should keep in mind the following aspects when selecting
the material for processing:

i. Choosing a less expensive material to reduce the cost.

ii. Choosing material which is easy to process.
iii. Planning effective utilization of materials.
iv. Using tools and supplies economically during processing.
v. Standardization of materials.
vi. Identification of the right source of supply of materials.

5. Operation Sequence and Processes: The focus will be shift from labor intensive manufacturing
to automation, where investment cost is more, low cost automation will be a good solution in order
to improve the manufacturing process, and the analyst should consider the following aspects.

i. changing the sequence of operations

ii. Automating the manual operations.

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iii. Efficient utilization of facilities.

iv. Manufacturing near net shape (minimizing secondary operations)

6. Setup and Tools: Setup and bowling are closely associated because tooling quite often
determines the setup and tear down time. Setup time can be reduced by single minute exchange of
dies Single-Minute Exchange of Dies (SMED) techniques.

7. Material Handling: Material handling which is thought of as transportation has to consider the
positioning also. Material handling includes motion, time, place and space limitations. The volume
of material handled and handling cost are to be reduced considering the following aspects:

i. Reduce the time spent in picking up material.

ii. Used automated material handling system
iii. Make use of gravity to move material [21].

3.2.2 METHODS ANALYSIS

Method analysis is the logical recording and significant examination of ways of doing things in
order to make improvements. Method analysis can also be defined as “systematic recording and
critical examination of existing and proposed ways of doing work as means of developing
and applying easier and more effective method and thereby reducing cost [11].

Methods analysis is the study of how a job is done. Whereas job design shows the structure of the
job and names the tasks within the structure, methods analysis details the tasks and how to do
them.

Methods analysis is a process concerned with the detailed process for doing a particular job.

Methods analysis is used by companies when developing new products or services and for
improving the efficiency of methods currently in use. Suppose your restaurant has an accepted
procedure for communicating a customer's dinner choices to the kitchen without errors. Methods
analysis documents this accepted procedure, including specific notations that identify customer
preferences. The result is a standard operating procedure your restaurant can use for training new
employees and for evaluating the performance of existing employees.

Methods analysis consists of the following steps:

 Identify the operation to be analyzed.

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 Gather all relevant information about the operation, including tools, materials, and
procedures.
 Talk with employees who use the operation or have used similar operations. They may
have suggestions for improving it.
 Chart the operation, whether you are analyzing an existing operation or a new operation.
 Evaluate each step in the existing operation or proposed new operation. Does the step add
value? Does it only add cost?
 Revise the existing or new operation as needed [27].

3.2.3 Methods design

Methods design is concerned with either of the following situations:

1) Design of a new method or process

 Required for new product or service and there is no existing standard
 Method must be designed from scratch, using best existing practice for similar
operations
2) Redesign of an existing method or process based on a previous methods analysis. [31]

3.3 Techniques of Methods Engineering

3.3.1 Techniques of work study and their relationship
The term "work study" embraces several techniques, but in particular method study and work
measurement.

1) Method study is the systematic recording and critical examination of ways of doing things in
order to make improvements.
2) Work measurement is the application of techniques designed to establish the time for a
qualified worker to carry out a task at a defined rate of working.

Method study and work measurement are, therefore, closely linked. Method study is concerned
with the reduction of the work content of a job or operation, while work measurement is mostly
concerned with the investigation and of any ineffective time associated with it; and with the
subsequent establishment of time standards for the operation when carried out in the improved
fashion, as determined by method study. The relationship of method study to work measurement

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is shown simply in figure 4. Although method study should precede the use of work measurement
when time standards for output are being set, it is often necessary.

Method study is 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. Work measurement is the application of techniques designed to establish the time
for qualified worker to carry out a specific job at a defined level of performance. There is a close
link between method study and work measurement. Method study is concerned with the reduction
of the work content and establishing the one best way of doing the job whereas work measurement
is concerned with investigation and reduction of any ineffective time associated with the job and
establishing time standards for an operation carried out as per the standard method. Method study
and work measurement are parts of work study. Part of method study is motion study. Work
measurement is also called by the name 'time study'.
Method study
To simplify the job and
develop more economical
way of doing it.
Work
study

Work measurement
To determine how long it
should take to carry out.

Higher
productivity

Figure 4.Basic procedure of work study

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[5]

3.3.2 classification of work study

Work study

Methods study Work measurement

Stop watch time study

(Repetitive cycle)

Analysis of existing Improving the existing Selection of the best Analytical estimation
method method method

Synthesis (non- repetitive cycle)

Reorientation of plant Relaying of workplaces
Activity analysis

Stop watch time study

Techniques followed Techniques adopted

Measurement by film analysis

Electronic time recorder

Charts Diagrams

1. Operations Charts Diagrams

1. Flow diagrams Other tools
process chart
2. Travel diagrams Simo- charts Flow diagrams
2. Follow process
3. String diagram
charts
3. Activity charts
1. Chorono cycle graph
2. Cycle graph
Method analysis (micro motion
study, motion study and applications
of the principles of motion economy)

Figure 5.Classification of work study [4]

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3.4 Charting and diagramming techniques

3.4.1 Commonly used recording techniques
Various recording techniques have been evolved in order to clarify working situation. They
comprise.

I. Charts:
1. Outline process chart 3. Two handed process chart
2. Flow process chart:( man type, 4. Multiple activity chart
material type and equipment type) 5. Travel chart
II. Diagrams:
1. flow diagram 3. Cycle graph
2. String diagram 4. Chrono cycle graph
III. Motion and film analysis (Micro-motion and Memo-motion studies)
i. Simo chart
ii. F.M.P.S.

3.5 Motion Study and Work Design

3.5.1 Motion Study
Motion-study technique, which may be defined as the study of the body motions used in
performing an operation, to improve the operation by eliminating unnecessary motions,
simplifying necessary motions, and then establishing the most favorable motion sequence for
maximum efficiency. [29]

Motion study is part of method study where analysis of the motion of an operator or work will be
studied by following the prescribed methods.

3.5.2 Principles of Motion study

There are a number of principles concerning the economy of movements which have been
developed as a result of experience and which forms the basis for the development of improved
methods at the workplace. These are first used by Frank Gilbreth, the founder of motion study and
further rearranged and amplified by Barnes, Maynard and others.

The principles are grouped into three headings:

(a) Use of the human body.

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(b) Arrangement of workplace.

(c) Design of tools and equipment.

(A) Uses of human body

When possible:

1. The two hands should begin and complete their movements at the same time.

2. The two hands should not be idle at the same time except during periods of rest.

3. Motions of the arms should be made simultaneously.

4. Hand and body motions should be made at the lowest classification at which it is possible to do
the work satisfactorily.

5. Momentum should be employed to help the worker, but should be reduced to a minimum
whenever it has to be overcome by muscular effort.

6. Continuous curved movements are to be preferred to straight line motions involving sudden and
changes in directions.

7. ‘Ballistic’ (i.e., free swinging) movements are faster, easier and more accurate than restricted or
controlled movements.

8. Rhythm is essential to the smooth and automatic performance of a repetitive operation.

The work should be arranged to permit easy and natural rhythm wherever possible.

9. Work should be arranged so that eye movements are confined to a comfortable area, without the
need for frequent changes of focus.

(B) Arrangement of the workplace

1. Definite and fixed stations should be provided for all tools and materials to permit habit
formation.

2. Tools and materials should be pre-positioned to reduce searching.

3. Gravity fed, bins and containers should be used to deliver the materials as close to the point of
use as possible.

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4. Tools, materials and controls should be located within a maximum working area and as near to
the worker as possible.

5. Materials and tools should be arranged to permit the best sequence of motions.

6. ‘Drop deliveries ‘or ejectors should be used wherever possible, so that the operative does not
have to use his hands to dispose of finished parts.

7. Provision should be made for adequate lightning, and a chair of type and height to permit good
posture should be provided. The height of the workplace and seat should be arranged to allow
alternate standing and seating.

(C) Design of tools and equipment’s

1. The color of the workplace should contrast with that of work and thus reduce eye fatigue.

2. The hands should be relieved of all work of ‘holding ‘the work piece where this can be done by
a jig or fixture or foot operated device.

3. Two or more tools should be combined where possible.

4. Where each finger performs some specific movement, as in typewriting, the load should be
distributed in accordance with the inherent capacities of the fingers.

5. Handles such as those used on screw drivers and cranks should be designed to permit maximum
surface of the hand to come in contact with the handle.

6. Levers, cross bars and wheel bars should be in such position that operator can manipulate them
with least body change and with greatest mechanical advantage.

3.5.3 An Example of Application of Motion Economy Principles

These principles can be applied to a simple situation (an example) of assembling a nut and a bolt
to form an assembly. If the nuts and bolts are kept on the work table on the two sides of the worker,
so that they are kept within easy reach, facilitating smooth curved symmetrical motion of both
hands (to be done simultaneously), are stacked or kept in such a way as to eliminate search, a
fixture provided to eliminate grasp by a hand while assembling, a chute provided to eliminate
transport and release by hand, then we have used some of the above principles to improve the
method and productivity [28].

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3.5.4 Recording Techniques of Motion Study

Most of the techniques mentioned in method study is used in the motion study. They are as follows:

1. Macro Motion Study

 Flow process chart

 Two handed process chart.

2. Micro Motion Study

SIMO chart. [28]

3.5.4 Work design

Work design is a relatively new science that deals with designing the task, workstation, and
working environment to fit the human operator better. In the United States, it is more typically
known as human factors, while internationally it is better known as ergonomics, which is derived
from the Greek words for work (ergo) and laws (nomos). [29]

3.6 Objectives of Charts and Diagrams

The Objectives of Charts and Diagrams are:

1. To permit work processes to be communicated and comprehended more readily.

2. To use algorithms specifically designed for the particular diagramming technique.

3. To divide a give work process into its constituent elements for analysis purposes.

4. To provide a structure in the search for improvements.

5. To represent a proposed new work process or method [11].

3.7 Charts and Diagrams

3.7.1 Process charts
A chart may be a diagram, a picture or a graph which gives an overall view of the situation, say a
process. It helps visualizing various possibilities of alteration or improvement. A chart
representing process may be called a Process Chart. A process chart records graphically or
diagrammatically, in sequence, the operations connected with a process. The chart portrays the

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process with the help of a set of (process chart) symbols and aids in better understanding and
examining the process with a purpose to improve the same [23].

Table 1.The ASME standard set of process chart symbols

symbol Description Example

Operation A large circle indicates an operation such as drive nail, mix and
drill hole
Transportation An arrow indicates transportation, such as move material by
truck, move material by conveyor and move material by
carrying (messenger).
storage A triangle indicates storage, such as raw material in bulk
storage, finished stocks tacked on pallets and protective filing
of documents.

Delay A large capital D indicates a delay, such as wait for elevator,

material in truck or on floor at bench waiting to be processed
and papers waiting to be filled.

Inspection A square indicates an inspection, such as examine material for

quality or quantity read steam gauge on boiler and examine
printed form for information.

[11]

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A record was created.

Information was added to a record.

A decision was made.

An inspection was performed in conjunction with an

operation.

An operation and transportation took place

simultaneously.

Figure 6.Non-standard process chart symbols [18]

A process chart is a graphic representation of the sequence of events and related information that
occur in the work method or procedure. The following are the various types of process charts:

1) Outline process chart.

2) Flow process chart.
3) Two handed process chart. [7]

3.7.1.1 Process chart symbols

Graphical method of recording was originated by Gilberth, in order to make the presentation of
the facts clearly without any ambiguity and to enable to grasp them quickly and clearly. It is useful
to use symbols instead of written description.

1) Operations :

An operation occurs when an object is intentionally changed in one or more of its

characteristics. This indicates the main steps in a process, method or procedure. An operation
always takes the object one stage ahead towards completion, e.g. turning, drilling, milling,
etc.

2) Storage :

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Storage represents when a finished good or raw material is waiting for an action or when an
item is retained for some time, e.g. cutting tool lying in tool store.
3) Inspection :

An inspection occurs when an object is examined and compared with standard for quality and
quantity. The inspection examples are visual observations for finish, counting of quantity of
incoming material, checking the dimensions, etc.

4) Transport :

A transport indicates the movement of workers, materials or equipment from one place to another,
e.g. movement of materials from one work station to another, etc.

5) Delay:

A delay occurs when the immediate performance of the next planned thing does not take place,
e.g. work waiting between consecutive operations. Examples are workers waiting at tool cribs
(area where tools are kept), operators waiting for instructions from supervisor, etc. In addition to
the basic symbols discussed above, there are symbols activities also and they are given below. The
important event has the outer symbol

6) Operation-cum-transportation:

Sometimes, it may be required to carry out an operation along with transportation, e.g. articles
are being painted as they are transported by the chain conveyor.

7) Inspection-cum-operation:
Inspection-cum-operation occurs when both inspection and operation occurs simultaneously
and are controlled automatically .eg. a powder milk tin is being weighted as it is filled. [5]
3.7.1.2 OPERATION PROCESS CHART
The operation process chart shows the chronological sequence of all operations, inspections,
time allowances, and materials used in a manufacturing or business process, from the arrival of
raw material to the packaging of the finished product. The chart depicts the entrance of all
components and subassemblies to the main assembly. Just as a blueprint displays such design
details as fits, tolerances, and specifications, the operation process chart gives manufacturing
and business details at a glance.

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Two symbols are used in constructing the operation process chart: a small circle denotes an
operation, and a small square denotes an inspection. An operation takes place when a part being
studied is intentionally transformed or when it is being studied or planned prior to productive
work being performed on it. An inspection takes place when the part is examined to determine
its conformity to a standard. Note that some analysts prefer to outline only the operations,
calling the result an outline process chart.
3.7.1.3 Flow process chart
In general, the flow process chart contains considerably greater detail than the operation process
chart. Consequently, it is not usually applied to entire assemblies, but rather used for each
component of an assembly. The flow process chart is especially valuable in recording
nonproduction hidden costs, such as distances traveled, delays, and temporary storages. Once these
nonproduction periods are highlighted, analysts can take steps to minimize them and hence their
costs.

In addition to recording operations and inspections, flow process charts show all the moves and
storage delays encountered by an item as it goes through the plant. Flow process charts therefore
require several symbols in addition to the operation and inspection symbols used in operation
process charts. [11]

A Flow Process Chart is a detailed version of outline process chart and it records all the events. It
sets out a sequence of flow (of a procedure or product), records all the events in sequence using
process chart symbols, marks distances travelled and time taken for completing an activity, and
mentions other important (or key) points, if any. There are three types of flow process charts,
namely:

a. Man type flow process chart.

b. Machine/equipment type flow process chart and
c. Material type flow process chart.
a. Man type flow process chart records the activities of an operator, i.e. what an operator does.
Equipment type process chart records the manner in which the equipment is used, and
Material type process chart records what happens to the material, i.e. the changes the material
undergoes in location or condition. [2]
b. Material type: A flow process chart which records what happens to material and its movements.

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c. Equipment type: A flow process chart which records how the equipment is used and its
movements. [7]

Flow process chart gives the sequence of flow work of a product or any part of it through the work
center or the department. The events are recorded in the flow chart using the appropriate symbols.
It is the amplification of the operation process chart in which operations; inspection, storage,
delays and transportation arc represented. Man type flow process chart records the activities of an
operator. Equipment type process chart records how the equipment is used. Material type process
chart records what happens to material.

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

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. An illustration of the flow chart (man and material type) is shown in the
figure.

3.7.2 Outline (Operation) process chart

It is also called as operation process chart. It provides an overall view, a quick idea of the entire
process from beginning to end at a glance. Operation process chart contains large number of lines,
one for each component. The chart does not show where the work takes place and who does it.
The general flow of the process is indicated by vertical lines, while horizontal lines indicate the
material being introduced. It is concerned with operations and inspection and hence only two
symbols only are used. Operation process chart is helpful to:

 To layout plant and location.

 It shows the relationship between various parts which enter the final assembly.
 It helps the analyst to visualize the process for examination as a means for better
understanding and improvement of the process.

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3.7.2.1 Steps in construction

1. Each operation/inspection is indicated by the corresponding symbol. Symbols indicating
operations are connected by lines and are numbered in sequence.
2. Brief description of the operation is indicated in the right side of the symbol and duration in
the left side.
3. During assembly, major process is charted in the right side and sub-assembly on the left side.
4. Sub-assembly flow lines are joined to the main flow line at their respective place of entry.
5. First operation in the main flow line is numbered ‘1’ and is continued until the next
component joins it.
6. The symbol on the main flow line after the junction of main and other flow entry' is assigned
the next higher serial number. [5]

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Figure 7.Operation process chart [4]

An outline process chart is intended to do broad analysis. It records an overall picture of the process
and stales only main events or steps sequence-wise, there are following functions of an outline
process chart and the same is shown in 7.

a. It helps in visualizing and comprehending the full process so that necessary improvements
may be made if required.
b. It shows relationship between the different activities.
c. It considers mainly operations and inspections, i.e.. it makes use of only two symbols.
d. Each operation and inspection is numbered from the beginning to the end of the chart.

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e. Description of operations and inspections are written on the right-hand side of the symbols.
f. Actually an outline process chart is the first step for the beginning of a detailed analysis.[2]

Figure 8. Outline process chart for nut, bolt and washer assembly

[7]

3.7.2.2 General guidelines for making a flow process chart

1. The details must be obtained by direct observation—charts 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. [15]

3.7.3 Two handed process chart

The two-hand process chart, sometimes referred to as an operator process chart, is a motion-study
tool. This chart shows all movements and delays made by the right and left hands, and the
relationships between them. The purpose of the two-hand process chart is to identify inefficient

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motion patterns and observe violations of the principles of motion economy. This chart facilitates
changing a method so that a balanced two-handed operation, and a smoother, more rhythmic cycle
that keeps both delays and operator fatigue to a minimum, can be achieved. [29]

Two handed process chart records the activities of the left hand and right hand of an operator
related to each other. The activities of two charts can be synchronized by providing a time scale
on the chart. This is also known as operator activity chart. The two handed gives synchronized and
graphical representation of the sequence of manual activities of the worker. [5]

Two-handed process chart is a specialized form of process chart and gives a graphical
representation of work and movement of the operator’s two hands in relationship to one-another.
A two handed process chart is made up of two columns in which are recorded the symbols
representing the activities of the left and the right hand respectively. Recording, in this case, is
made with ordinary symbols with the omission of the inspection symbol since inspections will be
shown as movement of hands. Also the triangle symbol used for storage implies “hold” in two
handed process chart. An example of two handed process chart is shown in Figure10 [7].

A two handed (operator process chart) is the most detailed type of flow chart in which the activities
of the workers hands are recorded in relation to one another. The two handed process chart is
normally confined to work carried out at a single workplace. This also gives synchronized and
graphical representation of the sequence of manual activities of the worker. The application of this
charts are:
 To visualize the complete sequence of activities in a repetitive task.
 To study the work station layout. [28]

Two-handed process chart records the sequence of activities performed by both hands of an
operator side by side. This chart is very much useful to analyze the activities of the operator and
come out with an improved method of performing the integrated task of importance. This chart
uses the same symbols except inspection which are used in flow process charts with the following
modified meanings.

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3.7.3.1 Symbols used in two hand process chart

This symbol is used to represent the activities performed by an operator which
are equivalent to operation. These activities include grasp, position, use, release,
etc. of a tool or material or sub-assembly.

This symbol is used to represent the movement of the hand/limb of the operator
while performing the work. The hand/limb may be moved from or to
assembly/work, tool or material.
This symbol is used to represent the idling time of the hand/limb of the operator
which will happen during certain part of the work cycle.

This symbol is used to represent the operation of holding the assembly/ work,
tool or material by one hand while the other hand does some other activity.

Figure 9.Symbols used in two hand process chart

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Figure 10.Two hand process chart for knurling wheel assembly [18]

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3.7.4 Multiple activity charts

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.
The multiple activity chart is extremely useful in organizing teams of operatives on mass-
production work, and also on maintenance work when expensive plant cannot be allowed to remain
idle longer than is absolutely necessary. [1]

Multiple activity chart : A multiple activity chart is a chart on which activities of more than one
subject (worker/machine/equipment) are each recorded on a common time scale to show their inter
relationship. [9]
Multiple activity charts arc very useful tool for understanding the flow of work in a cyclical process
and as a consequence understanding which resource is controlling the overall progress of the work.
A multiple activity chart records simultaneously the activities of all workers and machines on a
common time scale and thus shows inter-relation between them. A multiple activity chart is of one
of the following types:

 Man-machine chart one man handling one job or one machine.

 Man-multi-machine chart: one man handling a number of machines.
 Multi-man chart: a group or gang doing collectively one job
 Multi-man-machine chart: a number of persons working on a computer system. [14]

3.7.4.1 Man-Machine 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 chart.

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.

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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.

Man-machine chart is a type of multiple activity chart. Here, the activities of a number of machines
are recorded. An example of man-machine chart is shown in figure 1.5. Here one operator two
semi-automatic machines simultaneously. The activities of the operator is 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.

EXAMPLE

In many situations, certain facilities/machines/equipment will be managed by a single individual

or by a group of individuals. A multiple activity chart is a pictorial representation of activities of
individuals and associated facilities/machines/equipment simultaneously on a common lime scale.

Consider an example of an operator performing thread cutting on one end of a shaft using a lathe.
The sequence of activities involved in thread cutting is listed below.

1. Loading the shaft in the lathe (3 min)

2. Thread cutting (4 min)
3. Unloading the shaft from the lathe (2 min)

Since the operator will be idle for certain portion of the above work cycle that is during
thread cutting, he can be assigned more than one lathe. Let us consider the assignment of two
lathes for one operator, then the corresponding multiple activity chart which is known as man-
machines chart is shown in Fig. 2.8. In the figure, when the operator is loading/unloading a shaft
on/from a lathe, the respective lathe will be idle. These are explained with few cases as presented
below.
In Fig. 10, the operator is loading a shaft on lathe 1 during the first three minutes and he is
loading a shaft on lathe 2 during the next three minutes (from fourth minute to sixth minute). So,

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the lathe 1 is idle during the first three minutes and the lathe 2 is idle during the first six minutes.
Similarly, when both the lathes are performing thread cutting operation, the operator has to be idle
for that duration. During the seventh minute, both the lathes are performing thread cutting operation.
Hence, the operator is idle during this interval. This chart gives a complete sequence of activities for each
entity in the chart which will help the process to be executed as per expected schedule. A careful analysis
will help to assign the optimal number of machines to an operator which is beyond the scope of this text.

Figure 11.Multiple activity chart (man machine chart) [6]

Man and machine charts are graphic means of portraying the separable steps of the work performed
by a man and one or more machines and the relationship between the works of each. They are
usually used when the work of the machine or machines is a controlling factor.

A simple type of man and machine chart, called a "man and machine operation chart," is often
used to analyze the work of one operator and one machine when the operator's. [12]

Example: Man-Machine Chart

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Draw a man and machine chart showing one man (the operator) operating two semi-automatic
lathes. The cycle consists of LOAD M/C.1⁄2 MIN .MACHINE PART, 1 MIN. (the machine stops
automatically at the end of cut) and unload machine ¼ min. The two machines are alike and each
completes the machining operation and stops automatically. The man machine chart is to show the
operator starting the machines in the morning with both machines empty, and continues until each
machine completes two cycles, i.e. until it has machined two pieces. The man and machine chart
should have one column for the man and a column each for machine 1and machine 2.

Figure 12.Man-Machine Chart [19].

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3.7.4.2 Right-Hand/Left-Hand Activity Chart

Shows

 contributions of the right and left hands

 balance of the workload between the right and left hands example with pegs
 Task involves placing pegs into a peg board

Note that left hand is used as a work holder

Figure 13. Right-Hand/Left-Hand Activity Chart

3.7.4.3 Worker-Machine Activity Chart

 Shows how work elements are allocated between a worker and a machine
 Help to identify opportunities for cycle time improvements e.g., replacement of
external work elements by internal work elements

3.7.4.4 Worker-Multi machine Activity Chart

Can be used to indicate machine interference (when a machine must wait for service
because worker is currently servicing another machine). [31]

3.7.5 TRAVEL CHARTS

Travel or from-to charts can be helpful in diagnosing problems related to the arrangement of
departments and service areas, as well as the location of equipment within a given sector of the
plant. The travel chart is a matrix that presents the magnitude of material handling that takes place
between two facilities per time period. The unit identifying the amount of handling may be

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whatever seems most appropriate to the analyst. It can be pounds, tons, handling frequency, and
so on.

The chart which gives an estimate about the amount of material handling between various
work stations is known as travel chart. The amount of travel depends upon the frequency of
movements between sections of departments.

A travel chart helps improving the existing plant layout. A travel chart is advantageous because it
brings out the relative importance of having different parts of departments close to each other.

It is a two-way matrix table which provides quantitative data regarding the origin and
destination of the movement of any worker (or material or equipment) during a given
period. Travel chart is, therefore, very useful aid to examine the arrangement of machine or
departments for reducing or eliminating the movement [11].

A travel chart is a tabular record for presenting quantitative data about the movements of workers,
materials or equipment between any numbers of places over any given period of time. When the
movement patterns are complex, the travel chart is a quicker and more manageable recording
technique. [1]

Travel charts: These indicate the frequency of trips between points and are useful for modifying
layouts. For instance, if the clerk makes too many moves to a filing cabinet and back in a day, and
the clerk's desk is at one end of the room while the filing cabinet is at the other, it may be
worthwhile to position the filing cabinet closer to the clerk's desk. The travel chart is usually in the
form of a matrix. Journeys begin from the left hand row title to the column headings. Figure 7.3
shows a travel chart. If the crosses are added up in rows it gives the number of outward trips and
the sum of crosses in the columns gives the number of inward trips.
A B c D E

A XX X XXX

B X XXX X xxxx

C X X XX

D X X XXX

E X XXX X XXX

Figure 14.Travel Chart [11]

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3.7.6 SIMO (SIMULTANEOVS - MOTION- CYCLE CHART)

It is a recording technique for micro-motion study. It is a graphic representation of the sequence
of the therblings or group of therblings performed by body members of operator. It is drawn on a
common time scale. In other words, it is a two-hand process chart drawn in terms of therblings and
with a time scale. A video film or a motion picture film is shot of the operation. The film is
analyzed frame by frame. For the left hand, the sequence of therblings (or group of therblings)
with their time values arc 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 therblings. The
procedure is repeated for the right and other body members (if any) involved in carrying out the
operation. The movements in SIMO chart are recorded against time measured in winks.

1
[1 𝑤𝑖𝑛𝑘 = 𝑚𝑖𝑛𝑢𝑡𝑒 ]
2000
2000
Wink LH description Therblings Time Time in Time Therblings RH
counter 2000/m description
reading

Simo chart
From the motion analysis about the motions of the two hands (or other body members) involved
in doing an operation, inefficient motion pattern can be identified and any violation of the principle
of motion economy can be easily noticed. The chart, therefore, helps in improving the method of
doing the operation so that balanced two-handed actions with coordinated, foot and eye motions
can be achieved and ineffective motion can be either reduced or eliminated. The result is a
smoother, more rhythmic work cycle that keeps both delays and operator fatigue to the
minimum. [5]

A SIMO chart is a chart often based on the film analysis used to record therblings or a group of
therblings performed by different parts of the body of one or more workers, simultaneously on a
common time scale. [9]

SIMO Chart

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

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time scale the therblings or a group of therblings performed by different parts of the body of one
or more operators.

It is the micro-motion form of the man type flow process chart. To prepare a SIMO chart, an
elaborate procedure and use of expensive equipment are required and this study is justified when
the saving resulting from study will be very high [20]

3.7.7 String diagram

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. String diagram is a model or scaled plan of the shop,
in which every machine or equipment is marked and a peg/pin is struck in the area representing the
facility. It is especially valuable where journeys are irregular in nature. The main advantage of string
diagram over flow diagram is that repetitive movements between workstations are difficult to be traced on
the flow diagram can conveniently be shown on string diagram. When there is too much of movement
involved then, a flow diagram may become incomprehensible. The string diagram is drawn correctly to
scale, whereas the ordinary flow diagram will probably be drawn only approximately to scale. The flow
diagram makes use of pencils or pens to draw the path of the men or material whereas the string diagram
makes use of threads to draw the same.

Procedure to draw string diagram

1. Layout of workplace is drawn to a suitable scale.

2. Mark the location of workstations.
3. Pins are fixed to those locations.
4. Lines are drawn to represent the movement of worker between workstations. [5]

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Figure 15. Flow diagram [11]

3.7.7.1 Constructions of string diagram

1. Draw the layout of the shop to scale in a drawing sheet.
2. Mark the various work centers like machines, stores, work bench etc. in the diagram.
3. Hold the drawing sheet on a soft board and fix pins at the work centers.
4. Tie one end of a colored string to the work center from which the movement starts.
5. Follow the path of the worker to different work center 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 center 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.

3.7.7.2 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.

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5. Used to find out the most economical route. [15]

3.8.0 Flow Diagram
A flow diagram is a diagram which is drawn to scale. The relative positions of machineries, gang
ways, material handling equipment etc. are drawn first. Then the path followed by men or material
is marked on the diagram. Different movements can be marked in different colors. Process symbols
are added to the diagram to identify the different activities at different work centers. [15]

Flow diagram is a recording technique in the form of a drawing or a model drawn to scale of a
reality to show' the pattern of movements and the sequence of activities in a shop floor or in any
work area. This diagram helps to identify backtracking, congestion or long distance in a working
area, which are considered to be undesirable attributes. Based on the information in the diagram
on these metrics, the facilities will be re organized such that the above mentioned attributes, viz
backtracking, congestion and long distance between adjacent workstations are minimized. The
activities in the diagram are identified using the symbols that are used in flow' process charts, viz.
operation, transport, delay, inspection and storage.
Consider the present flow of a component as indicated in figure 12 in the form of flow
diagram, which contains eight processing centers and one testing center. The symbols that are used
in the flow process charts are used here also. Since, the flow is shown using the existing
arrangement of the machines/facilities; one can see too many backtracking/ crisscross movements
of the component.

Figure 16.Flow diagram [6]

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Flow diagram is generally used to show the pattern of movement of human being, materials etc.
within a definite work area.
Sometimes strings are used to show the path of movement. The optimal movement involved in a
task is clearly shown in the flow or string diagram. [25]
The flow diagrams are 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. [15]

3.9 BASIC MOTIONS

As part of motion analysis, the Gilbreths concluded that all work, whether productive or
nonproductive, is done by using combinations of 17 basic motions that they called therblings
(Gilbreth spelled backward). The therblings can be either effective or ineffective. Effective
therblings directly advance the progress of the work. They can frequently be shortened, but
typically cannot be completely eliminated. Ineffective therblings do not advance the progress of
the work and should be eliminated by applying the principles of motion economy. The 17
therblings, along with their symbols and definitions, are shown below.

3.9.1 Effective Therblings

Directly advance progress of work. May be shortened but difficult to eliminate completely.
Effective Therblings
Reach RE Motion of empty hand to or from object; time depends on distance moved; usually
preceded by Release and followed by Grasp.

Grasp G Closing fingers around an object; begins as the fingers contact the object and ends
when control has been gained; depends on type of grasp; usually preceded by
Reach and followed by Move.
Move M Movement of loaded hand; time depends on distance, weight, and type of move;
usually preceded by Grasp and followed by Release or Position.
Release RL Relinquishing control of object, typically the shortest of the therblings

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Preposition PP Positioning object in predetermined location for later use; usually occurs in
conjunction with Move, as in orienting a pen for writing.
Use U Manipulating tool for intended use; easily detected, as it advances the progress of
work.
Assemble A Bringing two mating parts together; usually preceded by Position or Move;
followed by Release.
Disassemble DA Opposite of Assemble, separating mating parts; usually preceded by Grasp and
followed by Move or Release.
3.9.2 Ineffective Therblings
Do not advance progress of work. Should be eliminated if possible.

Ineffective Therblings

Therblings Symbol Description

Search S Eyes or hands groping for object; begins as the eyes move in to
locate an object.
Select SE Choosing one item from several; usually follows Search.
Position P Orienting object during work, usually preceded by Move and
followed by Release (as opposed to prior to work for
Preposition).

Inspect I Comparing object with standard, typically with sight, but could
also be with the other senses.
Plan PL Pausing to determine next action; usually detected as a
hesitation preceding Motion.
UD Beyond the operator’s control due to the nature of the operation,
Unavoidable e.g., left hand waiting while right hand completes a longer
Reach.
Avoidable Delay AD Operator solely responsible for idle time, e.g., coughing.
Rest to Overcome R Appears periodically, not every cycle, depends on Fatigue the
physical workload.
Hold H One hand supports object while other does useful work.
[29]

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As staled earlier. Gilbreth indicated that certain of the Therblings were necessary for work. They are
called effective Therblings. Effective Therblings include the following:
 Reach  Grasp
 Preposition  Assemble
 Move  Release
 Use  Disassemble

When effective therblings are present in the motions performed, productive work is being
performed. Ineffective therblings are those which describe work that is generally not productive.
The analyst should strive to improve the job whenever any ineffective therblings are present. These
therblings are identified when a job is analyzed with a left-hand/right-hand chart. The ineffective
therblings include the following:

 Search  Unavoidable Delay

 Select  Avoidable Delay
 Position  Rest
 Inspect  Hold [8]

3.9.3 Analysis of Motion

The analysis of an operation or a set of operations arranged sequentially for the attainment of the
end objective is carried out in terms of individual motions of a worker as well as his work place
layout and ergonomics for the attainment of the highest level of productivity is known as motion
analysis.

The purpose of motion analysis is to design an improved method which eliminates unnecessary
motions and employs human efforts more productively.

The objective is also to cause minimum fatigue to the operators and at the same time obtain
maximum productivity from them. For accomplishing the above objective, the principle of motion
economy becomes substantially helpful.

The steps of motion analysis are detailed below:

a) Select the operation to be studied.

b) List and chart various motions performed by the operator. The process can also be video
graphed for belter analysis.

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c) Identify the productive and idle motions. Separate them out. Also identify the complex motions
which are difficult to perform.
d) Eliminate the non-productive and unnecessary motions. Look into the possibility of
simplifying the complex motions. Try to standardize the activities as far as possible.
e) Redesign the existing operating procedure by employing the minimum number of motions in
the most appropriate sequence and in accordance with the principles of motion economy.
f) Impart necessary instructions to the worker so that he develops a proper habit cycle. Once the
worker develops the habit cycle in performing the repetitive jobs, the execution of these jobs
happens automatically with lesser stress or fatigue and with better accuracy and speed. [24]

3.9.4 17 Therblings
Therblings are the micro-motion study elements and were originally suggested by Gilbreth.
Therblings were used to describe the basic elements of movements or the fundamental hand motion
of the work cycle. Every therblings is represented by a symbol, a definite color and with a word
or two to record the same.
A SIMO chart employs therblings which are of microscopic nature, whereas a process chart
uses symbols like operation, inspection, transportation, etc., which are macroscopic. A single
operation may consist of many therblings. The following elaboration can be a good example.
Macroscopic motion
Operation of picking up a component (therblings)
Microscopic motion
 Reach the hand for the component (transport empty)
 Grasp the same (grasp)
 Pick up the component (move)
 Place the component (transport loaded)
Though it is cumbersome to deal and chart the microscopic motions, they possess decisive
advantages over the macroscopic motions for better understanding, analysis and improvements.
As explained above, one macroscopic motion may contain a number of microscopic motions [25].

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Figure 17.shows the 17 therblings [4]

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Table 2.therblings their symbols, color and codes

Symbol Name Color Code Symbol Name Color Code

Search Black SH Disassemble Light DA

violet
Select Light ST Inspect Burnt /
gray ochre

Grasp Red G Pre-position Pale blue PP

Holz (prolonged Gold H Release load Carmine RL

grasp) ochre red
Transport Green TL Rest for Orange R
loaded overcoming
fatigue
Transport Olive TE Unavoidable Yellow UD
empty' green delay
Position Blue P Avoidable Lemon D
delay yellow
Assemble Violet A Plan Brown PM

Use Purple U Find (mental Gray F

reaction at the end of
search seldom used)
[5]

Example

Fundamental motions of right hand in signing a letter.

1. Reach for pen.

2. Take hold of pen.
3. Carry pen to paper.
4. Position pen on paper.
5. Sign letter.
6. Return pen to holder.
7. Let pen go off. 8. Move hand back to
letter.

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S.N Description of motion Name of therblings symbol

1 Reach for pen Transport empty TE
2 Take hold of pen Grasp G
3 Carry pen to paper Transport loaded TL
4 Position pen on paper Position P
5 Sign letter Use U
6 Return pen to holder Transport loaded TL
7 Position pen in holder Preposition PP
8 Let pen go off Release load RL
9 Move hand hack to letter Transport empty TE
[23]

3.9.5 Micro-motion Study

Micro motion study or film study (as it is loosely termed) was coined by F. B. Gilbreth and his
wife Lillian Gilbreth who happened to be trained a psychologist herself. It was in the year 1912
that Frank Gilberth at a meeting of ASME made a speech explaining the fundamental concept of
micro-motion study and the tremendous prospects of its application in the field of work
measurement. Micro motion study can be defined as a study of fundamental elements or minute
subdivisions of an operation with the help of a high speed movie camera, with the ultimate
objective of eliminating the unnecessary motions invoked in the operation and balancing the
necessary motions. But this definition of micro-motion study is incomplete until and unless we
define the term million. By micro-motion study we also come to the assigned time value of each
minute element. Elements which are nothing but finite subdivisions of the work cycle may be
repetitive or non-repetitive in nature. These elements are usually expressed in the unit of TMU.
Where I TMU = 0.0006 minute. In many cases for ease in work measurement, a few of these
relevant and consecutive infinitesimal elements may be grouped to be called work clement. These
minute subdivisions of work or motion elements arc classified into 17 basic elements known as
fundamental motions. Later on these fundamental motions came to be known as therblings
(Gilbreth spelt backward). Figures 16 gives a list of these seventeen basic elements. In the original
therblings, there are eighteen basic elements in the list—the first two being search and find

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respectively. But many authors combine these two elements into one and hence we classify the
basic motions into seventeen categories. [4]

Micro motion study has the following important advantages:

(a) It provides permanent record of motion study with the help of film.

(b) A large number of workers can see the procedure at any time even after the completion of
motion study.

(c) Differences in the old and new methods can be demonstrated, if both are filmed.

(d) Films can be demonstrated at any desired speed.

(e) It gives very accurate time for each motion or operation than that noted by the stop watch. [11]

Micro-motion study

Selection of operations Selection of equipment

1. Camera
1. Making motion film 2. Exposure meter
2. Processing Hints 3. Micro-chrono meter
3. Film analysis
4. Development of improved
Specification of camera Spring or motor driven
method

Slow speed (50-100 trames per minute)

Normal speed (960 frames per minute)

Modified normal speed (1000 frame» per min)

Sound speed (1440 frames per minute)

High speed (64 128 frames per second)

Very high speed (1000 3000 frames-s)

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Figure 18.Procedure for micro motion study.

Micro-motion analysis uses the basic fundamental hand motions developed by Frank Gilbreth
called "therblings' or the basic Methods- Time Measurement Data (MTM-1) to analyze the work
in detail. This allows a frame-by-frame analysis of the individual motions used to perform the job.

Micro motion study offers these advantages over other methods of data gathering:

 Permits greater detailing than eye observation

 Provides greater accuracy than pencil, paper and watch techniques
 Provides greater convenience
 Provides a positive record o Aids in developing a methods analyst [12]

Micro motion study is a technique for the analysis of man activity that involves the use of a
motion-picture camera and a timing device for the study of a job method. The timing device may
be a synchronous (constant speed) motor drive for the camera.

3.8.5.1Advantages of micro motion

Micro motion study has the following advantages over other methods of gathering data:

1. Permits greater detailing than eye observation.

Of course, the analyst should obtain from the film only that degree of detail best suited to his
analysis requirements. However, with crew work or work with irregular cycles, the
simultaneity of actions of the crew or the sequence as it occurs may be completely detailed by
the camera far beyond the capacity of any observer to observe and record without film.

2. Provides greater accuracy than pencil, paper, and watch techniques.

The time from picture to picture is approximately 0.001 minute when a 16-mm camera is used
at the normal speed of 16 frames per second. Smaller time intervals may be obtained by running
the camera faster. Slower speeds of 100 frames per minute (0.01 min. per frame), 60 frames
per minute (1 sec. per frame) and 50 frames per minute (0.02 min. per frame) are often
extremely useful and economical.

3. Provides greater convenience. The operation may be studied after a short run or after an
experimental run. The film can be stopped at will when being studied, so that each phase

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of the operation can be studied without bothering the operators. Even with such irregular
jobs as building custom truck bodies, a single unit could be usefully studied by means of
1-per-second films, developing data for better methods and better cost estimates on any
other order that even partially resembled the one studied. Films also permit group
observation without interrupting factory routine.
4. Provides a positive record. The film is without errors of the kinds that may enter into pencil
and paper records. This is particularly true of complex jobs like crew tasks, where the
recording of simultaneity depends upon the ability of the observer. A pencil and paper
record is at best, partly subjective, whereas a film is an almost true record of what happened
and is available for re-examination at any time.
5. Aids in developing methods men.

Training in the use of micro-motion study, particularly with the detailed breakdown, tends to
develop a “motion-mindedness” that almost invariably makes a person better able to develop more
effective methods. It appears as though greater familiarity with the detailed movements of which
jobs are composed helps one gain more facility for seeing possibilities of shifting them to achieve
better methods. This is extremely important. In addition to the above five advantages, films are
useful for preserving adequate records of job methods in intermittent jobs, for training, and for
certain phases of time study work.

The main disadvantage of micro-motion study is the/time lag between the taking of the data and
its transcription into usable form. However, with developing facilities available in many cities to
fill the needs of TV news films, films can usually be made available for study on either the same
day or the day after taking.

Micro motion study involves three separate phases of activity for performing step, analysis, of the
scientific method.

A. Filming

B. Film analysis

C. Graphic presentation of the method for study, criticism, and improvement. [13]

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Micro-motion study provides a technique for recording and timing an activity. It is a set of
techniques intended to divide the human activities in a groups of movements or micro-motions

(called Therblings) and the study of such movements helps to find for an operator one best pattern
of movements that consumes less time and requires less effort to accomplish the task. Therblings
were suggested by Frank O. Gilbreth, the founder of motion study. Micro-motion study was mainly
employed for the job analysis.

3.8.5.2 Application of micro motion

Its other applications includes the following:

a. As an aid in studying the activities of two or more persons on a group work?

b. As an aid in studying the relationship of the activities of the operator and the machine as a
means of timing operations.
c. As an aid in obtaining motion time data for time standards.
d. Acts as permanent record of the method and time of activities of the operator and the
machine. [28]

3.9.6 Memo Motion Study

Memo motion study is a special form of motion study in which the camera is operated at slow
speed that the number of frames per second is from 5 to 10. It was developed by M.E. Mendel in
1946 and published it in his book, Systematic motion and time Study. It is used to study the flow
of materials and components and their handling in shop floor, the activities of crew members,
multi-persons and machines relationship, store clerks, operations, etc. It helps to visualize quick
view’ of long sequence of operations.

Cycle Graph and Chrono- Cycle Graph

This section explains the concept of cycle graph and Chrono cycle graph.

3.9.6.1 Cycle Graph

Gilbreth developed the technique of analyzing the paths of motions made by body members while
working. Cycle graph uses a small electric bulb attached to figure, hand or anybody member of
the operator and allows the operator to perform the motions of the job assigned to him. These
motions are photographed for a complete cycle using a still photography in which the movements
of body members are clearly shown by the movement of the light of the electric bulb. This exercise

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helps to obtain a closed loop indicating the movement of the light of each bulb and in turn showing
the closed loop of the movement of the corresponding body member. This gives a permanent
record of the motions of the body members under consideration. This graph will not indicate the
direction of motion or speed of motion. [6]

Cycle graph and Chrono cycle graph

The techniques of analyzing the paths of motion made by an operator were developed by the
Gilbreth. These are techniques to record memo-motion studies. To make a cycle graph, a small
electric bulb is attached to the finger, hand, or any other part of the body whose motion is to be
recorded. By using still photography, the path of light of bulb as it moves through space for one
complete cycle is photographed by keeping the working area relatively less illuminated. More than
one camera may be used in different planes to get more details. The resulting picture (cycle graph)
shows a permanent record of the motion pattern employed in the form of a closed loop of white
continuous line with the working area in the background. A cycle graph does not indicate the
direction or speed of motion. It is used for improving the motion pattern and training purposes;
wherein, two cycle graphs may be shown with one indicating a better motion pattern than the other.
3.9.6.2 Chrono cycle graph
Chrono cycle graph is similar to the cycle graph, but the power supply to the bulb is interrupted
regularly using an electric circuit. The bulb is thus made to Hash. The procedure for taking
photograph remains the same. The resulting picture (chrono cycle graph), instead of showing
continuous line of motion pattern, shows short dashes of line spaced in proportion to the speed of
the body part photographed. Wide spacing represents fast moves while close spacing would
represent slow moves. A chrono cycle graph can thus be used to study the motion pattern as well
as to compute velocity, acceleration and retardation experienced at different locations.

Figure 19. Chrono cycle graph and cycle graph [5]

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Cycle graph is a photographic record of a body member's path movement. A small bulb on operator
traces in line over a still photographic film. A chrono-cycle graph is a variation of cyclic graph
with an interrupter added in the electric circuit to cause the light to flash. [9]

The technique of chronocycle graph is useful in the following situations:

1. Analyzing a complex single purpose movement.

2. Recording of unrestricted movements.

3. Developing new method.

4. Training of operators in operations requiring skill.

5. Differentiating between good and clumsy movements.

6. Short cycle operations.

7. Sharping the movements of hands. [11]

3.10 Solved exercises

Multiple Choice Questions

1. A management tool to achieve higher efficiency concerned with manual work is known as
a) Time study c) Work study
b) Work measurement d) Human study

2. The terms ILO lands for:

a) International labour organization c) International law organization
b) Indian labour organization d) None of these

3. Work study is the technique of:

a) Method study and work measurement c) Work measurement only
b) Method study only d) All of these
4. The father of scientific management was:
a) Frank Gillberth c) Frederick W. Taylor
b) M.J. Griffin d) J.J. Thomson
5. The father of motion study was

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a) Frank Gillberth c) M. J. Griffin

b) W. Taylor d) J. J. Thomson

6. Which of the following is not an objective of work study

a) Investigate and analyze the situation
b) To reduce rejection levels
c) Most efficient use of existing plant
d) To recommend & implement the improvements
7. Which of the following question is meant for re-sequencing the activities of the existing
method? The purpose for which.
a) What is done? c) When might it be done?
b) Why is it done? d) How else might it be done?
8. Which of the following is an indicator of value adding activity?
a) Transport c) Storage
b) Operation d) Delay

9. When a number of workers work in a group or an individual operator handles two or more
machines .The most appropriate chart is:

a) Multiple activity chart c) Travel chart

b) Flow process chart d) Outline process chart

10. Which of the following is the best for a situation of many repetitive paths on the shop floor

a) Flow diagram c) Outline process chart

b) String diagram d) None of these

11. Gilbreth introduced a technique to record the very fast movements of limbs, which is knownas

a) SIMO dart c) Micro motion study

b) Therblings d) Chrono cycle graph

12. When did the concept of scientific management came in origin?

a) 1800s c) 1900s
b) 1700s d) 1950s

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13. Who was the founder of mass production through assembly line?

a) Henry ford c) M Griffin

b) Frank Gillberth d) Frederick W. Taylor

14. The use of study mechanism is for

a) Systematic recording c) Development

b) Critical analysis d) All above

15. Micro motion analysis is done by using a combination of 17 basic motions which are know n
as

a) Micro motions c) Macro motions

b) Therblings d) None of above

16. According to the rules concerning to human body, there should be

a) Definite fixed and accessible place of tools

b) Both the hands should he engaged in the productive work
c) Gravity should he preferred to deliver the assembled part
e. Multi purse tools should be used
Solution
1. c 5. a 9. a 13. a
2. a 6. b 10. b 14. d
3. a 7. c 11. d 15. b
4. c 8. b 12. a 16. b

[2]

3.11 Case studies in context of Ethiopia

In Amahara metal industry and machine technology development enterprise various parts of
machine parts are made, one of this is spur gear for flexible factory gate. The production process
requires a combination of various different types of operations and machines. The production
operation requires power hacksaw cutting of the raw material and then the work piece moves to
the next step. The next step is operations related to lathe machining facing the end parts to the
required length, turning the tapers, drilling the hole at the center and finally chamfering the sharp

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edges. After the operation on the late machine is finished the work piece is transferred into the
horizontal milling machine, where indexing plate, module cutter and various types of milling
accessories are used for cutting the gear.

Figure 20.Shows spur gear for flexible factory gate

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Figure 21.Shows spur gear for flexible factory gate

Figure 22.Shows design of spur gear for flexible factory gate

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Figure 23.Shows milling process spur gear for flexible factory gate

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S. Activity Operation Distance traveled Time in

no in meter minute

1 Raw material from store o

(dia100mm)
2 Cut by power hack saw to o 12.5
length 60mm
3 Transport to machine shop o 26.4
4 Insert the work piece into the o 1
jaw of cnc lathe machine
5 Face the work piece in the given o 2.5
dimension
6 Write the turning code in the o 2
CNC lathe machine display
board.
7 Take offset o 1.3
8 Start the code o 9
9 Inspection o 1.5
10 Transport to milling machine o 3.2
11 Sett upping the accessories o 5.2
12 Making gear within given o 35
parameter
13 inspection o 1.2
14 Transport to shaper machine o 2.5
15 Set upping o 7.5
16 Slotting operation o 25
17 Inspection o 1
18 Move to drilling machine o 6
19 Set upping the accessory o 3
20 Drilling operation o 2.5
21 Inspection o 1
22 Move to assembly shop o 56.3
Total Total
distance=94.4m time=111.2
min

Figure 24.Shows flow process chart spur gear for flexible factory gate

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