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Topic 2 (Part I)

The document discusses method study, which involves systematically analyzing work processes to improve efficiency. It aims to simplify jobs, standardize recording techniques, and develop more economical work methods. The key goals of method study are to improve processes, reduce unnecessary fatigue, and increase productivity and safety. The basic procedure involves selecting a job to study, recording the current process, examining it for improvements, developing and evaluating alternatives, defining the new method, installing it, and maintaining the changes. Potential areas for change include human activities and motions, workstation layout and equipment, the process sequence, output design, and inputs. Method study also considers physical and psychological work environment ergonomics. It is used to solve problems arising

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17 views29 pages

Topic 2 (Part I)

The document discusses method study, which involves systematically analyzing work processes to improve efficiency. It aims to simplify jobs, standardize recording techniques, and develop more economical work methods. The key goals of method study are to improve processes, reduce unnecessary fatigue, and increase productivity and safety. The basic procedure involves selecting a job to study, recording the current process, examining it for improvements, developing and evaluating alternatives, defining the new method, installing it, and maintaining the changes. Potential areas for change include human activities and motions, workstation layout and equipment, the process sequence, output design, and inputs. Method study also considers physical and psychological work environment ergonomics. It is used to solve problems arising

Uploaded by

skyboxkeramat
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TOPIC 2:

METHOD STUDY
(PART I)
Method Study
To simplify the job and develop more
economical methods of doing it
Work
Study
Work Measurement
To determine how long it
should take to carry out

Higher
productivity
1. Definition (BS 3138)

The systematic recording and critical examination of ways of


doing things in order to make improvements.
1.1 Systematic Recording
1. Method study uses formal recording techniques to record
the sequence of activities, the time relationship between
different activities, the movement of materials and the
movement of staff.

2. To gather and record systematically so as to ease


analysis and avoid mistake.
3. The recording techniques should be designed with a view
to simplify the work and standardize the recording process.

4. However, the most commonly used technique used for


recording is by using flow charts.
2. Objectives of Method Study

1) Improvement of processes and procedures


2) Improvement in the design of plant and equipment
3) Improvement in the use of men, materials and machines
4) Economy in human effort and reduction of unnecessary
fatigue
5) Improvement in safety standards
6) Development of better working environment
3. Scope of Method Study

1) Layout of shop floor and working areas or work stations.

2) Workmen and materials movement with minimum of


backtracking.

3) Reducing cost through reduction in cycle time of operation.


4) Power required and available.

5) Material handling equipment and the ways to handle


them.

6) Working conditions (i.e. ergonomics, etc.)


4. BASIC PROCEDURE/APPROACH FOR METHOD STUDY
i. Select

ii. Record
iii. Examine

iv. Develop

v. Evaluate

vi. Define
vii. Install
viii. Maintain
i. Select : the work to be studied an define its boundaries.
ii. Record : the relevant facts about the job by direct observation
and collect such additional data as may be needed from
appropriate sources.
iii. Examine : the way the job is being performed and challenge
its purpose, place, sequence and method of performance.

iv. Develop : the most practical, economic and effective method,


drawing on the contributions of the concerned.
v. Evaluate : different alternatives to developing a new
improved method comparing the cost-effectiveness of the
selected new method with the current method of performance.
vi. Define : the new method, as a result, in a clear manner and
present it to those concerned (i.e. management, supervisors
and workers).
vii. Install : the new method as a standard practice and train
the persons involved in applying it.

viii. Maintain : the new method and introduce control procedures


to prevent a drifting back to the previous method of work.
5. AREA OF POSSIBLE CHANGES
i. Human Activities
▪ Body motion may be simplified to improve method of doing the
work.

▪ The two hands should begin and complete their movements at


the same time.

▪ Motion of the arms shall be symmetrical and should be made


simultaneously.
◼ Hands and body motions should be made at the lowest classification
at which it is possible to do the work satisfactorily.

◼ Rhythm is essential to the smooth and automatic performance of a


repetitive operation.

◼ Work should be arranged so that eye movement are confined to a


comfortable area, without the need for frequent changes of focus.
ii. Work station (equipment, layout & work place)
◼ Change design of the work station or equipment.

◼ Definite and fixed stations should be provided for all tools and
materials.

◼ Gravity feed, bins and containers should be used to deliver the


materials as close to the point of use as possible.
▪ Tools, materials and controls should be located within the maximum
working area.
▪ Materials and tools should be arranged to permit the best sequence
of motion.
▪ Provision should be made for adequate lighting.
▪ The colour of the workplace should contrast with that of the workplace
to reduce eye fatigue.
▪ Change in layout may reduce amount of human activities.
iii. Process or Sequence of Work
◼ Simplify the process or reduce the number of steps of doing work.

• Rapid prototype • Supplier meeting


product
iv. Output design
Design of product or service may be changed to simplify work.

• Modular design • Online meeting


and learning
v. Input
▪ Input such as raw material, information.

▪ Maybe in the form of shape, condition, specification and time (i.e. new
specification to meet design for recycle ability).
6. Physical and Psychological Work Environment
◼ Ergonomic factor plays a role in improving work.

Ergonomics (or human factors) is the scientific discipline concerned with


the understanding of the interactions among human and other elements
of a system, and the profession that applies theory, principles, data and
methods to design in order to optimize human well-being and overall
system performance.

International Ergonomics Association Executive Council, August 2000


i. Physical work environment
Physical ergonomics, therefore, involves issues like sitting posture,
motions, keyboard design, and generally overall workplace safety. Some
of the physical elements that may affect productivity either directly or
indirectly include the office furniture, lighting as well as temperature.
ii. Psychological work environment
While compensation is not a direct ergonomic factor, it plays a huge
role in the psychological aspect of self-worth that employees assign in
themselves and at the end of it all affects their output.
7. Identify Problem
Two reasons method study is required

i. A task has changed.


Existing method is not optimal or not applicable anymore
due to changes such as to product design, equipment or
material used.

ii. Problem in the activity


However method study can only solve problems related to
method of doing a job.
Problem source : Material
◼ Difficult to process

➢ This is a problem related to design of product and process.

➢ Work study may assist by exploring other ways to go


around this difficulties.
◼ Not to specification

➢ This is a problem related to the reliability of the suppliers.

➢ Cannot be solved through method study.


Problem source : Method
◼ Incorrect method

➢ Standing position

➢ Waste motions
Problem source : Machine
◼ Frequent breakdown:

➢ Work study cannot solve this if due to obsolete machine or


lack of maintenance.

➢ Work study can solve/minimize the problem if breakdown is


due to misuse or ineffective work method.
◼ Incorrect setup

Work study may :

➢ Identify and document the correct setup method and/or,

➢ Simplify the method of machine set up and mistake-proof it.


Problem source : Man

◼ Job is difficult
This may be eliminated or at least reduced through method
study. A better, simpler method may be identified.
◼Lack of training
Method study may identify a simpler method of doing a job thus
making the learning curve shorter.
Thank you

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