Method Study

Outline

1. Work Study

2. Method Study

3. Various Charts

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Work Study

Work Study is a generic term for management services

and system engineering techniques, used to investigate:

• Methods of performing work (Method Study).

• The time taken to do it (Work Measurement).

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Work Study (Cont.)

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Method Study

Method study is a technique to reduce the work content

mainly by eliminating unnecessary movements by
workers, materials, or equipments.

However, even after that, there could be substantial

unnecessary time taken for the process because of lack
of management control or inaction of worker.

Method Study approaches and tools of Method Analyst:

• Flow Diagrams & Process Charts etc.
• Critical questioning techniques.

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Method Study
Method study is the systematic recording and critical
examination of existing and proposed ways of doing
work, as a means of developing and applying easier
and more effective methods and reducing costs.
Used to analyze

▪ Movement of body, people, or material

▪ Activities of people & machines

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Method Study Objectives

Improvement of processes and procedures.

Improvement in the design of plant and equipment.

Improvement of layout.

Improvement in the use of men, materials and machines.

Economy in human effort and reduction of unnecessary

fatigue.

Development of better working environment.

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 Method study - Methodology
Procedure to accomplish method study, called "SREDIM" shall be as
follow:
1. Select: the job or operation that needs improvement,
2. Record: all facts, how work is done by chart methods,
3. Examine: every aspect of the job by asking; what, why, where,
when, who and how
4. Develop: review ideas, eliminate, simplify, combine, re-arrange,
make new method which more safe, chart new method, submit for
approval,
5. Install: the new method, consider best time to introduce, convince
all, train users,
6. Maintain: check frequently, match results, correct deviations.

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Methodology (Cont.)

Select
Record

Examine

OK?

Develop
Install
Maintain 9
Method Study Tools

Exploratory Tools
• Pareto Analysis
• Fish & Bone Diagrams
• Gantt and PERT charts
Recording and Analysis Tools
• Operation Process Chart
• Flow process chart
• Flow diagram
• Worker and Machine Process Charts
• Gang Process charts
• Synchronous Servicing

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Method Study Applications

The need for methods analysis can come

from a number of different sources :
▪ Changes in tools and equipment.
▪ Changes in product design or new products.
▪ Changes in materials or procedures
▪ Other factors (e.g. accidents, quality problems)

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Select

While selecting a job for doing method study, the following factors
are considered:
(a) Economical factors.
(b) Human factors.
(c) Technical factors

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Recording Techniques

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Recording Techniques
Charts
1. Outline process chart.
2. Flow process chart (man-type, material-type and
equipment-type): This is the use of symbols and description
to chart the sequence of work. The process, then, show what
is happening at different stages. The distances and time may
be given.
3. Two hands process charts.
4. Multiple activity charts: This technique is used to solve
problems where a number of items are dependent on each
other. The aim is to reduce idle times by using the optimum
number of each item. It depicts the occupied times-broken
down into the number of different activities and the idle times
both for the original and proposed methods of doing the job.

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Recording Techniques (Cont.)
Diagrams and models (2-D and/or 3-D)
1. Flow diagrams, which is the use of symbols for flow process charts,
superimposed on drawings and the "descriptions" are not necessary.
2. String diagrams, which is used for solving movement problems since
it shows congestions and excessive distances.
3. Cut-out templates (2-D models).
4. 3-D models.
Photography
1. Photographs,
2. Films,
3. Video.
Micro-Motion Study

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Assembly Chart

It is an analog model of the assembly process.

Circles with a single link denote basic
components,
Circles with several links denote assembly
operations/subassemblies, and squares
represent inspection operations.
The easiest method to constructing an
assembly chart is to begin with the original
product and to trace the product disassembly
back to its basic components.
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Assembly Chart (Cont.)

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Outline Process Flow Chart

• Gives an overall view of a process by recording only the main

operations and sequences in proper sequence.
• So, its obvious that such a chart requires only symbols for
‘Operations’ and ‘inspection’.
• A brief note of the nature of each inspection and operations is written
alongside the symbol.
• Allowed time where ever, known, can also be added.

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An operation process charts has the following
uses:
• Improved plant layout.

• For specifying the basic manufacturing system.

• For determining the sequence of assembly.

• To introduce manufacturing system to new

technical personnel.

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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.
Two symbols are used in constructing the operation
process Chart : an operation and an inspection.

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Operation Process Chart (Cont.)

Operations charts show the introduction of raw

materials at the top of the chart on a horizontal line.
Pieces / Hr
Operation
Number
Hours / 1000
Some parts require no fabrication steps. These parts are
called buyouts. Buyouts are introduced above the
operation
Tape

Carton

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Operations Chart Steps
Step by Step Procedures For Preparing an
Operations Chart:
Identify the parts to be manufactured and purchased
Determine the operations required to fabricate each part
and sequence them
Determine the sequence or assembly for buyouts and
fabricated parts
Draw the operations chart as explained
Put time standards, operation numbers and descriptions
Calculate and write down the total hours required per
1,000 units

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Operation Process Chart

Operation Process Chart for

Refrigerator Support

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Operation Process Chart

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Flow Diagrams
A flow diagram is essentially a flow process chart drawn to:
1. Show the layout of a facility.
2. Show the flow of work through that area
3. Show overcrowding areas, crossing worker paths, total travel.
4. Identify how layout can be redesigned to reduce travel,
motion, collisions, etc.
5. Store materials near where they are used.
6. Increase efficiency and safety.
Usually, the objective is to look for spatial relationships.
It depicts the probable movement of materials in the floor plant. The
movement is represented by a line in the plant drawing.

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Flow Diagram (Cont.)

Buyer

75 ft.

You

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Flow Diagram (Cont.)

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Flow Process Charts (Cont.)

A flow process chart is a chart of all the activities involved

in a process.
It is similar to an operations process chart, except that
more detail is shown by including transportations and
delays as well as operations, inspections, and storages.
Not usually used for entire assemblies, it is used for just
one component (or operator)
Add in information on:
▪ Operation duration (time to complete)
▪ Distance traveled (for transport operations)
Good for showing savings of a new method.

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Flow Process Charts (Cont.)

Process charts summarizes the whole process

They are used to compare the existing and the
proposed methods
Process is observed, who, what, where, when,
and how questions are asked
Every detail is understood and the chart of the
existing situation is drawn

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Flow Process Charts (Cont.)

Quantity:
▪ Operations: Pieces per hour
▪ Transportation: How many are moved at a time
▪ Inspection: How many pieces per hour if under time standard and/or
frequency of inspection
▪ Delays: How many pieces in a container
▪ Storage: How many pieces per storage unit

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Flow Process Charts (Cont.)

Time in Hours per Unit

▪ If 250 pieces are processed in an hour then 1 unit is processed in
0.00400 hours. Record 400
▪ If 200 units are moved in 1 minute, then 1/200 = 0.005 minutes per part,
and 0.005/60 hours/part =0.00008 hrs/part. Record 8.

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Flow Process Types:
There are three types of flow process charts.
1. Man type flow process chart. This flow process
chart records what the worker does.
2. Material type flow process chart. This flow
process chart records how the material is handled
or treated.
3. Equipment type flow process chart. This flow
process chart records how the equipment or
machine is used.

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ASME Standard Symbols

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Flow Process Chart Symbols

Operation Delay

Transportation Storage

Inspection Operation cum

Transportation

Inspection
cum operation
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 Operation
Occurs when an object is intentionally changed
in one or more of its characteristics

Usually occurs at a machine or a work station

Drilling, Painting, Data Entry, Cutting, Sorting,

etc.

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 Transportation
Occurs when an object is moved from one place
to another

except when the movement is part of an

operation or an inspection

Using elevator, carrying, moving with material

handling devices

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 Inspection
Occurs when an object is examined for
identification or is compared with a standard as
to quantify or quality

Examine the quantity or quality, read steam

gauge on boiler, detect the defectives

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 Delay
Occurs when the immediate performance or the
next planned action does not take place

Work In Process inventory waiting to be

processed, Employee waiting for an elevator,
Waiting for accumulation of a certain quantity for
packaging

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 Storage
Occurs when an object is kept under control
such that its withdrawal requires authorization

Bulk storage of raw material, finished products

inventory, archived documents

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Combined Symbols

Two symbols may be combined when two

activities are performed concurrently.

Operation and Inspection

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Flow Process Chart-An Example

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Flow Process Chart-An Example

Process: Emergency room admission Summary

Subject: Ankle injury patient Number Time Distance
Beginning: Enter emergency room Activity of steps (min) (ft)
Ending: Leave hospital
Operation 5 23 —
Insert Step Transport 9 11 815
Inspect 2 8 —
Append Step
Delay 3 8 —
Remove Step Store — — —

Step Time Distance

no. (min) (ft) Step description
1 0.50 15 X Enter emergency room, approach patient window
2 10.0 - X Sit down and fill out patient history
3 0.75 40 X Nurse escorts patient to ER triage room
4 3.00 - X Nurse inspects injury
5 0.75 40 X Return to waiting room
6 1.00 - X Wait for available bed
7 1.00 60 X Go to ER bed
8 4.00 - X Wait for doctor
9 5.00 - X Doctor inspects injury and questions patient
10 2.00 200 X Nurse takes patient to radiology
11 3.00 - X Technician x-rays patient
12 2.00 200 X Return to bed in ER
13 3.00 - X Wait for doctor to return
14 2.00 - X Doctor provides diagnosis and advice
15 1.00 60 X Return to emergency entrance area
4.00 -
16 X Check out
2.00 180
17 X Walk to pharmacy
4.00 -
18 X Pick up prescription
1.00 20
19 X Leave the building

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Material Type - Example

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Man Type - Example

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Left-Hand-Right-Hand Charts

Useful in analyzing the work performed by one

person at one specific workstation. As the name
implies, the chart follows the motion of the left
and right hands of one operator .
Each hand of the worker is treated as an activity.
Each hand’s activities are broken into work
elements and plotted side by side on a time
scale.

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Left-Hand-Right-Hand Charts (Cont.)

Lists the work performed simultaneously by each hand

• To assist in finding a better method of performing the task and
• To train the operator in the preferred method.

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Symbols

Two symbols are used in this chart:

• Transportation (either an arrow or a small circle)
• Action (e.g., grasp, position, use, release)

A sketch of the workplace is drawn, indicating

the contents of the bins and the location of tools
and materials.
• Record the motions of one hand at a time
• Usually necessary to redraw the chart

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Left-Hand-Right-Hand Chart (An Example)

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Left-Hand-Right-Hand Chart (An Example)

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L-R Hand Chart of Signing a Letter
LEFT HAND RIGHT HAND
Reach for pen

Grasp pen

Carry pen to
paper

Hold Letter Sign letter

Return pen to
holder
Release pen in
holder
Move hand back
to letter
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Man-machine chart

The worker and machine process chart (Man-machine

chart) is used to study, analyze, and improve one
workstation at a time.
The chart shows the exact time relationship between the
working cycle of the person and operating cycle of the
machine.
These facts can lead to utilization of both worker and
machine time, and a better balance of the work cycle.

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Worker-Machine Chart for a Gourmet Coffee Store

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 Worker-Machine Chart for a Gourmet Coffee Store

The customer, the clerk, and the coffee grinder (machine) are
involved in this operation. It required 1 minute and 10
seconds for the customer to purchase a pound of coffee in
this particular store. During this time the customer spent 22
seconds, or 31 percent of the time, giving the clerk his order,
receiving the ground coffee, and paying the clerk for it. He
was idle during the remaining 69 percent of the time. The 56
Multiple Activity Charts

Also known as Gang Process Charts

 Used when several workers operate a single
machine or render a single service
 Used when a single worker is operating several
machines
 Used to show the exact relationship between
idle and operating times of both workers and
machines

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Multiple Activity Charts (Cont.)

An operation performed by one member of the

group may continue while another member is
performing more than one operation.

The chart should cover the complete cycle for

the longest performing member.

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Multiple Activity Charts (Cont.)

• One Man- One Machine Chart

• Two Man- One Machine Chart
• One Man- Two Machine Chart

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Activity Chart for Two-Person

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Activity Chart of Emergency Tracheotomy

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String diagrams

The string diagram is a scale layout drawing on which, length of a

string is used to record the extent as well as the pattern of
movement of a worker working within a limited area during a
certain period of time.

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String diagrams

Procedures to draw string diagram-

1. A layout of the work place of factory is drawn to
scale on the soft board.
2. Pins are fixed into boards to mark the locations
of work stations, pins are also driven at the
turning points of the routes.
3. A measured length of the thread is taken to
trace the movements (path).
4. The distance covered by the object is obtained
by measuring the remaining part of the thread
and subtracting it from original length.
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Photography

• Photographs,
• Films,
• Video.

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CYCLEGRAPH

• It was introduced by Gilbreth.

• It is a photographic record of the path of movement of
the operator doing a job.
• Little source of light (bulb) is attached to the hand or
finger or any other body part, whose motions are to be
analyzed. When he/she performs the operation and
photograph is taken continuously, the path of motions
is recorded on the film as CONTINUOUS STREAK OF
LIGHT as shown below
OPERATO R

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 CHRONOCYCLEGRAPH
• It is a special type of cycle-graph in which the light
source (bulb) is suitably INTERRUPTED ELECTRICALLY
so that the path of motion in the photograph appears as
a SERIES OF PEAR-SHAPED SPOTS instead of
continuous streak of light as shown below

PEAR-SHAPED SPOTS

MOTION DIRECTION

• The pointed end of the pear shows the direction of movement.

• More elongated and spaced pear-spots indicate higher speed of
operation..
• It helps in studying the complex and restricted motions also.
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Any Question

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