16.03.

2021

WORK STUDY & ERGONOMICS

Method study (Method study, motion economy principles)

-Lecture 2-

Method Study
Method study is the technique of systematic
recording and critical examination of existing and
proposed ways of doing work and developing an easier
and economical method.

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Objectives of method study

 Improvement of manufacturing processes and
procedures.
 Improvement of working conditions.
 Improvement of plant layout and work place layout.
 Reducing the human effort and fatigue.
 Reducing material handling
 Improvement of plant and equipment design.
 Improvement in the utility of material, machines and
manpower.
 Standardization of method.
 Improvement in safety standard.

The steps for method study

 Select the work to be studied.
 Record all facts about the method by direct
observation.
 Examine the facts critically.
 Develop the most efficient and economic
method.
 Define the new method.
 Install the new method
 Maintain the new method by regular checking.

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1. Select the work to be studied

(a) Economical factors.
(b) Human factors.
(c) Technical factors.

1.a Economical factors.

The money saved as a result of method study should
be sufficiently more. Then only the study will be
worthwhile. Based on the economical factors, generally
the following jobs are selected.

(a) Operations having bottlenecks (which holds up other

production activities).
(b) Operations done repetitively.
(c) Operations having a great amount of manual work.
(d) Operations where materials are moved for a long
distance.

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1.b Human factors

The method study will be successful only with the
co-operation of all people (workers, supervisor, trade
unions etc.). Workers may resist method study due to

 The fear of unemployment.

 The fear of reduction in wages.
 The fear of increased work load.

then if they do not accept method study, the study

should be postponed.

1.c Technical factors

To improve the method of work all the technical
details about the job should be available. Every
machine tool will have its own capacity. Beyond
this, it cannot be improved. For example, a work
study man feels that speed of the machine tool may be
increased and HSS (High-speed steel) tool may be
used. But the capacity of the machine may not
permit increased speed. In this case, the
suggestion of the work study man cannot be
implemented. These types of technical factors should
be considered.

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2. Record all facts about the

method by direct observation.
All the details about the existing method are recorded. This is done
by directly observing the work.
Symbols are used to represent the activities like operation,
inspection, transport, storage and delay. Different charts and
diagrams are used in recording. They are:
 Operation process chart
 Flow process chart (Material type, operator type, equipment
type)
 Two-handed process chart (Left hand-right hand chart)
 Multiple activity chart
 Flow diagram
 String diagram

Process chart symbols

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Process chart symbols

(Combined activities)

2.a Operation process chart

An operation process chart is a graphic representation of the sequence of all
operations and inspections taking place in a process. It is also known as outline
process chart. It gives a bird‘s eye view of the overall activities. Entry points of all
material are noted in the chart.
The steps are:
1. Write title at the top of the chart.
2. Begin the chart from the right hand side top corner.
3. Represent the main component at the right extreme.
4. Represent the sequence of operations and inspections by their symbols. Connect
them by vertical flow lines.
5. Record the brief description of the activity to the right side of the symbols.
6. Note down the time for each activity to the left of the symbol.
7. Number all operations in one serial order. Start from the right hand top (from
number 1).
8. Similarly number all inspections in another serial order (starting from 1).
9. Continue numbering, till the entry of the second component.
10. Show the entry of purchased parts by horizontal lines.

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2.a Operation process chart

(example)

2.b Flow process chart

A flow process chart is a graphical
representation of the sequence of all the
activities (operation, inspection, transport, delay
and storage) taking place in a process.
Process chart symbols are used here to
represent the activities. There are three types of
flow process charts. They are:
 Man type flow process chart
 Material type flow process chart
 Equipment type flow process chart

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2.b Flow process chart (Steps)

 The details must be obtained by direct observation—charts
must not be based on memory.
 All the facts must be correctly recorded.
 No assumptions should be made.
 Make it easy for future reference.
 All charts must have the following details:
 Name of the product, material or equipment that is observed.
 Starting point and ending point.
 The location where the activities take place.
 The chart reference number, sheet number and number of
total sheets.
 Key to the symbols used must be stated.

2.b Flow process chart (Man

type)

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2.b Flow process chart (Material

type)

2.b Flow process chart

(Equipment type)
 Equipment Type Process Chart records the
manner in which the equipment is used.

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2.c Two handed process chart

 It is the process chart in which the activities of two hands
of the operator are recorded.
 It shows whether the two hands of the operator are idle or
moving in relation to one another, in a timescale.
 It is generally used for repetitive operations.
The steps:
 Provide all information about the job in the chart.
 Study the operation cycle a few times before starting to record.
 Record one hand at a time.
 First record the activities of the hand which starts the work first.
 Do not combine the different activities like operations, transport
etc.

2.c Two handed process chart

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2.d Multiple activity process chart

(Man-machine chart)
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.
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.

2.d Multiple activity process chart

(Man-machine chart)
Example 1 Example 2

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2.e Flow diagram

In any production shop, repair shop or any other department,
there are movements of men and material from one place to
another. Process charts indicate the sequence of activities.
They do not show the frequent movements of men and material.
If these movements are minimized, a lot of savings can be
achieved in cost and effort. If the path of movement of material is
not frequent and simple, a flow diagram is used for recording the
movement.
A flow diagram is a diagram which is drawn to scale. The
relative position of machineries, gang ways, material handling
equipment etc. are drawn first. Then the path followed by men
or material is marked on the diagram. Different movements can
be marked in different colours. Process symbols are added to the
diagram to identify the different activities at different work centres.

2.e Flow diagram

The flow diagram are used for the following purposes:
 To remove unwanted material movement.
 To remove back tracking.
 To avoid traffic congestion.
 To improve the plant layout.
Conventions adopted are :
 Heading and description of the process should be given at the top of the
diagram. Other information like location, name of the shop, name of the
person drawing the diagram are also given.
 The path followed by the material is shown by a flow line.
 Direction of movement is shown by small arrows along the flow lines.
 The different activities are represented by the symbols on the flow lines. (Same
symbols used in flow process chart are used here).
 If more than one product is to be shown in the diagram different colors
are used for each path.

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2.e Flow diagram

2.f String diagram

We make use of flow diagram for recording the movement of men or material when the
movement is simple and the path is almost fixed. But when the paths are many and are
repetitive, it may not be possible to record them in a flow diagram. Here a string diagram is
used.
String diagram is a scaled plan of the shop. Location of machines and various facilities are
drawn to scale in a drawing sheet. Pins are fixed at the various work centres in the drawing
sheet. A continuous coloured thread or string is taken round the pins where the material
or worker moves during the process.
Constructions
1. Draw the layout of the shop to scale in a drawing sheet.
2. Mark the various work centres like machines, stores, work bench etc. in the diagram.
3. Hold the drawing sheet on a soft board and fix pins at the work centres.
4. Tie one end of a coloured string to the work centre from which the movement starts.
5. Follow the path of the worker to different work centre and accordingly take the thread to
different points on the drawing board.
6. At the end of the session note down the number of movements from one work centre to
another.
7. Remove the string and measure the total length of the string. Multiply by the scale and get the
actual distance of movement

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2.f String diagram

Applications
 It is used for recording the complex movements of
material or men.
 Back tracking, congestion, bottlenecks, under utilized
paths are easily found out.
 It is used to check whether the work station is
correctly located.
 Used to record irregular movements.
 Used to find out the most economical route

2.f String diagram

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3. Examine the facts critically.

Critical examination is done by questioning
technique. This step comes after the method is
recorded by suitable charts and diagrams. The
individual activity is examined by putting a number of
questions.
 The following factors are questioned
 Purpose – To eliminate the activity, if possible.
 Place – To combine or re-arrange the activities.
 Sequence – -do-
 Person – -do-
 Means – To simplify the activity.

3. Examine the facts critically.

(Questions)
The following sequence of questions is used:
1. Purpose – What is actually done? , Why is it done?, What else could be
done?, What should be done?
2. Place – Where is it being done?, Why is it done there?, Where else could
it be done?, Where should it be done?
3. Sequence – When is it done?, Why is it done then?, When could it be
done?, When should it be done?
4. Person – Who is doing it?, Why does that person do it?, Who else could
do it?, Who should do it?
5. Means – How is it done?, Why is it done that way?, How else could it be
done?, How should it be done?

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4. Develop the most efficient and

economic method.
The answer to the questions given below will result in the
development of a better method.
 Purpose – What should be done?
 Place – Where should it be done?
 Sequence – When should it be done?
 Person – Who should do it?
 Means – How should it be done?

Basic Data Collection & Analysis

Tools
1. Histograms
2. Pareto charts
3. Pie charts
4. Scatter diagrams
5. Cause and effect diagrams

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Histogram
A statistical graph consisting of bars representing
different members of a population, in which the length
of each bar indicates the frequency or relative
frequency of each member
 A useful tool because the analyst can quickly visualize
the features of the data, such as:
 Shape of the distribution
 Any central tendency in the distribution
 Approximations of the mean and mode
 Amount of scatter in the data

Histogram for Data Display

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Pareto Chart
Special form of histogram in which attribute data are
arranged according to some criterion such as cost or
value
 Based on Pareto’s Law: “the vital few and the trivial
many”
 Often identified as the 80%-20% rule
 80% of a nation’s wealth is owned by 20% of the
population
 80% of sales are accounted for by 20% of the SKUs

Pareto Distribution

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Pie Charts
 Example: Annual sales revenues and customer
distributions for two years

Scatter Diagrams
An x-y plot of data collected on two variables,
where a correlation between the variables is
suspected.
 The data are plotted as pairs; for each xi value,
there is a corresponding yi value
 The shape of the collection of data points often
reveals a pattern or relationship between the two
variables

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Scatter Diagram
 Effect of cobalt
content on wear
resistance for a
cemented carbide
cutting tool

Cause and Effect Diagram

A graphical-tabular chart used to list and analyze
the potential causes of a given problem
 Can be used to identify which causes are most
consequential and how to take corrective action
against them
 Also known as a “fishbone diagram”

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Cause and Effect Diagram

5. Define the new method.

Once a complete study of a job has been made and a new method is
developed, it is necessary to obtain the approval of the management before
installing it. The work study man should prepare a report giving details of the
existing and proposed methods. He should give his reasons for the changes.
The report should show:
(a) Brief description of the old method.
(b) Brief description of the new method.
(c) Reasons for change.
(d) Advantages and limitations of the new method.
(e) Savings expected in material, labour and overheads.
(f) Tools and equipment required for the new method.
(g) The cost of installing the new method including.
Cost of new tools and equipment.
Cost of re-layout of the shop.
Cost of training the workers in the new method.
Cost of improving the working conditions.

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5. Define the new method.

Written standard practice: Before installing the new method, an
operator‘s instructions sheet called written standard practice is
prepared.
The written standard practice will contain the following information:
(a) Tools and equipment to be used in the new method.
(b) General operating conditions.
(c) Description of the new method in detail.
(d) Diagram of the workplace layout and sketches of
special tools, jigs or fixtures required.

6. Install the new method.

This step is the most difficult stage in method study. Here
the active support of both management and trade union is
required. Here the work study man requires skill in getting
along with other people and winning their trust. Install stage
consists of:

(a) Gaining acceptance of the change by supervisor.

(b) Getting approval of management.
(c) Gaining the acceptance of change by workers and trade
unions.
(d) Giving training to operators in the new method.
(e) To be in close contact with the progress of the job until it is
satisfactorily executed.

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7. Maintain.
The work study man must see that the new method introduced
is followed. The workers after some time may slip back to the old
methods. This should not be allowed. The new method may have
defects. There may be difficulties also. This should be rectified
in time by the work study man. Periodical review is made.
The reactions and suggestions from workers and supervisors
are noted. This may lead to further improvement. The
differences between the new written standard practice and the
actual practice are found out. Reasons for variations are
analysed. Changes due to valid reasons are accepted. The
instructions are suitably modified.

Motion Study and Work Design

Basic Motion Elements and Work Analysis
Principles of Motion Economy and Work Design

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Definitions
 Motion study - analysis of the basic hand, arm, and body
movements of workers as they perform work
 Work design - design of the methods and motions used to
perform a task
 Includes:
 Workplace layout and environment
 Tooling and equipment used in the task

Basic Motion Elements

 Therbligs – 17 basic motion elements
 Basic building blocks of virtually all manual work performed at
a single location
 With modification, used today in several work measurement
systems, e.g., MTM and MOST
 Some of the motion element names and definitions have been revised

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17 Therbligs
1. Transport empty (TE) – reach for an object
2. Grasp (G) – grasp an object
3. Transport loaded (TL) – move an object with hand and
arm
4. Hold (H) – hold an object
5. Release load (RL) – release control of an object
6. Use (U) – manipulate a tool

17 Therbligs (continued)
7. Pre-position (PP) – position object for next operation
8. Position (P) – position object in defined location
9. Assemble (A) – join two parts
10. Disassemble (DA) – separate multiple parts that were
previously joined
11. Search (Sh) – attempt to find an object using eyes or hand

2nd
ter f ed
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17 Therbligs (continued)
12. Select (St) – choose among several objects in a group
13. Plan (Pn) – decide on an action
14. Inspect (I) – determine quality of object
15. Unavoidable delay (UD) – waiting due to factors beyond
worker control
16. Avoidable delay (AD) – worker waiting
17. Rest (R) – resting to overcome fatigue

Classification of Therbligs
Effective therbligs: Ineffective therbligs:
 Transport empty  Hold
 Grasp  Pre-position
 Position
 Transport loaded
 Search
 Release load
 Select
 Use
 Plan
 Assemble
 Unavoidable delay
 Disassemble  Avoidable delay
 Inspect
 Rest

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Micromotion Analysis
 Analysis of therbligs that make up a repetitive task
 Objectives:
 Eliminate ineffective therbligs if possible
 Avoid holding objects with hand – Use workholder
 Combine therbligs – Perform right-hand and left-hand motions
simultaneously
 Simplify overall method
 Reduce time for a motion, e.g., shorten distance

Principles of Motion Economy

 Developed over many years of practical experience in work
design
 Guidelines to help determine
 Work method
 Workplace layout
 Tools, and equipment
 Objective: to maximize efficiency and minimize worker
fatigue

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Three Categories of Principles

1. Principles that apply to the use of the human body
2. Principles that apply to the workplace arrangement
3. Principles that apply to the design of tooling and
equipment

Use of Human Body

1. Design work to fully utilize both hands
2. The two hands should begin and end their motions at the
same time
3. Hand and arm motions should be symmetrical and
simultaneous
4. Design work to favor preferred hand
5. Worker’s two hands should not be idle at the same time

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Use of Human Body

6. Method should consist of smooth continuous curved
motions rather than straight motions with abrupt changes
in direction
7. Use momentum to facilitate task
8. Take advantage of gravity – Don’t oppose it
9. Method should achieve a natural rhythm of the motions
involved
10. Minimize eye focus and travel

Use of Human Body

11. Use lowest classification of hand and arm motion (five
classifications)
1) Finger
2) Finger and wrist
3) Finger, wrist, and forearm
4) Finger, wrist, forearm, and upper arm
5) Finger, wrist, forearm, upper arm, and shoulder
12. Design method to utilize feet and legs where appropriate

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Workplace Arrangement
 Normal and maximum working areas in the workplace
(key and dimensions given in text)

Workplace Arrangement
1. Locate tools and materials in fixed positions within the
work area
2. Locate tools and materials close to where they are used
3. Locate tools and materials to be consistent with sequence
of work elements

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Illustration of First Three Principles

Poor arrangement of parts and tools in workplace

Illustration of First Three Principles

Good arrangement of parts and tools in workplace

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Workplace Arrangement
4. Use gravity feed bins to deliver small parts and fasteners

Two types of bins used for

small parts and fasteners
in the workplace:
(a) gravity feed bin
(b) conventional
rectangular bin

Workplace Arrangement
5. Use gravity drop chutes for completed work units where
appropriate
6. Provide adequate illumination
7. A proper chair should be provided for the worker
 Adjustable to the size of the worker
 Seat height and back adjustments
 Padded seat and back

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Adjustable Chair for Workplace

Design of Tooling and Equipment

1. Workholding devices should be designed for the task
2. Hands should be relieved of work elements that can be
performed by the feet using foot pedals
3. Combine multiple functions into one tool where possible
4. Perform multiple operations simultaneously rather than
sequentially

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Design of Tooling and Equipment

5. Where feasible, perform operation on multiple parts
simultaneously
6. Design equipment controls for operator convenience and
error avoidance
7. Hand tools and portable power tools should be designed
for operator comfort and convenience
8. Mechanize or automate manual operations if economically
and technically feasible

EXAMPLE FOR METHOD STUDY

A: Fiber cutting machine

B: Fibers before inspection
C: Fibers passed from inspections
D: Fibers failed from inspections
M: Inspection table

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EXAMPLE FOR METHOD STUDY

 There are 6 fiber cutting machines in a workshop.
The fibers must have a specified quality. The
quality control man continuously checks these
fibers.

For improving the system, firstly, the flow process

chart for quality audit man is performed.

The flow process chart for

present situation

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Observations and proposal

 As observed from the flow process chart, the quality control man
walks too much and carries fibers. This causes the worker to be
very tired and makes the quality control process slow.
Depending on the increasing demand, this quality control
process is wanted to be made faster. The proposals are as
follows.
 The fiber cutting machine operators will be trained about quality
control process and they will perform the quality control of their
own products.
 The machines will be changed with the ones controlling the
diameters of the fibers.
 The cut fibers will be carried to the controller’s table with the
conveyor.
 The table of the quality control man will be made mobile and the
defective fibers will be carried under this moving table.

New Method
 The proposal making the inspection table moving is
accepted and the flow process chart is drawn for the
new situation.
 With the new proposed methodology, the distance is
decreased from 30 meters to 4 meters. 2
transportation and 1 operation event is saved.

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The flow process chart for

proposed situation

Application
The activities of a stenographer is as follows:
 The stenographer sits in her seat. When she hears the bell (3
sec.). She goes to manager’s room (10 sec. , 6 m.). She takes
down dictation (120 sec.). She returns to her seat (10 sec., 6 m.).
She prepares typewriter (15 sec.). She types the letter (150
sec.). She checks the matter (40 sec.). She goes to manager’s
room (10 sec., 6 m.). She waits till the manager signs (20 sec.).
She returns to her seat (10 sec., 6 m.). She types envelope (20
sec.). She puts the letter inside envelope (5 sec.). She puts
envelope in dispatch tray (5 sec.).

 Draw the flow process chart for the current situation.

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Application

References
 R. Kesavan, C. Elanchezhian, B. Vijaya Ramnath,
‘Process planning and cost estimation’, New Age
International Publishers.
 Mikell P. Groover, ‘Work Systems and the Methods,
Measurement, and Management of Work’, Pearson
International Edition.
 Andris Freivalds, ‘Niebel’s Methods, Standards, and
Work Design’, McGraw-Hill International Edition.
 Mehmet Tanyaş, ‘Endüstri Mühendisliğine Giriş’, İrfan
Yayımcılık.

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