5 WORK MEASUREMENT # Steps in making a time = Definition » Objectives of time study « Techniques of time peel Se the jobs into Study Selecting job for time study « Obtaining and recording informal Guidelines for breaking jobs elements» Reasons for breaking jobs into elements © Types a Seen te oe uements * Number of cycles to be timed « Measuring duration of oe Geena observed time into normal time » Thne study equipment Selection of worker fo ling Synthetic data anes Tating methods * Allowances + Computation of standard time « Work serie licacs 1 RMTS ‘(Predetermined Motion and Time Study) © MTM (Method Time * MOST(Maynard's Operation Sequence Technique), 5.1. DEFINITION ‘ Work measurement is also called by the name “Time study”. Work measurement is absolutely denna! for both the planning and control of operations. Without measurement data, we cannot | determine the capacity of facilities or itis not Possible to quote delivery dates or costs. We are not in a position to determine the rate of production and also labour utilisation and efficiency. It may Rot be possible to introduce incentive schemes and standard costs for-budget control Time study has been defined by British standard Institution as ““Phe‘application of techniques igned to establish the time for a qualified worker to sav ox! specified job at a defined level of performance.” 7 / > c /< 35a basis for incentives is only a small part of its total application. measurement are to provide a sound basis for. 1. Comparing alternative methods. —— F Assessing the correct initial manning (manpower requirement planning), 3. Planning and control 4, Realistic costing. 5. Financial incentive schemes. 6. Delivery date of goods... / 7. Cost reduction and cost control. 8. Identifying substandard workers, 9. Training new employees,WORK MEASUREMENT - fepeat continuousl;, during the time spent at the job. These a tremely short duration repetitive wor fa cia cycle itself is hardly ever repeated identically, Various techniques of work measurement are: PF. Time study (stop watch technique, Synthesis, \EX Work sampling, Pay a \o4Analytical estimating, se \ = 5 Predetermined motion and time study, 2 Time study and work sampling involve direct observation and the remaining are data based and analytical in nature. ‘Time study: A work measurement technique for recording the times and rates of working for the clements of a specified job cartied out under specified conditions and for analysing the datiso as to determine the time necessary for carrying out thc job at the defined level of performance. Synthetic data: A work measurement technique for building up the time for a job or parts of the job at a defined level of performance by totalling element times obtained previously from time studies on other jobs containing the elements concerned or from synthetic data. Work sampling: A technique in which a large number of observations are made over a period of time of one or group of machines, processes or workers. Each observation records what is happening at that instant and the percentage of observations recorded for a particular activity, ot : delay, is a measure of the percentage of time during which that activities delay occurs. Predetermined motion time study (PMTS): A work measurement technique whereby times established for basic human motions (classified according to the nature of the motion and conditions under which Tt is made) are used to build up the time for a job at the defined level of performance. The most commonly used PMTS is known as Methods Time Measurement (MTM). PLY to work cycles of ex. Analytical Estimating A work measurement technique, being a development of estimating, whereby the time required to carry out elements of a job at a defined level of performance is estimated partly from knowledge and practical experience of the elements concemed and partly from synthetic data, The work measurement techniques ad their applications are shown in Table § 1. Table 5.1: Werk Measurement Techniques and their Application, Techniques Applications Unit of Measurement 1. Time study Short cycle repetitive jobs. Widely used for | Centi minute (0.01 miny direct work 2. Working sampling | Long cycle jobs/heterogeneous operations, | Minutes 3. Synthetic Data Short cycle repetitive jobs Centi minutes 4. M™ Manual operations corfined to one work | TMU (1 TMU = 0.006 min) centre $._Analytical estimating | Short eycle non-repetitive job Minutes Steps in Making Time Study Stop watch time is the basic technique for determi mical for repetitive type of work. Steps in taking the lect the work to be studied. 3 all the information available about the to affect the time stay work. ing accurate time standards. They are time study are: Job, the operator and theRODUCTION MANAGEME), = tof a specified acti, eenience of observaig! 1G AND PI INDUSTRIAL ENGINEERIN' form each eleme, ator to pet i the oe he time by means ofa stop watchs taken By the OPE iming ne a time by means of a st serves Of the operation Ether conan method of Snap Bate Pork relative 10 the observe 5. At the same time, assoss th operators effec! ing. seeds th fled performance rati element AoneePt OF Normal’ speed. This is called perfor normal time for each Adjust the observed time by rating factor to oblait Observed time x Rating 199 : sonal needs, contingencies, et, nsate for fatigue, Per Normal time = + Add the suitable allowances to compe ; to give standard time for each element. ing elemental standard times considering 8. Compute allowed time forthe entre job by adding elem: Jan lWency of occurrence of each element ich the standard time is es, °. Makes ue Job description describing the method for whic! tablished, ’ are represent, 10 Test and review standards where necessary, The basic sleps in time study are tep SI by a block diagram in Fig. 5.1. STEPS IN TIME STUDY SELECT The job to be timed f 4 OBTAIN & RECORD Petails Regarding method, Operator, Job and Working Conditions ‘The clements, Break the job into elements con. venient for timing ih Observed time into norma time Basic time) PT ih x hoa = if DETERMINE Rel laxation and personal allowances et eal dlowinas |ry "WORK MEASUREMENT n 1. Selecting Job for Time Study t ‘The reasons for which time study may be done: (@) The job in question is new one or not previously carried out. ‘ (6) Change in the method of existing time standard, : (©) Complaint received from Workers or unions regarding the time standard, (@) ‘A particular operation becomes-botte-neck operation which holds up number of sun. sequent activities. (© Change in the management policy regarding how time standards are used, i, General Purpose or wage incentive plans. The general guidelines for selecting the job for time study: -ck operations. jobs. (©) Jobs using a greater deal of manual labour, (@) Jobs with longer cycle time. sae () Sections/deoartment frequently working overtime. 2, Obtaining and Recording Information During this step, all the relevant and necessary information regarding the method, operator and details of working conditions are recorded: * The accuracy of time standards depends upon the correctness of the method employed by the operators. So wrong methods should not be timed. The method is to be standard and the time required to carry out the job as per the standard method is to be timed, * The selection of an operator refers to choosing an operator amongst many operators doing the same job. He should be a representative worker with a normal pace neither (00 fast nor too slow. So the details of the operator is essential to be recorded before starting actual time study. * Information to enable the identification details such as. Part number and name, machine No. speed and feed, materials, operator details, etc, * Working conditions under which an operator carries out the job like temperature, dust, smoke, vibrations, noise, etc, ‘* Working position such as standing, sitting, bending, etc., and weights handled, protective clothing, etc. 3. Breaking the Jobs into Elements Once the recording of the basic information regarding the Job and, operator are done, the next step is breaking job into elements. Element is a distinct part of a specified job selected for convenience of observation, measurement and analysis, Work cycle is a complete sequence of elements necessary to perform a specified activity or job to yield one unit of production. It may also include the elements which do not occur with every cycle. Reasons for Breaking the Jobs into Elements 1. Tocnsure that productive time is separated from unproductive activities (separating effec- tive time and ineffective time). _ 2. To permit the rate of performance to be assessed more accurately than would be possible if the assessment were made over a complete cycle, fo enable different types of clements to be identified and distinguished so that cach cle- tis given an appropriate treatment. involving a high degrce of fatigue to be jolated and to make the allo ‘more accurately, eQpUGIE NG AND roduced: elements. To enable the detailed work specification te ae ‘humem ge, omissions and errors p, Tp cable machine elements to be citi Bed Seana ¢ able time standards to be checked oF 4, be Pctitiea ras the loading/unloading op - For accuracy of rating. rents, suc! mpilation of stang, c 2 arring elements, Suet comp 7 "ei ca te ~~ ted data, 54. TYPES OF ELEMENTS INDUSTRIAL ENGINEER! ry work eyele ofthe job. Example, ineve : 7 A repetitive element is an clement abe Fa eerk jece in a PARENTS ocr Picking up part for assembly, element of locating a vavery work CYC! AM occasional element is one that does nor occur in after sometime, adjusting tension may occur at regular intervals. Examples, tool changing al element is useful work to be or machine setting, instruction from supervisor. Oceasion' ’ included in rd time. jut constant whenever jt 4. Astestdat Gents ex olenazt fr ahaa Arsenic rar OO is performed. Examples, Switch on machine, measure diam can to some basic 4. 4 variable clement is an element for which the basic time V1 eas weight ke characteristics of the product, equipment or process. Examples, ity, ete “5. Am: 7 § A machine element is an clement execs) Examples, Press working parts, annealing tubes, 7. Governing element is an clement occupying a longer time than that of any other element {ihich is being performed concurrently example Gauge dimencione white turning diameter (uring diameter will be a governing element) 7 /® A foreign clement is one that is observed during study but do not form part of the given 7 activity Of the cycle. Example, Dropping work em ihe floor, operator talking to his col. i /2. element is an element pecan ym es ed by a power driven machine idelines for Breaking Jobs into Elements {| 1. Elements should be easily identified, 2. Each element should have a definite beginning and end. 3. Manual elements should be ‘separated from variable clements, 4. Occasional elements should be timed Separately, 5. Blements should be as short as can be conveniently 6. Elements should be chosen so that they represent n trict segments of the ‘operation, Example of Standardised Element Breakdown DRILLING WITH TWIST DRILL iN BENCH TypE MACHINE Element Break Point (end) Moving jig. towards spindle start Machine feed engages Tool stars cuttingSto Element Break Point (end) [Rema Take out of jig place aside | Noise when piece reaches bottom ‘Small piece of containcr A 3 of Take out of jig The moment when the piece is| Pieces which not nd. Separated trom jig away Smore SHey | Place aside (2) Piece released from hand grip | Pieces which cannot be thrown (0) Crane hook released after away Patt Sash = reaching floor container i es, R pre How Many Cycles to be Timed ? ‘ 1. The number of cycles through which any particular job should be observed varies directly as the amount of variations in the times of the elements of the job. - 2, The number of cycles to be observed will depend on the degree of accuracy desired, This in turn will depend on the length of run of the job and the number of people engaged on it. : 3. The study should be continued through a sufficient number of cycles to ensure that occa sional elements such as handling boxes of finished parts, periodical cleaning of machines, etc,, can be observed several times. 4. Where more than one operator is engaged on the same job it is preferable to take a short study on each of several operators rather than timing too long on a single operator. The number of observations at 95% confidence level and accuracy of + 5 per cent is given by the statistical formula n= [+0 ae vn = ie where n= number of preliminary readings, Xx = sum of preliminary set of observations m= sample size (number of observations) (Measure) Duration of Each Element When elements have been selected, the next step is starting the timing, of operations. There are ‘Wo principal methods of timing with the stop watch: (a) Cumulative timing, and (b) Fly back timing. In cumulative, the watch runs continuously throughout the study, It is started at the beginning of the first element of the first cycle to be timed and is not stopped until the whole study is completed, At the end of each element the watch reading is recorded and individual element times are obtained by successive subtractions after the study is completed. In fly back timing, the hands of the stop watch are returned to zero at the end of each element and allowed to start immediately, the time for each clement is obtained direcily. While recording the time of the elements, operators speed of working is assessed and recorded ‘on the observation sheet. Rating is the time study engineers assessment of the operator’s pace of ‘working in relation to the concept of standard or normal. Rating is used to conyert observed ti into normal time. Extend Observed Time into Normal Time wrt entative time established from the observation data is the time which an operator has working at a certain pace. The observed time is converted into basic or normal time it by rating factor. Observed time x performance ratin 100 other allowances- ” NGINEERING 7" " " INDUSTRIAL El sly. Some additional tin, h work contin? te is needed to: Calculate Standard Time for the Job licable to get the standard time Narious allowances are added to the normal time #s aPP! ‘Thus basic constituents of standard time are: 1. Elemental (observed time). ¢ working. 2. Performance rating to compensate for difference in pace O} 3. Relaxation allowance. 4. Interference and contingency allowance. 3. Policy allowance. -5 TIME STUDY EQUIPMENTS , ard, Basic time study equipment required to make the time study are: (1) Time study board, (2) So atch, and (3) Time study forms. Time study board: Time study board is simply a flat board, usually os aa et = Suitable plastic sheet and it should have fittings to hold stop watch and ti re i: iene Use Of board provides support and resting face while writing observations on the shop-floor bi makes the hands free to write and operate stop watch, mi Stop watch: Stop is the measuring instrument to observe the elemental timings and usually decimal watch is used, : ‘ A decimal minute stop watch has two hands. The small hand represent minutes on dial and ipletes one revolution in 30 minutes. The large hand represents centi minutes (1/100th minute) Two commonly used types of stop watches are: _Lumulative stop waten: The watch is started by Pressing the winding knob located on the head of the watch and is stopped by pressing the winding Knott Pressing winding knob third time finds the hands back to zero. Once started it will run until required number of cycles have been Fly back stop watch: This is most commonly used watch. In this type of watch the movement is started and stopped by a slide (A) at the side of the winding knob (B). Pressure on the top ofthe winding knob causes both the hands to fly i Which point they move forward immediately, cumulative timing method. The stop watch is shown in Fig, 5.2, Electronic timers are most widely used ti ime study. The electronic timer which performs the same function as the ‘Stop watch is sometimes, icy toas "sae stop watch. puters and motion picture ci 8 a] motor drive) are also used for the purpose, “mera (with constant spec Time study forms: Time study forms are usually printed ae f » standaed forms is desirable as the constant information a ae ceystandard size. The use of ‘ «atic we Part number and part name, ae atice description, observers y of ay aay eeacbtion ar pre-printed eee top of the form ing missed. As the sine of the forms are Tencing. Time Study forms are shown in Fig. they can be easily filed for future rete 5 Se6.ASUREMENT ~~. RINT. y ‘A= Slide for stopping and starting the movement B = Winding knob. Pressure on this knob returns both the hands to zero, Fig. 5.2: Decimal-minute stop watch. Selection of Worker for Time ‘Study If a choice of workers is available, itis good policy to consult the foreman and the workers Tepresentatives to suggest the one most suitable t . The worker selected should be and should have a good temperament, His pace of performance should be close to the age so that observed times are near to the normal times, a large number of workers are worki in one qualified worker. d is made between a qualified worker and Tepresentative worker. A representative 'g¢ of the group under consideration, A ied worker. ing On the job, it is a good policy to take studies onWun menouncment 69 Observed Time Normal Time In other words, rating is a levelling factor to convert observed timings into normal timings Affecting Performance Rating here exists a variation ftom element to element and even among the elements in the same peration. This is due to the inconsistency in the speed of the working o ator. Bach worker by nature has different temperament and attitudes towards the work. Some y workers by their nature are fast (above the speed of the average worker) and some are by nature Performance rating = 100 slow. Both these workers will not represent a normal worker. ‘The variation in actual times for a particular element may be due to the factors both internal and’ external. The external factors which are not in control of work study man are: ‘* Variation in the quality or other characteristics of the material used even though it is in prescribed tolerance limit ‘+ Changes in the operating efficiency of tools and equipment within their useful life. * Unavoidable changes in methods or conditions of operations. * Change in working conditions like heat, light, dust, etc. Factors which are within control (Internal Factors) are: * Acceptable variation. in the quality of the product. * Variation due to operators ability. Variation due to his attitude of mind. syyil ) | =AAhe various methods of performance rating are: (1) Speed rating, (2) Westing house system of » ‘tating, (3) Synthetic rating, and (4) Objective rating. z ‘Speed rating: In this technique the speed of the movements of the operator is the only factor considered for performance rating. The speed rating is found by the observer by comparing pace ‘of operators working with his own concept of normal pace. An average worker is rated at 100%, better than average worker is rated at a figure higher than 100 and below average worker will be rated below 100. If a worker is rated at 125% it means that the spced is 25% higher than the observers concept of normal and rating of 80% means the worker is working 20% below the observers concept of a normal worker. In speed rating, the process of rating is confined to the comparison of speed of movements with concept of normal speed. On the basis of this assumy with training in developing the concept of normal in his judgement. Westing house method of rating: Westing house system utilises a set of criteria to measure the performance of the operators. The factors are: Skill, Effort, Consistency, Conditions. 1. Skill: Measures the workers proficiency in adhering to a given method, coordination of proper hand and eye movements, rhythm of the movements. The skill has been classified into six degrees, each degree indicating a specified class of skill within which an operaior performs the task. 2. Effort: Measures the speed with which the skill is ap] six degrees. sistency: Measures factors which affect the consistency cycle repeatedly within the same time. Elements wh in materials, hard spots, presence of foreign n, the rating process is made simpler and pace, the observer can become quite proficient plied. The effort is also divided into y of the operator to perform the ich affect the consistency are— elements. ConsistencINDUSTRIAL ENGINEERING *°~ v ibratior i Sonny, isons ike temper anures YiPFAKORS iy, | nd ition: Measure the extent to which the 20nd and conditions { and Noise affect the ‘operator's pectorparey skill, effort, consistency ate shown in Tralee a for a criteria of particular tay, Hi ‘AS Ber this system, the time study observer assign F8UNE ine, performance rating py | Wing Sil Yalucs are than obtained from Table 5.2 and est ‘lise the observed time. " Adding the four values and ‘adding the levelling factor to normalis tis Applied to the cycle time in case of a manual time times, safety mi Table 5.2: Performance Rating Table. (Westing poe Skill eSSi ve I +015 ‘ae Superskill +013 AS ue i +013 AD +012 a2 rn +011 BI Excellent 0:10 BS + 0.08 B2 +008 iy + 0.06 cr Good +0105 ec a i + 0.03 ce + 0.02 a 0.00 D Average 0.00 D eae aee | ~ 0.05 EI Fair = 004 El a | Hi = 0.10 £2 = 0.08 2 ii ~0.16 FI Poor ~ 012 FI Poor i = 0.22 F2 = 0.17 Fl ' Conditions Consistency + 0.06 A Teal + 0.08 A Perfect, +004 B Excellent +003 B Excellent +002 c Good +001 c Good 0.00 D Average 0.00 D ‘Average = 0.03 E Fair — 0.02 Bo Fair [ag F Poor = 0.04 F Poor Ilustration of Westing House Method: An observed time for an Operation is 0.05 minutes and the ratings are as follows: evo bed. Skill (Excellent) B2 Effort (Good) C2 Condition (Good) C Consistency (Good) C ‘The values for the ratings are assigned from vit cele pasar secs ih subtte vips\ hn i = 005 «113 = 0.0565 minutes Synthetic rating: The performance rating under this method is establis observed time of some of the manual elements with those of know: from predetermined motion and time studies (PMTS). The procedure is to make the time study in a usual manner and th for the elements with predetermined time values for the same elements, A ratio is Computed between predetermined time value for the element and actual time value for the element. This ratio is the performance index or rating factor for the operator for the particular element. hed by comparing m time values of the elements len Compare the actual time Performance rating factor, (R) is given by vas oA ; P = Predetermined time for elements (minutes) A = Average actual time value (selected time) for the same element ‘P’ (minutes) Objective rating: In this method, the operator’s speed is rated against a single standard pace which is independent of job difficulty. The observer merely rates speed of movement or activity, Paying no attention to job itself. After the pace rating is made, an allowance or a secondary adjustment is added to the pace rating to take care of job difficulty. Job difficulty is divided into six classes, and percentage is provided for each of these factors, The job difficulties as per the founder of this system—M.E. Mundel have been categorised into six classes as follows: 1, Amount of body used. 2. Foot pedals. 3. Bi-manualness, 4. Eye-hand coordination. 5. Handling requirements. . Weight. ae /. . ALLOWANCES Yi a ie normal time for an operation does not contain any allowances for the worker. It is impossible to work throughout the day even though the most practicable, effective method has been developed. Even under the best working method situation, the job will still demand the expenditure of human effort and some allowance must therefore be made for recovery from fatigue and for relaxation. Allowances must also be made to enable the worker to attend to his sonal needs. The allowances are categorised as: (1) Relaxation allowance, (2) Interference allowance, and (3) Contingency allowance. axation Allowance Relaxation allowances are calculated so as to allow the worker to recover from fatigue. Relaxation allowance is a addition to the basic time intended to provide the worker with the ity to recover from the physiological and psychological effects of carrying out specified der specified conditions and to allow attention to personal needs. The amount of intended to compensate the operator for the time n personal needs like drinking water,PRODUCTION MATAGE YR, ~ p i INDUSTRIAL ENGINEERING AN 4 ible Allowance. ing under poor environmen, Variable allowance is allowed to an operator who is no the job. Conditions that cannot be improved, added stress and strain in pep to an operator who is emgagey | ‘The variable fatigue allowance is added to the fixed allow \ditions. The amount of variat, a medium and heavy work and working under abnormal cont / 2 |) satiate allowance varies from organisation to organisation. Interference Allowance é sate the oper por tian allowance of time included into the work content of the job he ime machine / for the unavoidable loss of production due to simultaneous stoppage Acca cial jor being operated by him. This allowance is applicable for machine pment elt) ae Interference allowance varies in proportion to number of machines assig _( f The interference of the machine inctease the work content. Contingency Allowance 3 i Seragency allowances asmall allowance oftime which may be included ina sands time icet legitimate and cxpected items of work or delays, the precise measurement of which is uneconomical because of their in frequent or irregular occurrence This allowance provides for small. unavoidable delays as well as for occasional minor, extra work. Somme of the examples calling for contingency allowance are; * Tool breakage involving removal of tool from the holder and all other activities to insert NEw tool into the tool holder. * Power failurcs of small duration, * Obtaining the necessary should not exceed 5%. Personal Allowance ‘ools and gauges from central tool store. Contingency allowance 4_ WORK MEASUREMENT a 73 oh 4 Policy ae Policy allowances are not the genui i leq Gatins only ts eiBaaty denned (ati Part of the time study and should be used with: utmost ‘The usual reason for making the i Policy allowance is to line up standard times wi requirements of wage agreement betweer employers and trade unions. . a ; The policy allowance as defined by ILO. SA policy allowance is an increment, other than bonus increment, applied to a standara ‘ time (or to some constituent part of it, 2 s ? €-8 work content) to provide a satisfactory level of earnings for a specifi ance under exceptional circumstances. Policy allowance are sometimes made a; imperfect . functioning of a division or part of a plant.” Various allowances used to build the standard time is shown in Fig. 5.5. 5.8. COMPUTATION OF STANDARD TIME Standard time is the time allowed to an operator to carry out the specified task under specified conditions and defined level of performance. of standard time are as shown in Fig. 5.6. The basic constituents Ratir Cont. a Observed time factor allowance (performed at a pace |Besl greater than standard pace) 5 aad 5 Work content STANDARD TIME gy Fig. 5.6: How the standard timo for a simple manual ob is made up. Problem 1; The elemental times (in minutes) for 4 cycles of an ‘Operation using a stop watch Presented below: va So r Cycle time in minutes . 1 . 3 4 Te ei, 1s LS 13 14 Abichs 2.60 20 24 (26 a / a) 32) 34 0 3.4 ABE bdo 2 Helo 051 051 052 0.49 ‘Calculate standard time for the operation if ( Elements 2 and 4 are machine elements ther elements, the operator is rated at 110% allowances are 15% of the normal time, a: The normal times are shown in Table 5.3. hapa sith Voge sacissho ike lc1G AND PRODUCTION MAN * INDUSTRIAL ENGINEERIN lormal Time Table 5.3: Computation of N Tpaiing (A) | Normal time = py ae ea recat No. le Time tne (min.) fx Inet 05 110% 1.495 x 11 = 1564 | tsi] 1a We ee. 515 24 | 2.6 ae 110% 3.325 X 1.1 = 3.655 34 | aa 3.325 be ts | 12] aa} a2 1175 oe (FSO SEIS seq f 051 | 052] 04 0.505 =9.531 568 + 2.575 43,658 + 1.175 + 0.555 =9. 9.531 + (0.15 x9.531)) = 10.484 minutes Normal time for the eyele Standard time ration. Table shows Problem 2: The following data refers to the study conducted for an oper: actual time for elements in minutes Cycle— 1 2 3 4 5 Elements 1 25 2 22 Gognqunlna ss 2 S.2 6,00 S561 so Sm a 5.0) 3 23-22) Ea 21 2.2 4 Pao SIM § 2890 was © Element 2 is a machine element, (4) Consider the observations as average time of that element, (G2) Take performances rating as 120. abnormal and delete the same if they are more than 2 % of Fatigue allowance—15%, contingency a 9peration and production per 8 hours shift, Solution: On observation, for element no. 1, cy ‘le no. 4, the cycle time is 5.4 min, which is more than 25% of the average time for that clement far “The eyele time 5.4 is ne; . a : jae No. Grete IE i 2 3 4 5 Time 1 25 21 22 754 2 62 6.00 6.1 59 2 3 at 3 23 20 21 au oe ra 4 24 21 28 3.0 23. 232 | Total observed eyele ime Normal time for the cycle‘PWORKMEASUREMENT, 78 (@ Production Rate Per Shitt ‘Total time per shift of 8 hrs — Tess personal allowance * © = $80min Effective production time "480 inih Production in 8 hrs shift = Time availablefor production = —450_ ~ 18.259 = 24.64 = 25 jobs. Problem 3: The following table shows a time study data. The times shown are continuous watch readings in minutes. Initial setting of stop watch is at 0.00. No. | Element Cycle Time Performance rating } J 2 J ae ‘Get two cases Os 42 8.6 1.05 Put parts into cases LS St 99 WAS 3._| Clamp two parts in position 3.8 81 126 0.95: ‘Take relaxation allowance as 15% and find the standard time. Solution: This is a cumulative timing method the cycle times are tabulated as shown in table. S.No. Elenient Cycle Time ‘Avg. time | Rating | Normal time | i 2 5 1, |Get two cases Os 04 Os 0466 | 1.05 | 0.49 2. | Put parts into cases 1.0 1s 13 1266 | 115 | 1.456 3.__|Clamp two pants in position | 2.3 24 27 2.466 095 | 2.343 Standard time = Normal time (1 + 0.15) = (0.49 + 1.456 + 2.343) (1.15) = 4.932 min. Problem 4: The observed times and the performance ratings for the five elements are given compute the standard time assuming rest and personal allowance as 15% and contingency allowance as 2% of the basic time. Element 1 2 3 4 5 Observed time (min) 0.2 008 050 O12 0.10 Performance rating 85 80 90 85 80 Solution: The normal time is computed from the observed time as shown in the table below: Element Observed time (minute) Rating Normal time (min) 85 02 % 85/100 = 0.170 80 08 x 08 = 0.064 90. 050x 09 = 0.450 85 0.12 x O85 = 0.102 80 110x 08 = 0,080 0.866's |ON MANAGEMENy ‘AND PRODU INDUSTRIAL ENGINEERING Ne rmal time per Piece = 0.866 min. Comat Porton allowance m 0.18 x 0.866% 0.01299 rs ontibgeacy allowanoe 0.62 0.886 2 ETA alae al allowance : on : ‘ard time per piece = Normal time/piece + Rest and pets + contingency allowance 1.866 + 0.1299 + 0.0173 .0732 minutes, Jements. The description Problem 5: A worker operating on a machine performs the ote standard time for the Cf clement, their observed time and ratings are given. Comp component, — 7 Relaxation Allowance | Element | Lescription Observed vime | Rating 10% A Position the job 0.25 80% i% B Switch “ON" and lower drill 0.09 a 12% c Drill hole 28 ee 10% D Raise drill and switch ‘OFF’ 0.05 80 11% Ez Remove job from jig 015 10 ‘Stiation: The relaxation allowance is given separately for each element $0 the’ elementwise standard time is to be computed and then added to together to get the standard time for the job. ‘The computation of standard time is shown the table: [ Btement | Observed time Rating | Normal tine | Relaxation allowance] Standard time (min.)| A 0.25 80. 025 «08 10 ee B 0.09 100 0.09 x 1 O11 0.099 c. 2.80 90 0.80 «0.9 09 2.746 D 0.05 80 0.05 x 0.8 08 0.043 Ez os ho 1s x14 1 0.183 —_"WORK MEASUREMENT Solution: ‘The normal time for each component is computed as shown in Table 5.4, Table 5.4: Computation of Normal Time a Element Observed time Rating Frequency Normal time am (2) (3) (4) (5) A 0.2 90 1 0.080 B 0.05 80 0.040 c 0.03 100, x 0.030 D 0.78 100. 1 0.7800 E 0.06 100 I 9.0600 F 0.05, 100 ‘ , 0.0500 G 0.02 85 us 0.0340 H 0.06 80 1 0.0480 1 aiG 90 1 0.0900 J 0.04 90 1720 0.0180 Normal time for the operation = 1.330 Standard time = Normal time + allowance -330 (1 + 0.14) 5162 min, Problem 7: Turning gear blanks on centre lathe involves the following elements. The stop watch data is given. Assuming the rest and the personal allowance as 13% and contingency allowance of 2%, calculate the standard time, Element Description Observation Rating Oe Fa 3 1 | Pick and place 02 146 5.22 649 14.25 90 2 | ‘ON’ Mic and tool approach 03 155 530 13.10 14,35 110 3 | Tum diameter 1.05 2.31 6.05 13.84 15.10 110 4 | Withdraw tool and stop Machine | 1.13 2.38 6.14 13.92 15.17 110 5 Release part and place it asidé 128 2.54% 6.29 14.06 15,32 95% Element No. | Observation No. 4, Foreign element 2.54 to 5.02 Element No. 5, Observation No. 2, Foreign element 6.29 to 12.98 Solution: Calculate the individual element times considering the stop watch readings. The times for the foreign elements are excluded from the corresponding elemental times, ‘The ‘individual timing are shown in table: Elemental time value in min. Average time (minutes) L Qual 3 | lily eae 0.20 0.18 0.20 0.2 O19 0.1940 0.09 0.08 0.12 0.10 0,0980 0.76 075 0.74 0.75 0.7500 0.07 0.09 0.08 0.07 0,0780 0.16 01S 0.14 0.016 0.1500 scomental by multiplying observed time by rating factor,79 Work Sampling | Predetermined "Sep Wack | lime Standards | Timing b Interruption of work operations Moderate Low Fairly high i E ‘Applicability: for physical, clerical, | Very good Average ‘Average professional work | Savings: How quickly how much Average to high | High Average to high | 10. | Usability: In Scheduling production, | Average to high | High High | evaluating performance | | W en requirements difficulty of | Average Average Average | furnishing data }0, WORK SAMPLING Q jork sampling was originally developed by L.H.C. Tippett in Britain in 1934 for the British Cotton Industry Research Board. Work sampling is a fact finding tool. Work sampling is defined as: \,_/A technique in which a statistically competent number of instantaneous observations are //Aaken, over a period of time, of a group of machines, processes or workers. Each /” observations recorded for a particular activity or delay is a measure of the percentage of “time observed by the occurrence.” _ Work sampling has three main application . Activity and delay sampling: To measure the activities and delays of workers or machine. /~ eg, the percentage of time in a day, a person is working and the percentage that a person is not working. i 2. Performance sampling: To measure working time and non-working time of a person on ‘4 manual work, and to establish a performance index or performance level for a person during his working time. 3. Work measurement: Under certain circumstances, to measure a manual task, that is, to 7 // eStablish.a time standard for an operation. bed gaan Procedure for Conducting a Work Sampling Study ‘ ‘The following steps are involved in'making sampling study: 1. Decide on the objective of the study: It is very important to first set the objectives of study as the duration of the study, number of observations, the design study sheet and clemental breakdown depends upon the objective . Obtain the approyal of the supervisor of the department in which work study is to be con- ducted. Make sure that the operators to be studied and the other people in the department understand the purpose of the study. Obtain their cooperation, . Decide upon work and delay elements: Work and delay elements represent the headings under which the observations are to be recorded. The nature of the work and delay ele- ‘ments differ from company to company depending upon the objective of the study and the Decide upon the duration of the tive, number of observers, A study: The duration of study depends upon the objec- the accuracy desired and the frequency of occurrence of the ine the desired accuracy of results: This may be stated as the standard error of a se of desired acura praca vel is also to be stated.ROUEEror m = ND PI inovsrrua ENGINEERING A ‘es 7. Design th (a) Decors ae of observations to be made. (2) Determine number of observers need. cop the study: (©) Determine the number of days or shifts tions, and. () Make the detailed plans for taking observa Bee dus, (©) Design the observation form. analyse and summ or 8. Make the observations according to the plan, the end of the study = 9. Check the accuracy or precision of the data at 10. Prepare the report and state conclusions. Design of Work Sampling Stud; 1 Diaries ae Required Number of Observations The number of observations depends upon: * Activity percentage (P) ae * Limits of accuracy (4) — * Confid | — is Nahar oe atic at a confidence level of 95% is given by Co | wet@=) j ‘ Lae 4 cha Setting Performance Standards with Work Senet: nee fe lure to develop performance standards are detaile ‘i ; ee the san Pe sampling study is carried out forthe operation whose standard : Lime is to be determined. Observations are made at random intervals of time and are noted, to: jntther subject understudy is working or idle are noted. Reasons for delays and interrup. a tion are recorded. The observations of production activity (working) are divided into my chine working and hand working. Operators pace of performance is noted down whey manual working is observed. 2 Rating index: Individual performance ratings are averaged out to obiain an overall rating index. 3. Production quantity: Number of mined from production reports, 4 Overall time per unit (T.): Its calculated by dividing Production time (duration of study) by number of pieces produced, 5. Effective time per unit (T.): Overall time per piece includes even the Productive activites. Overall time is multiplied by percen 2 of Bet the effective time per piece. Te bredact Let T, = Overall time per piece N= Total number of observations, Ny = Observations of Produ Nn + Np = Observations of machine controlled : work. Nj_= Observations of hand controtied work, + Effective time per piece (7,) = arr i Per piece (T.) = Overall time / nit X production Pieces produced during the period of study are deter: 1 spent on un- ive activities 10 ction activity, Di activity % =N ive time per piece (T.) can be compared a , effective time is broken down ints mane ate of Stop watch study. To get . ‘machine controlled time.WORK MEASUREMENT 81 and Manual (hand) controlled time (7) 0 = x or (T.-T) Normal time per piece Let R be the performance rating index Hand controlled portion of effective time Machine controlled effective time a eeen Rating is applied to only manual (hand controlled) elements Standard time per piece Standard time is calculated by adding relevant allowances to the normal time. Normal time = Control Charts in Work Sampling Control charts are/used in work sampling to continuously keep track of particular activity. A chart is employed where the proportions of activities obtained from work sampling. are represented as a function of time. The points in the chart gives the idea of the trend and the Presence of out of control condition if exist. An investigation is made if the point falls outside the control limits. Control chart is useful aid to a work sampling man. Adyantages of Work Sampling Compared to Time Study MA 5 Many operations or activities which are im practical or costly to measure by time study can ly of several operators or machines mey be made by a a work sampling study instead or weeks thus reducing the chances of be measured by work sampling. ALusually requires lesser man-hours and costs less to make of making a continuous time study. . Any interruption during study will not affect the-results, .. Work sampling measurements may be made with a pre-assigned 2. A simultaneous work sampling stud: single observer. 3 a Observations may be taken over a period of days day-to-day variations affecting results, degree of reliability. + Work sampling studies are preferred to continuous time studies by the operators being studied. . A stop watch is not needed for work sampling studies .. Work sampling studies cause ts ee and are les tedious, intages of Work Sampling — Le (| >) Work sampling is uneconomical for short cycle jobs. 2. Itis also uneconomical for studying a single workman or even small machines. group of workmen or ing on seeing the observer, making the dy of very little value. ions are likely to produce inaccurate results, for speed of the operator.SSE 1 PRODUCTION 001, 82° ENGINEERING ta INDUSTRIAL pines, A work sampling styg BG = 9 fe se machi study conducted reveaic} roblem 1: 4 job order shop has 12 general PUIPO™ The sy My Fre shoP- : the entire 5 T designed 10 know the ineffective time of fe the accuracy of sq Ineffective time is to the extent of 30% required to hav aT the are ‘Ompute the number of observations that Confidence level of 95%. 4u-P) ‘Solution: Number of observations (N) = a / a? yn P= t i ) ~~ \ctivity percentage > ee a 0.30 (in the problem it is the ineffective A= Accuracy required = 0.02 ‘Substituting the values in the equation, ye sea=03)- (0.02)? «0,3 (<= 23333 observations i tandard tim Problem 2: A work sampling study was conducted to eee the stan © for ay ©Peration. The observations of the study conducted is given below: Total number of observations 160 —— Manual (hand controlled work) = 14° Machine controlled work = 106 Machine idle time =40~ Average performance rating = 80% No. of parts produced =36 Allowance for personal needs and fatigue = 10% Study conducted for 3 days vailable working hours/day = 8 hrs ig Calculate the standard time per piece. Solution: ‘Total number of observations (N) = 1606 No. of observations of product tion activity (V,) = 120 Observations of machine controlled work (N) = 106 ss Observations of hand controlled work (manual) Ny, = 14 r Average performance rating: R= g066- Duration of study =3 days (Each day 8 hour) eh maa Ne 0. of pars producediday i (@) Overall time per unit (1, eer rgany oeiat WORK MEASUREMENT — = 40x 006419 = 30min i). Breakdown of effective time controlled portion Tm = machine controlled portion of the effective time per piece Tn Tex Nn Nn+Ny 106 ‘ 106 414 7 26:5 min. Hand controlled portion of effective time per piece (Ms) Nn Ts - Wat Ny er piece into machine controlled portion and hand =Tx =30% 14 =e; = 3.5 minutes Normal time per piece ‘Normal time per piece = Machine controlled portion of effective time per piece + Normal time of hand controlled portion of effective time/piece = Tm + (Ty R) = 265+3.5x08 = 29.3 mi Standard time per picce= Normal time + allowances 29.3 (1 +0.1) = 32.23 min. 7 ‘3: A work study was conducted in a machine shop. The data has been recorded, | number of observations = 2000 4 1 lo activity = 500 The ratio between manual to machine=3:1 . / \ portion of the activities 7 Average performance rating = 85% xy Total number of pieces produced = 120 during study uration of the study ~ 60 hrs. Calculate the standard time/ piece assuming 15% relaxation allowance. Solution: (i) Overall time per unit (T,) Duration of stud ~ No. of pieces produced during study 120 T,ERING AN > ET je rae INDUSTRIAL ENGIN! es break the effective time ing / ti trolled activi chit ing iso be applied to only husnan com s*hine controtied and hivan conlled: areca “ Machine controlled time per pieve ~ (Zn) peal land controlled time/piece ce we = Normal time per piece = 7m + 7 + 18 x 0.85 = 21.3 min. F ances Standard time per piece (,) T, = Normal time + allows = 21.3 x (1+ 0.15), = 24.5 min. 18 min. sindlBF ons Comiponcn, Cte 4: The following data refers to a sampling study of produc! 2. Number of operators = 10 [ 1. Duration of data collection 5 days @ 8 hours per day 3. Allowances given for the process = 15% f fe 4. Production quantity in 5 days = 6000 components / 5. Sampling data collected 4 5 Days is, span Ma 225 No. of observations 230 «240 «200-180 a Occurrence of activity 200 190 170 «1502 Calculate standard time of production of the component if average performance rating of thy operator is 120% and the entire operation is manual, ‘Solution : No. of observations @ No. of observations (W, (working) Overall time per piece = T, = Total time worked No. of units produced = SX8x10x60 = 6000 : = 40 min, Effective time per picce (T;) = 1, x Ne ox 920 = 40% T0975 = 34.23 Normal time = Observed time x Rating = 34.23 x12 = 41.07 min, ‘Standard time = Normal time (1+ allowances) 9 = 41.07 (1 +0.15) in 24 Seis 47.24 min, f the job At a defined level of performance mg ta Mi lia ah ac eae isi 4ity WORK MEASUREMENT 85 iar, Analyse jobs into constituent elements (activity 1 ding toe be applied if ey. nts (activity grouping to enable ‘synthetic elements to 3. Select appropriate basic mes from synthetic data covering contingent factors, & Select and apply synthetic data cavering contingent factors 2 Nerify details of elemental analysis for job method and condition & Total the basic times, rating and allowances to compute standard time for the job. Advantages Although synthesis was originally developed to establish the work content for short batch Production and jobbing work, it can be used in place of time Siu Study to determine times for many other types of work including repetitive work Provided necessary data is available. The main advantage of synthesis is the reduced cost af application. By means of synthesis it is possible to establish times, which a e equally satisfactory for planning and proguctioff control purpose. ee oe MOTION TIME ANALYSIS (PMTS) oe Meee. indard time for a job or an operation may be established by time study, by work sampling or by the usé of predetermined times, A predetermined time system consist of a set of time data and a systematic procedure which analyses and subdivides any manual operation of human, task into.motions, body motions, or other clements of human performance, and assigns to ‘each the appropriate time value. This system of time data was originally developed from extensive studies ofall aspects of human performance through measurement, evaluation and validation procedures. (Predetermined times. are the tabulated values of normal ti rerform individual movems }oving an arm from one position to another, etc..The total times neéded to Perform the operation is the sum of the times nigeded for basic motions. By arranging the basie motions and aggregating associated times. an existing task can be analysed or a proposed operation can be timed without actually performing it. Factors to be Considered While Using PMTS * Application of PMTS requires that an operation which is to be measured is divided into basic _motior jc system selected. Each system has its own specific rules and procedures which must be followed cxacily. Most PMTS do not include allowances, so those are added as in stop watch study, Atthe time of application of PMTS for the first time in a company the adjustment should be made if necessary, in order to match company’s performance level which is one time activity PMTS can be classified as to accuracy level, time required for application and the extent of met lescription, is (MTA): A. B. Segur of Oak Park Illinois was one of the first to sStablish the relationship between the time clement and the motion itself. Segur stated that the method must be well defined before an attempt is made to time-analyse the motions involved. He ‘veloped a table of improvement principles involying many of his basic motions such as hold, L Preposition, position, avoidable delay and balance delay. The improvement principle here is in the elimination of the left hand as a holding device. In MTA, motion values are CWE): This is first system of PMTS to have a general use with the work tn. determine I the work factor time for manual tasks by the use of analysis of each of the task is made based upon the ident| 86 AND PRODUCTION MANAGEY,, eERING STRIAL ENGIN! ‘ | ee it of measure: Then the standarg . - re ee YETabIAs or Wenn and the use of work factor as @ uni : URUREES Ut modes vane applied to each motion. 1. aalOr Variables of work factor system are: ; 1. Body member istance, 3. Manual control, 4. Weight or resistance, ris ystem is applicable to highly repetitive system. Methods Time Measurement (MTM) Methods Time Measurement procedure is defined 28: method Into the basic motion, ' “A Procedure which analysis any manual operation jetermined time standard whet is Fequired to perform it and assigns to each motion a pred r which it was made,” determined by the nature of the motion and the conditions unde’ and it establishes methog, The primary objective of MTM is to improve methods of operation Stk Accurately before production staris by determining correct times and oper: Basic Motion Time study (BMT) i | Basic motion time study was developed and is thought by J.P. Woods baereanrion a Toronto, Canada. Like other Predetermined motion time system, all manual activity has bec, divided into basic motions. is and Gordon, is defined as “Any motion which starts from igh space, and ends at rest.” (Type 2) Move (Type 3) Turn The body motion and symbols are very similar to the body motions employed by MTM. The nly difference lies in the step, where the distance measured ip the distance the foot travels. A ges of PMTS - Short cycle jobs can be timed accurately. 2. Rating, the most difficult part of time study is not necessary, | 8. The results obtained are consistent, 4. A reasonable estimate of work content can be obtained before the task is actually carried - out. lOD TIME MEASUREMENT (MTm) The objective of MTM is the establishment of rt the scientific measurement of human effo, Method Time Measurement is defined'as "Qeible, understandable and acceptable data for ined time standard which is conditions under which it is made.” Developing effective methods and plans in advance of beginni, m wving existing methods. =" ne mceinng production, shin; bes £1 tsar wansant87 MIM procedure recognises: — + Eight manual movements, * Nine pedal and trunk movements, + TWo ocular movements, ‘Thus there are nineteen fundamental motions to be considered in the establishment of any ober apanem. Whe time for eack of these mations ate determine? not only by the physical conditions involved in the mental conditions, Unit of MTM is TMU. One TMU = 0.0006 minutes. CONVENTIONS FOR RECORDING MTM DATA 0 simplify recording’ individual MTM methods, a system of MTM conventions has been developed. By using this system, every detail of the motion can be easily recorded. For example: Reach: Reach is the basic clement when the predominant purpose is io mune the hard or finger ie a Gestination. The time for making a reach varies with (1) condition (nature of destination), (2) length of the destination, (3) type of reach, Classes of reach: There are five classes of reach. The time to perform a reach is affected by the nature of the object towards the reach is made, Case A Reach: to object in fixed location or to object in other hand ot on which other hand rests, Case B Reach: to object whose general location known. Location may vary slightly from cycle to cycle, Case C Reach: to object jumbled with other objects in group, Case D Reach: to very sinall object or where accurate grasp required Case E Reach: to indefinite location to get hand into position for body balance or next move or out of the way, The length of @ motion is the true path, not just the straight line distance between the two terminal poinis. For example, R 8 C represent Reach 8 inches, case C. R 12 A represent Reach 12 inches, case A. ‘The values of TMUS for these symbols are obtained from MTM tables ‘Similarly, the details for other symbols: Move, Turn, Apply pressure, Grasp, Position, Release, Disengaive. Eye motions, Body leg and foot motions are obtained from the MIM tables (published), MTM VERSIONS rec ntTM-1 is the most accurate. Provides the most detailed method detailed deseription but uires the longest time for analysis. __ MT™M-2 was developed by constructing motion combinations from basic motion of MTM-1 The analysis can be done more quickly than MTM-1 MTM-3 is the simplest of the MTM systems and is intended fot use with long cycle short run d of analysis is seven times faster than MTM-1, M5 Should not be used for analysing manual motions with a frequency higher than 10 oré CTION MANAGE INDUSTRIAL ENGINEERING AND POPU ial ‘(CHNIQUE” (Most) 'NTROD, UENCE TECHNIC U ie N SEQ! ig new SyStem“Was bro, Hp 2UCTION To ‘MAYNARD OPERATION # system and this 1 tahoe Fectiog part aNd Company has introduced Mi ‘de recognition tio Level 2 tS 1s that are like srs sei os nama pet to mt be Performed lesser than 150 time per week. An operation in this ¢ to more than s ve » rformed mor, , } Basic MOST. a a feet level, operations that are ee ae MOST. s 150 times but lesser than 150 times per week should be analysed wit iled and precise methods Mini MOST: At the lowest level, mini-MOST provides the most detai ny operation likely ig | fualysis. In general, this level of devail ast precise is required to analyse any y { be repeated more than 1500 times Per week. DEFINITIONS OF SOME TERMS RELATING TO MOST SYSTEM 1. Operation: It is a Job task consisting of one or snore ore eiament tially in one location or the performance of any planned work. 2. Sub-operation: A ib Seals is desecrate, logical and measurable part of an ‘operation, The content of such 4 sub-operation may vary depending on type of operation requirements and application area 3. Time standard: It is the total allowed time including manual time, process time and al- lowance that it should take to perform a task or de ajob. 4. Activity: It is defined as the series of logical events that take place when an object is moved, observed or treated by hand, a tool or transportation device, 5. Method step: A method step is a descriptive formulation of an activity one or more steps Organised in sequence according to the applied method i operation usually done essen. . Movement of an obj, F ins in control with a surface or it Is attached to another Object cin unr bee ase ® The TOOL USE SEQUENCE (for the use of Common hand tools),