IM-UNIT 3- METHOD

STUDY
-Dr. Anubhuti Nigam
Method Study

■ Definition:
– Method study is the systematic recording and critical examination or existing
and proposed ways or doing work as a means or developing and applying
easier and more effective methods and reducing cost.”
■ Method study enables the industrial engineer to subject each operation to
systematic analysis.
■ The main purpose of method study is to eliminate the unnecessary operations and
to achieve the best method of performing the operation.
■ Method study is also called methods engineering or work design.
Method Study

■ Method study is the process of subjecting work to systematic, critical scrutiny to

make it more effective and/or more efficient. It is one of the keys to achieving
productivity improvement.
■ It was originally designed for the analysis and improvement of repetitive manual
work but it can be used for all types of activity at all levels of an organisation.
■ It is mainly concerned with developing a better method of doing a job.
■ It increases efficiency by removing unnecessary operations, avoidable delays and
other forms of inefficiencies.
Objectives and Scope

■ The objectives of method study are:

1. To record and analyse true facts regarding the situation under study.
2. To examine the facts critically
3. To develop best possible solution under given circumstances.
■ Scope of method study:
1. Is not limited to manufacturing industries only.
2. It can be effectively used in service sector, in offices, hospitals, banks and other
service organisations.
Basic Procedure and Steps involved

■ The process includes the following main steps:

1. Select (the work to be studied);

2. Record (all relevant information about that work);
3. Examine (the recorded information);
4. Develop (an improved way of doing things);
5. Install (the new method as standard practice);
6. Maintain (the new standard proactive).
1. SELECTION OF JOB FOR METHOD
STUDY
■ Work selected for method study may be an identified problem area or an identified
opportunity.
■ It may be identified through a systematic review of available data, normal monitoring
or control processes, high levels of dissatisfaction and complaint or as part of a
change in management policy, practice, technology or location, and usually because
it meets certain conditions of urgency and/or priority.
■ Before any method study investigation is begun, it is necessary to establish clear
terms of reference which define the aims, scale, scope and constraints of the
investigation.
2. Record

■ The Record stage of method study involves gathering sufficient data (in terms of
both quality and quantity) to act as the basis of evaluation and examination.
■ A wide range of techniques are available for recording; the choice depends on the
nature of the investigation; the work being studied; and on the level of detail
required.
■ Many of the techniques are simple charts and diagrams, but these may be
supplemented by photographic and video recording, and by computer based
techniques.
■ Especially with "hard" (clearly defined) problems, method study often involves the
construction and analysis of models, from simple charts and diagrams used to
record and represent the situation to full, computerised simulations.
Recording Techniques for Method Study

■ Depending upon the situation following charts and diagrams are used as recording
techniques:
A. Charts indicating Process Sequence
• Outline process chart
• Flow process chart
• Two-hand process charts
B. Charts using Time Scale
– Multiple Activity Chart
– Simo chart
Recording Techniques for Method Study

C. Diagrams indicating Movements

– Flow diagram
– String Diagram
– Cyclegraph- for those movements which are too fast to be traced by human eye.
– Chronocyclegraph- gives the direction and the speed of movements
– Travel chart
Symbols used in flow charts
Outline Process Chart
Flow Process Chart
Two-hand process charts
Micro-motion Study and Memo-motion
Study:

■ Micro-motion study is carried out for very short cycle, highly repetitive operations.
The operation is filmed at 960 to 1000 frames/minute and the film is analysed for
frame for the purpose of method improvement. The study is very costly.
■ Memo-motion Study:
– To a cine-film-camera—a timing device is connected which at 60 frames per
minute only. This study cost 6 percent of the cost of micro-motion Study.
Fundamental motions and Therbligs

■ Therbligs comprise a system for analyzing the motions involved in performing a task.
■ The identification of individual motions, as well as moments of delay in the process,
was designed to find unnecessary or inefficient motions and to utilize or eliminate
even split-seconds of wasted time.
■ Frank and Lillian Gilbreth invented and refined this system, roughly between 1908
and 1924.
■ He developed a set of 17 smaller hand motions which could be combined to give the
complete motion.
■ These smaller motions were termed THERBLIGS after his own name Gilbreth when
spelled backward.
Simo Chart
■ SIMO is an acronym for Simultaneous-Motion Cycle.
■ The chart is used in conjunction with Therbligs to study the detailed activity of a
worker, to capture how long the operation takes, and what activities are being
performed by each hand.
■ It is one of the tools used by Frank and Lillian Gilbreth. The table separates and
documents the left and right arm under research in a visual table format.
Examine

■ Examine
■ The recorded data are subjected to examination and analysis; formalised versions of
this process are critical examination and systems analysis.
■ The aim is to identify, often through a structured, questioning process, those points
of the overall system of work that require improvements or offer opportunity for
beneficial change.
Develop

■ Develop
■ The aim here is to identify possible actions for improvement and to subject these to
evaluation in order to develop a preferred solution.
■ Sometimes it is necessary to identify short-term and long-term solutions so that
improvements can be made (relatively) immediately, while longer-term changes are
implemented and come to fruition.
Install

■ Install
■ The success of any method study project is realised when actual change is made 'on the
ground' - change that meets the originally specified terms of reference for the project.
Thus, the Install phase is very important.
■ Making theoretical change is easy; making real change demands careful planning - and
handling of the people involved in the situation under review.
■ They may need reassuring, retraining and supporting through the acquisition of new
skills.
■ Install, in some cases ,will require a parallel running of old and new systems, in others, it
may need the build-up of buffer stocks, and other planning to manage the change. what
matters is that the introduction of new working methods is successful.
Maintain

■ Maintain
■ Some time after the introduction of new working methods, it is necessary to check
that the new method is working, that it is being properly followed, and that it has
brought about the desired results. This is the Maintain phase.
■ Method drift is common - when people either revert to old ways of working, or
introduce new changes. Some of these may be helpful and should formally be
incorporated; others may be inefficient or unsafe.
■ A methods audit can be used to formally compare practice with the defined method
and identify such irregularities.
Framework for method study