Unit - I (Introduction to Industrial Engineering)

METHOD STUDY METHOD STUDY

Method study – Systematic recording and critical Other Names for Method Study:
examination of existing and proposed ways of doing work, as a
means of developing and applying easier and more effective  Methods Engineering
methods and reducing costs [British Standards Institution].  Works Science
Method study is essentially concerned with finding better  Work Design
ways of doing things. It adds value and increases the  Job Design
efficiency by eliminating unnecessary operations, avoidable
delays and other forms of waste.  Work Methods Design or Work Measurement
 Motion And Time Study.

RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE

METHOD STUDY Scope: METHOD STUDY Objectives:

Lies in Improving Work methods and Operations analysis such 1. Improvement of processes and procedures
as: 2. Improvement in the design of plant and
1. To improve work methods and procedures equipment
2. To determine the best sequence of doing work 3. Improvement of layout
3. To smoothen material flow with minimum of back tracking 4. Improvement in the use of men, materials and
and to improve layout machines
4. To improve the working conditions and hence to improve
labor efficiency 5. Economy in human effort and reduction of
unnecessary fatigue
5. To reduce monotony in the work
6. To improve plant utilization and material utilization 6. Improvement in safety standards
7. Elimination of waste and unproductive operations 7. Development of better working environment.
8. To reduce the manufacturing costs through reducing cycle
time of operations
RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE
Unit - I (Introduction to Industrial Engineering)

METHOD STUDY Applications:

ADVANTAGES OF WORK STUDY

i. To improve work methods and procedures

 Higher productive efficiency.
ii. To determine the best sequence of work
iii. To smoothen the material flow and back tracking in  Create better employee-employer relations.
layout  Provide better service to customers.
iv. To reduce monotony in the work
 Provide better working conditions to the
v. Elimination of waste and unproductive operations
vi. To reduce the manufacturing costs through cycle time employee and employer
reduction

120 RAMESH KT, DEPT of IEM, BMSCE

METHOD STUDY STEPS:

Videos of Method Study 1. Select the job or process to be studied.
2. Record all relevant facts about present method.
3. Examine the recorded facts critically and challenge
Video 1: Video 2: everything that is done (purpose, Place of sequence and
(Micro-motion study) (Methods) method of performance.
4. Develop the most efficient, practical and economic method.
Comparison Garment Industry 5. Evaluate different alternatives to develoing a new imoroved
method comparing the cost-effectiveness of selected proposed
method with present method and their performance
6. Define the new method to those concerned (i.e.
Video 3: Management, Supervisors and workers) .
F-1 Pit stop 7. Install the new method as a standard practice and train
the persons involved in applying it.
8. Maintain that standard practice.
RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE
Unit - I (Introduction to Industrial Engineering)

Selection of jobs for Method Study: Select – Where to Look

The job selected for method study are based upon the following
considerations:
• Poor use of resources
• Economic considerations • Bad layout
Select

- Bottlenecks • Bottlenecks
Record

- Movements of material over long distances • Inconsistent quality Examine

- Operations involving repetitive work • High fatiguing work Develop

• Technical considerations Evaluate

• Excessive overtime
- Relatively straight forward
• Employee’s complaints Define

- Based on the technical knowledge of the process Install

• Human considerations Maintain

- Most difficult to foretell – because of mental and
emotional nature.
- Select an unpopular job for method study.
RAMESH KT, DEPT of IEM, BMSCE

Select – Economic Considerations Select – Technical Considerations

Will it pay to begin, or continue, a method study Desire to acquire more advanced technology
Select Select
of this job?
Record Record

• Key profit- generating operations Examine • Extensive paperwork Examine

• Key costly operations Develop • Repetitive work (automation) Develop

• Repetitive work Evaluate • Hazardous work Evaluate

• Long travels Define • Inconsistent quality Define

• Excessive overtime Install Install

Maintain Maintain
Unit - I (Introduction to Industrial Engineering)

Select – Human Considerations Select – Limiting the Scope

Workers satisfaction/resentment Setting boundaries and determining content

Select Select

Record Record

• Satisfaction level Examine • One operation or a sequence Examine

• Start with non-controversial jobs Develop • The whole operation or part Develop

• Health Safety & Environment (HSE) Evaluate • Which aspect: worker, materials, equipment, … Evaluate

etc.
Define Define

Install Install

Maintain Maintain

Select – Possible Results Select – Pareto Analysis (80 – 20 Rule)

• Increased production rate

Select Select
• Reduced cost
Record Record
• Less labor, materials, or equipment
Examine Examine
• Improved quality
Develop Develop
• Improved safety
Evaluate Evaluate
• Reduced scrap
• Improved standards of cleanliness Define Define

Install Install

Maintain Maintain

A rule of thumb that states that 80% of outcomes can be

attributed to 20% of the causes for a given event
Unit - I (Introduction to Industrial Engineering)

Record Method study charts and diagrams

• It is the phase of data collection. • Charts indicating process • Charts using a time scale
sequence
• Data is relevant facts pertaining to the existing method - Multiple activity chart
- Outline process chart (OPC)
which are collected and recorded to carry out the - SIMO chart
Select - Flow process chart (FPC)
investigation. - PMTS chart
Record
– Man, Material and
Equipment type
• Recording Techniques depend on type and nature of Examine
- Two-handed process chart
the data. Develop

Evaluate
The broad techniques are • Diagrams indicating movement
Define
 Charts – for process and time records - Flow diagram - Chronocyclegraph
Install
 Diagrams and Models – for path of movement of - Sting diagram - Travel chart
men or materials Maintain
- Cyclograph
 Photographics aids
132 RAMESH KT, DEPT of IEM, BMSCE

Why charts and diagrams? Examination

Select

Record

• It gives a complete picture of what is being done and helps Examine

to understand the facts and its relationship to one another. Critical examination is done by questioning Develop

technique. Evaluate
• Details on the chart must be obtained from direct
Define
This step comes after the method is recorded by
observation. Should not be from memory.
suitable charts and diagrams. Install

• Neatness and accuracy. Maintain

The individual activity is examined by putting a

• Increased value. number of questions (Primary and Secondary).

RAMESH KT, DEPT of IEM, BMSCE 135

Unit - I (Introduction to Industrial Engineering)

Examine- The Questions Examine- Secondary Questions

Purpose: What is actually done? Purpose: What is done?
Why is it necessary? Why is it done?
Place: Where? Why? What else might be done?
Select Select
Sequence: When? Why? What should be done?
Record Record
Person: Who? Why?
Examine With a view to: Examine
Means: How? Why?
Develop • Eliminate Develop

With a view to: Evaluate • Simplify Evaluate

• Eliminate Define Define

• Combine or Rearrange Install Install

• Simplify Maintain Maintain

Examine- Secondary Questions Examine- Secondary Questions

Place: Where is it done? Sequence: When is it done?
Why is it done there? Why is it done then?
where else might it be done? when might it be done?
Select Select
Where should it be done? When should it be done?
Record Record

Examine Examine

Develop Develop

With a view to: Evaluate With a view to: Evaluate

• Combine or Rearrange Define • Combine or Rearrange Define

Install Install

Maintain Maintain
Unit - I (Introduction to Industrial Engineering)

Examine- Secondary Questions Examine- Secondary Questions

Person: Who does it? Means: How is it done?
Why does that person do it? Why is it done that way?
Who else might do it? How else might it be done?
Who should do it? Select
How should it be done? Select

Record Record

Examine Examine

Develop By doing this questioning Develop

With a view to: Evaluate • Unwanted activities can be eliminated Evaluate

• Combine or Rearrange Define • Number of activities can be combined or re- Define

arranged
Install Install
• Method can be simplified.
Maintain Maintain
• All these will reduce production time

Develop Evaluate
Select Select

Record Record
The answer to the questions given below will result in One the new method is developed it is once again
the development of a better method. Examine
evaluated Examine

Develop Develop

The developed method should be: Evaluate Evaluate

 Practical & Feasible

Define Define
 Safe & effective
Install Install
 Economical and
 Acceptable to design, production control, quality Maintain Maintain

control and sales department

142 143
Unit - I (Introduction to Industrial Engineering)

Define Install
Once a complete study of a job has been made and a new This step is the most difficult stage in method study. Here the
method is developed, active support of both management
Select and trade union is required. Here the work study man Select

It is necessary to obtain the approval of the management Record

requires skill in getting along with other
Record
before installing it. people and winning their trust.
Examine Examine
Install stage consists of
The work study man should prepare a report giving details Develop (a) Gaining acceptance of the change by supervisor. Develop

of the existing and proposed methods. Evaluate (b) Getting approval of management. Evaluate
(c) Gaining the acceptance of change by workers and trade
Define Define
He should give his reasons for the changes suggested. unions.
Install Install
(d) Giving training to operators in the new method.
Maintain (e) To be in close contact with the progress of the job until it Maintain

is satisfactorily executed.
144 145

Maintain Process Chart

The work study man must see that the new method
• A chart may be a diagram, a picture or a graph which gives
introduced is followed.
 The workers after some time may slip back to the an overall view of the situation, say a process. a process chart
old methods which should not be allowed.
Select
records graphically or diagrammatically in sequence the
The new method may have defects. And should be Record operations connected with a process.
rectified in time by the work study man. By Periodical Examine
• All the details about the existing method/ process are
review . Develop recorded and represent in chart. This is done by directly
The reactions and suggestions from workers and Evaluate observing the work.
supervisors are noted for further improvement.
 The differences between the new written standard Define • Symbols are used to represent the activities like operation,
practice and the actual practice are found out. Install inspection, transport, storage and delay.
Reasons for variations are analysed. Changes due to lMaintain
valid reasons are accepted. The instructions are suitably
modified.
146
Unit - I (Introduction to Industrial Engineering)

Process Chart Symbols Process Chart Symbols

• The recording of the facts about the job or 1. Operation
operation in a process chart is done by using • A large circle indicates operation.
standard symbols.
symbols • An operation takes place when there is a change in physical
or chemical characteristics of an object. An assembly or
disassembly is also an operation.
• When information is given or received or when planning or
calculating takes place it is also called operation.
• Example:
Example: Reducing the diameter of an object in a lathe.
Hardening the surface of an object by heat treatment.

Process Chart Symbols

Process Chart Symbols
2. Inspection 3. Transport
• A square indicates inspection. Inspection is checking an • An arrow indicates transport. This refers to the movement of
object for its quality, quantity or identifications. an object or operator or equipment from one place to another.
• Example:
Example: Checking the diameter of a rod. Counting the When the movement takes place during an operation, it is not
number of products produced. of an object by heat called transport.
treatment. • Example: Moving the material by a trolley Operator going to
the stores to get some tool.
Unit - I (Introduction to Industrial Engineering)

Process Chart Symbols Process Chart Symbols

4. Delay or temporary storage 5. Permanent storage
• A large capital letter D indicates delay. This is also called • An equilateral triangle standing on its vertex represents
as temporary storage. Delay occurs when an object or storage. Storage takes place when an object is stored and
operator is waiting for the next activity. protected against unauthorized removal.
• Example: Raw material in the store room.
• Example
Example:: An operator waiting to get a tool in the stores.
Work pieces stocked near the machine before the next
operation.

OPERATION Process / OUTLINE PROCESS The conventions / procedure followed

Chart in preparing the chart
• An outline process chart is a process chart giving an over-all 1. Write title at the top of the chart.
picture by recording in sequence only the main operations and 2. Begin the chart from the right hand side top corner.
inspections. 3. Represent the main component at the right extreme.
4. Represent the sequence of operations and inspections by
• An operation process chart is a graphic representation of the their symbols. Connect them by vertical flow lines.
sequence of all operations and inspections taking place in a 5. Record the brief description of the activity to the right side of the
symbols.
process.
• It gives a bird‘s eye view of the overall activities.
• Entry points of all material, the sequence of all operations and
inspection associated with the process are noted in the chart.
Unit - I (Introduction to Industrial Engineering)

Ex: OPC for Repair of punctured scooter

The conventions / procedure followed tyre
in preparing the chart
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.

157

Ex: OPC for Assembly of Ball point Pen

Ex: OPC for assembly of Valve

158
Unit - I (Introduction to Industrial Engineering)

OPERATION Process /
OUTLINE PROCESS Chart: Flow Process Chart
example : manufacture of
electric motor
• 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.
7 1 • It is the detail version of outline process chart recording
all the event.
4
• Process chart symbols are used here to represent the
activities.

Objectives of flow process charts

General guidelines for making a flow process chart
1. The details must be obtained by direct observation—charts must not be • Set out sequence of flow of events occurring in the
based on memory.
process.
2. All the facts must be correctly recorded.
3. No assumptions should be made. • To study the event in a systematic way.
• To improve the layout.
4. Make it easy for future reference. • To improve material handling.
5. All charts must have the following details: • To reduce delays.
(a) Name of the product, material or equipment that is observed. • To eliminate, combine or rearrange the events in a systematic way.

(b) Starting point and ending point. • To compare between two or more alternative
(c) The location where the activities take place. methods.
(d) The chart reference number, sheet number and number of total sheets. • To select operations for detailed study.
(e) Key to the symbols used must be stated.
Unit - I (Introduction to Industrial Engineering)

Types of Flow Process Charts

STANDARD FORMATS USED FOR FLOW PROCESS CHART
Material or product type.
Man type.
Machine type or equipment.

Material or product type flow process chart:-

Records what happens to the material or product i.e. the changes the
material or product undergoes in location or condition (includes
operation and transportation).

Man type process flow process chart:-

Records the activities of worker or operator i.e. what a worker or
operator does. In this type of chart usually storage term is not applicable.

Machine or equipment type flow process charts:- Records

the manner in which a machine or an equipment is used.
164 165

Flow Process Chart for Writing a letter Flow Process Chart for Manufacture of the
(Man type - Typist) component (Material type)
• To officers cabin • Lying in store
• Take dictation • Transported to machine (10 m)
• To his own seat • Loaded on to the machine (2 Mins)
• Prepare for typing • Machining of component (5 Mins)
• Types letter • Moved to inspection bench (12 m)
• Checks for mistakes • Waited till inspector is free (15 mins)
• Place in file for signature • Component inspection (2 mins)
• To officer's cabin • Moved to stores (12 m)
• Places file for signature • Placed in the rack (0.5 Mins)
• Waiting during checking and signature • Stored in the rack
• Back to own seat
• Type envelope
• Put letter in envelope
• Keep letter in "out" tray 166 167
Unit - I (Introduction to Industrial Engineering)

Two-Handed Process Chart (or) Right Hand,

Left Hand Chart (or) Operator Process
Chart • Operation: Represents the activities grasp, position, use, release
etc. of a tool, component or material.
• It is the process chart in which the activities of two hands • Transport: Represents the movement of the hand or limb to or
of the operator are recorded. from the work or a tool or material.
• Motions of both hands of worker are Right hand-Left hand • Delay: Refers to the time when the hand or limb is idle.
chart recorded independently.
• Storage (Hold): The term ‘hold’ is used here instead of storage.
• It shows whether the two hands of the operator are idle or This refers to the time when the work is held by hand.
moving in relation to one another, in a timescale. • The activity ‘inspection’ by hand is considered as an operation.
• It is generally used for repetitive operations. Hence, the symbol for inspection is not used in this chart.
• Its main advantage lies in highlighting un-productive • Two-handed process chart can be used for assembly, machining
elements such as unnecessary delay and hold so that and clerical jobs.
analyst can take measures to eliminate or shorten them.

General guidelines for preparing the

Two-Handed Process Chart
1. Provide all information about the job in the chart.
2. Study the operation cycle a few times before starting to
record.
3. Record one hand at a time.
4. First record the activities of the hand which starts the
work first.
5. Do not combine the different activities like operations,
transport etc.

171
Unit - I (Introduction to Industrial Engineering)

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

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

172 173

Two Hand Process Chart for assembly of Nut

& Bolt
LEFT HAND RIGHT HAND
Idle Idle
Reach for bolt in bin 1 Reach for nut in bin 2
Grasp bolt head Grasp nut
Carry bolt to work area Carry nut to work area
Position bolt Position nut

Hold Bolt Place the nut on bolt

Fasten the nut
Release the nut

Carry assembly to bin 3

174
Release assembly
Unit - I (Introduction to Industrial Engineering)

Prepare A Two Handed Process Chart For A

Task of Sharpening the pencil Example of a Two-handed process
LEFT HAND RIGHT HAND
flowchart
Pick the Pencil Delay / Wait Fixing Screw on a Assembly
Hold Pick the sharpener
Insert the pencil in sharpener Hold
Rotate the Pencil Hold
Move away from the Move away from the pencil
sharpener

Check for Sharpness Delay

Place the Pencil Place the Sharpener

Idle Idle 176 177

Practical steps for travel chart

Travel chart (Movement Chart) implementation.
• It is a tabular record for presenting quantitative data about • Identify a number of departments to measure movement.
movements of workers, materials or equipment between any • Department name fills in row and column.
number of places over any given period of time.
• Measure the distance of departmental movement & fill the
• A travel chart is the easiest tool of method study & quickly travel chart table.
developed.
• Focused on max. distance of departmental movement.
• It is represented as a square matrix: columns indicating origin
of movement and rows the destination. Or vice versa. • Plan to minimize departmental movement based on
improvement ideas.
• Data could be travel time taken, distance traveled etc.
• Conduct the travel chart study in the proposed method.
• The main objective of travel chart is to identify the
unnecessary movements • Measure saving, if reduced movement between departments
then standardizes the proposed method.

RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE
Unit - I (Introduction to Industrial Engineering)

Multiple Activity Chart Or Man-machine

Chart Or Gang Process Charts

• A man-machine/ Multiple Activity 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 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.
• The chart shows the idle time of the worker or machine
Travel chart during the process.

RAMESH KT, DEPT of IEM, BMSCE

Multiple Activity Chart Or Man-machine Chart

Purpose of Multiple Activity Chart
• 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 • To detect the idle time on machine and workers
team work in production or maintenance. • To optimize work distribution between workers and
• Only two symbols are used in man-machine/ Multiple machines.
Activity Chart : • To decide no. of workers in a group.
• To balance the work team
• To examine the activities.
Working Idle • It is used for recording the complex movements of material
or men.
• Types of Multiple Activity Chart : • Used to find out the most economical route.
• Man – Machine Chart
• Man – Multi machine Chart
• Multi – Man Chart
• Multi – Man machine Chart
Unit - I (Introduction to Industrial Engineering)

Example on Man Machine Chart

EXAMPLE ON MAN MACHINE CHART
TIME MAN MACHINE TIME (Summary of Present method)
(MIN) (MIN)
0.2 Remove finished casting IDLE
cleans with compressed air CYCLE TIME(MIN)= 2.0
0.2 Gauge depth of slot on IDLE
surface plate
Man – Working Idle Time Utilization
0.4 PLACE in a box obtains IDLE
new casting Machine Time (min.)
(min.) (%)
0.2 Cleans machine with IDLE
compressed air
0.2 Locates castings in fixture, IDLE
starts machine
MAN 1.2 0.8 60%
IDLE Cutting slot 1 0.2
IDLE Cutting slot 2 0.2 MACHINE 0.8 1.2 40%
IDLE Cutting slot 3 0.2
184 185
IDLE Cutting slot 4 0.2

Example on Man Machine Chart

The operator engaged on the machine performs the

following operations:
1. Pick up the job, place it between the jaws of a hydraulic
vice (0.2 min).
2. Make the switch 'ON' to tightly hold the part (0.08 min).
3. Make the switch 'ON' start automatic cycle of the
operation (0.08 min).
4. Machining of the part on auto cycle (1.5 min).
5. Wait till the vice opens automatically (0.08).
6. Pick up the machined job from the vice (0.05).
7. Keep it in the tray (0.05).
Construct the multiple activity chart for the machining
operation.
186 187
Unit - I (Introduction to Industrial Engineering)

Example on Man Machine Chart (Improved Method)

EXAMPLE ON MAN MACHINE CHART
TIME MAN MACHIN TIME
(MIN) E (MIN)
(Summary of Improved method)
0.2 REMOVED FINISHED CASTING CLEANS IDLE 0.2
WITH COM PRESED AIR
CYCLE TIME(MIN)= 1.4
0.4 CLEAN MACHINE WITH COMPRESED AIR IDLE 0.4

LOCATEES A NEW CASTING IN A FIXTURE IDLE

0.6
START MACHINE
0.6 Man – Working Idle Time Utilization
Machine Time (min.)
0.8 BREAKS SHARP EDGES WITH FILES CUTTING 0.8
(min.) (%)
CLEANS WITH COMPRESSED AIR SLOT 1

1.0 GAUGE DEPTH OF SLOT ON SURFACE CUTTING 1.0

PLATE SLOT 2 MAN 1.2 0.2 85.7%
1.2 PLACES CASTING IN A BOX PICKS UP CUTTING 1.2
NEW CASTING AND PLATE BY MACHINE SLOT 3

MACHINE 0.8 0.6 57.0%

1.4 IDLE CUTTING 1.4
SLOT 4

188 189

COMPARISION BETWEEN
PRESENT AND IMPROVED METHOD

CYCLE MAN IDLE MACHINE

TIME TIME(MIN) IDLE TIME (
(MIN) MIN)

PRESENT 2.0 0.8 1.2

METHOD

IMPROVED 1.4 0.2 0.6

METHOD

190 191
Unit - I (Introduction to Industrial Engineering)

Worker-
Worker-Machine Chart for a Coffee Store
Worker-
Worker-Machine Chart for a Gourmet Coffee Store

192 193

Multiple activity chart for doing three loads of

laundry
Flow diagram
Time Operator Machine 1 Machine 2
(Sec) Washer Dryer  It’s a top view of the work area correctly indicating the
45 Load clothes & detergent in Being loaded Idle positions of machining and other locations affecting the
machine 1 movement of subject.
1800 idle Run Idle  Therefore it gives “on-the-spot observation” of the paths of
45 Remove clothes from machine 1 Being unloaded Idle
movement of product sometimes using symbols of process
charts.

45 Load clothes into machine 2 Idle Being loaded

45 Load clothes & detergent into Being loaded Run
machine 1

1800 Idle Run Run

45 Remove clothes from machine 2 Idle Being unloaded

120 Hang clothes Idle Idle 195

Unit - I (Introduction to Industrial Engineering)

Conventions adopted are:

The flow diagram are used for the following
1. Heading and description of the process should be given at the purposes:
top of the diagram.
2. Other informations like location, name of the shop, name of the
person drawing the diagram are also given.
1. To remove unwanted material movement.
3. The path followed by the material is shown by a flow line.
4. Direction of movement is shown by small arrows along the 2. To remove back tracking.
flow lines.
3. To avoid traffic congestion.
5. The different activities are represented by the symbols on the
flow lines. (Same symbols used in flow process chart are used 4. To improve the plant layout.
here).
6. If more than one product is to be shown in the diagram
different colours are used for each path.

196 197

Construction:
 A scale plan or model on which a thread is used to trace 1. Draw the layout of the shop to scale in a drawing sheet
and measure the path of workers, material or equipment. 2. Mark the various work centres like machines, stores, work
 A thread is used to measure distance. bench etc. in the diagram.
3. Hold the drawing sheet on a soft board and fix pins at the
 Necessary that the string diagram be drawn correctly to
work centres.
scale, whereas regular flow diagram can be drawn only
approximately to scale. 4. Tie one end of a coloured string to the work centre from
which the movement starts.
 Thus, string diagram and flow chart can give clearest
possible picture of what is actually being done. 5. Follow the path of the worker to different work centre and
accordingly take the thread to different points on the drawing
 String diagram can be used to plot movements of material
board.
to know how far the materials travel.
6. At the end of the session note down the number of
 Most commonly, the string diagram is used for plotting movements from one work centre to another.
the movements of workers.
7. Remove the string and measure the total length of the string.
198 Multiply by the scale and get the actual distance of movement.
199
Unit - I (Introduction to Industrial Engineering)

Examples
Applications

1. It is used for recording the complex movements of Present Method

material or men.
2. Back tracking, congestion, bottlenecks, under utilized paths
are easily found out.
3. It is used to check whether the work station is correctly
located.
4. Used to record irregular movements.
5. Used to find out the most economical route
200

SIMO chart
FOLD

• Simultaneous Motion (SIMO) chart

DRILL+CUT • Based on film analysis, used to record simultaneously on a
RIVET common time scale the therbligs or group of therbligs
performed by different parts of the body of one or more
workers.
MARK • Micromotion form of the man type process flow chart.
OQC
• Primarily used for operations of short duration, often
performed with extreme rapidity.
IQC • At times, it is necessary to compile them from films made of
the operation which can be stopped at any point or projected
SHEET STACK in slow motion.
METAL END
START 202 RAMESH KT, DEPT of IEM, BMSCE
Unit - I (Introduction to Industrial Engineering)

SIMO chart
Videos of Method Study
• The movements in SIMO chart are recorded against time
Video 1: Video 2: measured in “winks.”

(Micro-motion study) (Methods) • 1 wink = 1/2000 minute.

Comparison Garment Industry • These are recorded by “wink counters” placed in such a
position that it can be seen rotating during the filming.
• Some SIMO charts are drawn up listing the fingers used, wrist,
Video 3: Video 4: lower and upper arms.

F-1 Pit stop PIZZA • The corresponding 17 therblig symbols are used for the activity.

RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE

SIMO Chart Symbols (THERBLIGS)

Video 1:
(Therbligs)

https://www.youtube.com/watch?v=souFzyZs2
gU&list=PPSV

RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE
Unit - I (Introduction to Industrial Engineering)

THERBLIGS Fundamental motions of right hand in

signing a letter.
i. Reach for pen.
ii. Take hold of pen.
iii. Carry pen to paper.
iv. Position pen on paper
v. Sign letter
vi. Return pen to holder.
vii. Position Pen in the holder
viii. Let pen go off,
ix. Move hand back to letter.

209

Sl. No Description of Motion Name of Therblig Notation Symbol

1 Reach for Pen Transport empty TE

2 Take hold of Pen Grasp G
3 Carry pen to paper Transport loaded TL
4 Position pen on paper Position P
5 Sign letter Use U
6 Return pen to holder Transport loaded TL
7 Position pen in holder Preposition PP
8 Let Pen go off Release load RL
9. Move hand back to letter Transport empty TE

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Unit - I (Introduction to Industrial Engineering)

Micro motion study Micro motion study

• The Speed of the camera used range from 960 to 1000 frames per
Micro motion study is the study of fundamental element or minute.
subdivision of an operation by means of a motion picture • Faster cameras may be used to study very fast hand motions or
camera and a timing device which accurately indicates the complex operations.
time interval on motion picture film. • Applicable for operations with very short cycles which are repeated
thousands of times.
Micro motion study provides a valuable technique for making • Goes into greater details to determine where movements and efforts can
minute analysis of those operation that are short in cycle be saved and to develop the best possible patterns of movements.
contain rapid movement and involve high production over a • Enables operators to perform the operation repeatedly with minimum
long period of time. For example. Sewing of garment, effort and fatigue.
assembly of small parts.
• The technique used for this typically involves filming the operation and
hence is known as micromotion study.
• Examples of operators studied could be cashier in the bank – routine
job of taking payment slips from customer and issuing cash!
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Micro motion study Use of films in micro motion study

• Based on the idea that human activity can be divided into Main advantages of films over visual methods are:
movements or group of movements (therbligs) according to • Permit greater detailing than eye observation;
the purpose for which they are made.
• Provide greater accuracy than pencil, paper and stop watch;
• The therbligs cover movements or reasons for the absence of
movement. • More convenient;
• Each therblig has specific color, symbol and letter for • Provide a positive record;
recording purposes. • Help in the development of the work study person.
• Therbligs refer primarily to motions of the human body at the
workplace and to the mental activities associated with them.

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Objective of Micro motion study Procedure/ Step in micro motion study

1. Filming the operation to be studied.
1. To find most efficient way of doing work 2. Analyzing the film.
2. Helps to study repetitive short cycle operation which 3. Charting the result of analysis.
cannot be studied by ordinary method. 4. Developing and improve method.
3. To train operator regarding motion economy. Filming :-
4. It is permanent means of keeping record of method. The filming speed is 16 frames per second with a 16
5. It assists in research project in the field of work study mm movie camera.
6. It helps to study complex activities of short duration
performed with extreme rapidity. Film Analysis:-
1.A Projector is used for analysis purpose.
2. Projector runs the films very slowly and film can
be stopped & reversed whenever required.

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EQUIPMENT REQUIRED

Cyclegraph
 A record of path of movements, usually traced by a
continuous source of a light on a photograph.
 The path of movement of a hand, may be recorded
1. 16 mm film. 2. Movie Camera. 3. wink counter. on a photograph by putting a ring carrying small
light on worker’s hand.
 A path of light resembling a white wire is seen.
 Later it is used with a stereoscopic camera to show
the path in three dimensions

Exposure meter. Motion picture projector with

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screen
Unit - I (Introduction to Industrial Engineering)

Light (bulb) attached to the Chronocyclograph

hand
 This is a development of the cycle graph by interrupting
the flow of current so as to obtain, in the resulting
sequence of flashes, a record of the time and direction of
the motions under observation. The resulting image was a
chronocyclograph.
 The path of light appears as a series of pear-shaped dots,
the movement being in the direction in which the dots
point.
 The spacing between the dots indicate the speed of
movement and show acceleration and deceleration.
 This is done by using a turning fork, which is vibrating at
a known speed, and connected with a “make and break”
contact.
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Chronocyclograph A woman demonstrating light tracking

hand motions.

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Unit - I (Introduction to Industrial Engineering)

Chronocyclegraph of Woman Staking Chronocyclograph of golf champion

Buttons

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Images of Cycle graph and Cyclegraph

Chronocyclograph
• A record of path of movements,
usually traced by a continuous
source of light on a photograph.
• The path of movements of a hand,
may be recorded on a photograph in
this way if the worker is asked to
wear a ring carrying a small light
which may make the trace on the
photograph.
• If the purpose is to record the path
over which the worker moves, this
light may be attached to the helmet.

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Unit - I (Introduction to Industrial Engineering)

Chrono-cycle-graph Memo – Motion Study

• The Speed of the camera used range from 960 to 1000 frames per
• A special form of cyclegraph in
which the light source is suitably minute.
interrupted so that the path • It is a time lapsed cine photography
appears a series of pear-shaped
dots. • Time interval lies between ½ sec to 4 sec.
• The pointed end of the pear • 10 to 20 mins recording may be compressed to 1 minute.
indicates the direction of
movement. • In addition to its use in industrial operations, it is used to study
• The spacing indicates the speed of many other operations such as check-in operations as airline
movement.
counters, the manner in which customers select items in the store,
• The application of these recording
techniques is limited compared to traffic flow on highways, and in banks.
the process flow charts and
• It costs less than micromotion study (only costs 6% of the cost of a
diagrams mentioned earlier.
micromotion study.
RAMESH KT, DEPT of IEM, BMSCE 229

Principles of Motion Economy (i) Use of the human body

• Concept was derived from Gilbreth later refined by Barnes,
Lowry and Maynard. When possible –
• Principles of motion economy provides a set of guidelines that will
help to determine work method, workplace layout, tools and 1. The two hands should begin and complete their movements at
equipment. the same time.
• The objective of motion economy is to Maximize efficiency, 2. The two hands should not be idle at the same time except
Minimize unwanted motions and Worker fatigue. during periods of rest.
3. Motion of arms should be symmetrical and in opposite
Classified as : directions and should be made simultaneously.
A. Use of human body. 4. Hand and body motion should be made at the lowest
B. Arrangement of the workplace. classification at which it is possible to work satisfactorily.
C. Design of tools and equipment. Hand Motions, Wrist Motions, Forearm motions, Upper arm
D. Time Conservation (New) motions and Shoulder motions
5. Momentum should be employed to help the worker, but
should be reduced to a minimum whenever it has to be overcome by
RAMESH KT, DEPT of IEM, BMSCE muscular effort. RAMESH KT, DEPT of IEM, BMSCE
Unit - I (Introduction to Industrial Engineering)

Use of the human body Use of the human body

6. Continuous curved movements are to be preferred to
straight-line motion involving sudden and sharp changes
in direction.
7. Free-swinging movements are faster, easier and more
accurate than restricted or controlled movements.
8. Rhythm is essential to the smooth and automatic
performance of a repetitive operation.
9. Work should be arranged so that eye movements are
confined to a comfortable area, without the need for
frequent changes of focus.

RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE

RAMESH KT, DEPT of IEM, BMSCE 235

Unit - I (Introduction to Industrial Engineering)

Classification of movements (ii) Arrangement of workplace

1. Definite and fixed station should be provided for all tools and
Class Pivot Body parts moved materials to permit habit formation.
1 Knuckle Fingers 2. Tools and materials should be pre-positioned to reduce
searching.
2 Wrist Hand + above 3. Gravity feed, bins and containers should be used to deliver the
3 Elbow Forearm + above materials as close to the point of use as possible.
4. Tools, materials and controls should be located within the
4 Shoulder Upper arm + above maximum working area and as near to the worker as possible.
5 Trunk Torso + above 5. Materials and tools should be arranged to permit the best
sequence of motions.
6. The color of workplace should contrast with that of the work
and thus reduce eye fatigue.

RAMESH KT, DEPT of IEM, BMSCE

RAMESH KT, DEPT of IEM, BMSCE

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Unit - I (Introduction to Industrial Engineering)

Arrangement of workplace

7. “Drop deliveries” or ejectors should be used wherever

possible so that the operator does not have to use his
hands to dispose of the finished work.
8. Provision should be made for adequate lighting, and a
chair of the type and height to permit good posture should
be provided.
9. The height of the workplace and seat should be arranged
to allow alternative standing and sitting.

RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE

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Unit - I (Introduction to Industrial Engineering)

(iii) Design of tools and equipment

1. The hand should be relieved of all work of holding the
work-piece where this can be done by a jig, fixture or
foot-operated device.
2. Two or more tools should be combined wherever possible.
3. Where each finger performs specific movements, the load
should be distributed in accordance with the inherent
capacities of the fingers.
4. Handles such as those on cranks and large screwdrivers
should be designed so as to permit as much of the surface
of the hand as possible to come in contact with the handle.
5. Levers, crossbars and hand-wheels should be so placed
that the operator can use them with the least change in
body position and the greatest “mechanical advantage.”

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Unit - I (Introduction to Industrial Engineering)

248 RAMESH KT, DEPT of IEM, BMSCE

(iv) Time Conservation ADVANTAGES OF METHOD STUDY

 Even a temporary delay of work by a man or machine  Determine the time required to do a job which the time
should not be encouraged. obtain will be compared to alternative method and define
 Machine should not run idle, it is not desirable that a lathe the fastest method.
machine is running and its job is rotating but no cut is  Determine the resources required, budgeting and
being taken. costing for a job.
 Two or more jobs should be worked upon at the same  Provides information for effective production planning
time or two or more operations should be carried out on a and maintenance procedures.
job simultaneously if possible.  Aids in calculating exact delivery dates.
 Number of motion involved in completing a job should be  Provides a basis for fair and sound incentive schemes
minimize RAMESH KT, DEPT of IEM, BMSCE RAMESH KT, DEPT of IEM, BMSCE