Lab Title: Finding the time standard for a given job using direct time study method in an assembly

operation.

Course Title: Work Study and Methods Engineering (IE-315 L)

Practical No: _______
Student Name: _____________________________________________
Registration no: _____________________________________________

Evaluation Criteria
Taxonomy Max Marks
Knowledge Components Domain Contribution
Level Marks Obtained

1. To Analyze and Compare nature of

work, methods engineering & work Cognitive Analyze (C4) 10 % 01
measurement techniques.

2. Analyze the different problems of

work study and refine the existing
system (Method, Layout, Material Precision (P3) 20 % 02
Handling, Workers Efficiency and
Reduce Delay.
Psychomotor
3. Demonstration of Charts using
standard symbol and to find out the
Manipulating 05
Dexterity, Basic time, Bottleneck, 50%
(P2)
Allowances and Standard time of
different activities.

Students will be able to Express and

Behave effectively in each Affective Valuing (A3) 20 % 02
Situation/Task/Scenario.

Total Marks 10

Signed by Course teacher/ Lab Instructor

 Experiment No.6
Finding the time standard for a given job using direct time study method in an assembly
operation.
OBJECTIVE:
To learn how to conduct a direct time study on a operation and later finding out the standard time
for that operation.

STEPS IN CONDUCTING A TIME STUDY

The successful completion of time study involves a number of steps

1. Before commencing any time study or other work study project it is important to
communicate with all persons who are likely to be involved such as manager, supervisor,
operator etc.
2. Insure that the operator is properly trained.
3. Materials of satisfactory quality are available in sufficient quantity during the time study
period.
4. Machinery and equipments are adequately maintained and services.
5. Safety equipments and protective clothing is in good condition.
6. Method and layout is suitable.
7. Obtain all the necessary details about the jobs, operators, and machines and surrounding,
to gather we complete description of method.
8. Make a number of time study observations, this is necessary to breaking down the jobs
into elements and measuring the time taken by the operator to perform each element of
the operation, it will also improve the performance rate.
9. Convert the above observe time into basic time.
10. Determine the frequency or number of time each operation occur.

Four major elements of time studying for any operation are:

 Pick  Operation
 Align  Dispose

Selection of Worker for Time Study

The selection of worker for time study is a very important factor in the success of the study. If
there is only one person on the job, as usually is, then there is no choice. But if more than one
person is performing the same operation, the time study man may time one or more of the
workers. If all the workers are using the same method for doing the job and there is different in
the rate of their doing it, it is necessary to select a suitable worker for the study. The worker on
which time study should be conducted must
 have necessary skill for the job.
 have sufficient experience with the given method on the job (that is, he should have crossed
the learning stage).
 be an „average' worker as far as the speed of working is concerned.
 be temperamentally suited to the study (those who can't work in normal fashion when
watched, are not suitable for the study).
 have knowledge about the purpose of study

SC (Single Cycle)
Single Cycle can be defined as a complete rotation of the work operation in some sequential way
from its initial point to its finishing point.
Breakup of stitch cycle:
 Get & match part together
 Placing it under the foot
 Stitch and thread trimming
 Remove from the machine and inspect
 Disposal
Single cycle = Pick + align + operation + dispose

BMV (Basic minute Value):

There are two important things involved in determining BMV.

 Time Measurement.
 Rating.
Time Measurement:
We use a time measuring device (frequently known as Stop Watch) to measure the time in which
a particular operation is completed.

Rating
Direct observation techniques (such as time study) and analytical estimating include a process
for converting observed times to times for the “qualified worker working at a defined level of
performance” the common set of these process is known as rating. This involves the observer
(after appropriate training) making an assessment of the worker‟s rate of working relative to the
observer‟s concept at the rate corresponding to standard rating. This assessment is based on the
factors involved in the work. Such as effort, dexterity, speed of movement and consistency, the
assessment is made on a rating scale, of which there are three or four in common usage. Thus on
the 0-100 scale, the observer makes a judgment of the worker‟s rate of working as a percentage
of the standard rate of working(100)The rating is then used (in a process known as “extension” in
time study to convert the observed time to the basic time using a simple formula.
Rating is regarded by many ways, as controversial area of measurement. Where different
observes rate differently, the resulting basic times are not comparable. However, practiced rating
practitioners are remarkably consistent. It is important that those undertaking the rating are
properly trained, and that this training is regularly updated (to maintain a common perception of
standard rating) through rating “clinics”
Factors involving Rating
1. Skill 3. Conditions
2. Efforts 4. Consistency

The first thing is that operator must be a qualified worker, his work place must be arrange before
time study and he has all necessary equipments like trimmer, scissors, needles ,tailoring chalk
etc. After that we observe the operation and find the breaking points of the operation and by
using these breaking points we divide the operation in a number of parts then we step wise
calculate the time for the first part of the operation and also give the rating ,for example 70
%,80%, 90% etc at the same time. In this way we calculate the time for every part of the
operation and note down the rating as well, then we convert the observe time into basic time.
SC * Rating = Basic Minute Value
Question:
Let's Suppose, Cycle time = 0.22 min, Rating = 75 %
Calculate Basic Minute Value (BMV)
Answer:
Basic Minute Value = SC X Rating (%)
= 0.22 * 75%
BMV = 0.19
Other Examples
Cycle time(SC) Rating Basic time(BMV)
0.4 65 .26
0.6 40 .24
0.28 85 .24
SMV (Standard Minute Value) or SAM (Standard allowed minutes)

“Time required for completing a task @ 100% efficiency” SMV means 100% efficiency, without
100% efficiency we cannot call it SMV.
EXPLANATION
We determine SMV for each operation separately and for complete garment as well. We can also
determine that if a particular operator works on 100% efficiency level (or not.) then what should
be the production rate and how many pieces should be stitched. It is a work measurement
technique designed to establish the time for a qualified worker (Operator) to carry out specified
elements under specified condition. It is measured at a defined rate of working, recorded by the
direct observation of the times using a time measuring device and ratings for the individual
element. All these things are done by a method study officer. In SMV we find the efficiency
level of a particular operator and Production Unit as well we set their motions , work place and
handling as well. We can easily determine that the operator is working on 100 % level or not.
BM + allowances = SMV

ALLOWANCES
When carrying out work over a complete shift or working day, workers obviously suffer from the
fatigue imposed both by the work undertaken and the conditions under which they are working.
The normal practice is to make an addition to the basic time (commonly referred to as an
“allowance”) to allow the worker to recover from this fatigue and to attend to personal needs.
The amount of the allowances depends on the nature of the work and the working environment,
and is often assessed using an agreed set of guidelines and scales. It is usual to allow some of the
recovery period inherent in these allowances to be taken away from the work place (and it is
essential in adverse working conditions)
Thus work design should include the design of an effective work rest regime. The addition of
allowances should never be used to compensate for an unsafe or unhealthy working environment.
One minority school of thought suggest that relaxation allowances are unnecessary with work
which involves say the carrying of heavy weights, this school suggests that observer
automatically adjusts the concept of standard rating to allow for the weight. Thus if the standard
rate of performance for walking on level ground, carrying no weight is equivalent to four miles
per hour, than an observer rating a worker walking while carrying a weight will not expect the
equivalent rate thus, it is argued that the weight has been allowed for in the adjustment of
standard rating and any relaxation, allowance is simply a duplication of this adjustment on many
jobs there are small amounts of work that may occur irregularly and inconsistently. It is often not
economic to measure such infrequent work and an additional allowance is added to cover such
work and similar irregular delays. This allowance is not as contingency allowance and is
assessed either by observation, by analysis of historical records (for such items as tool,
sharpening or replacement) or by experience.
These allowances are explained as followed one by one:

1 Relaxation allowance.
2 Contingency allowance.
3 Machines breakdown allowance.
4 Bundle Handling Allowance
5 Policy Allowance

Relaxation allowance

It is an addition to basic time intended to provide the worker with an opportunity to

recover from the psychological and physic logical affects of carrying out specific work under
specified condition and to call attention to personal needs the amount of allowances will depend
on the nature of work. It may be fixed allowance or personal needs allowance”.
In Sitting Position ------------ RA = 11 %
In Standing Position --------- RA = 15 %

Contingency allowance

It is a small allowance of time which may be included in the standard time to meet
legitimate and expected items of work or delays. The precise measurements of which is
uneconomical because of their in frequent or irregular occurrences.

Some Machine Allowances (From Apparel sector)

These are the different machine working allowances e.g. start up allowance, shut down
allowance, cleaning allowance, thread breakage, broken needle, bobbin tension, thread tension
and SPI adjustment.

Sr. # Machine Name % age allowance

1 SNLS 12.5 %

2 DNLS 17.5 %

3 SNCS 7%

4 DNCS 9%

5 Bartack 5%

6 Button Hole 5%

7 Over lock (3 Thread) 7%

 8 Over lock (5 Thread) 9%

9 Trimmer 5%

Bundle Handling Allowance

It is estimated rate of operator's time wastage on collecting and arranging required

bundle.
Bundle Handling = 0.03

The end result is a standard time which includes the time the work “should” take (when carried
out by a qualified worker) plus additional allocation in the form of allowances, where
appropriate, to cover relaxation time, contingency time and perhaps, unoccupied time which
increases the overall work cycle (such as waiting for a machine to finish a processing cycle)

Let's Suppose
BMV = 0.74
Relaxation allowance=7% of basic time
Contingency allowance= 2% of basic time
Machine allowance =5% of basic time
Bundle handling = 0.0024

Solution:

SMV = BMV + RA (of BMV) + CA (of BMV) + MA (of BMV) + B. Handling

SMV = 0.74 + 0.0518 + 0.0148 + 0.037 + 0.0024
= 0.85 mint
Ball point Assembly Methodology
Repeat the process for 25 Ball Points and note down the time for each operation in the table.
Step # 01

The Performer should be

Positioned as shown in the
Figure

Step # 02

Move both hands

simultaneously for picking ink
tube with left hand and Spring
with right hand and Insert
Spring into the ink Tube as
shown in the Picture

Step # 03

Pick ink-tube attached spring

with Right hand and Main
Body with Left hand,

Insert the ink tube which have

attached spring into the Main
Body of the Ball Point

Step # 04

Hold main body with left hand

and attach Clipper to the main
Body. Clipper should be
Touched the first hole of the
main Body. As shown in the
picture
Step # 05

Put the clipper in 2nd hole and write on the

Paper “5th SEMESTER GROUP1/2”

Step # 06

Put the Assembled Ball Point Aside

Step # 07
Note: Repeat the process from step 1 to 6 for 25 Ball Point and note down the time for
each operation with stop watch)

Observation and Calculation:

Note: Bundle Handling Time 5%, other Allowances 15 % and Rating 90%

Table 1.1 SAM Calculation for Ball Point

Sr # Task Name Task time (sec) Rating Normal Time Allowance SAM
1.

2.

3.

4.

Total Product SAM

 Table 1.2 Efficiency Calculation of Different Lines
Total Total Line
Total Working Line Output Product
Minutes Minutes Efficiency
Line # Operator Hours Production SAM
Available Produced (F/E*100)
(A) (B) (C) (D)
E=A*B*60 F=C*D (%)
Ball
Point

Discuss Efficiency Graph

Should we include Helpers in Line Efficiency Calculation?

Why we cannot remove all WIP from manual assembly lines?

How Operation Bulletin helpful to start a new product in Production line.

Point out the safety parameters while you are performing the experiment.

Write your learning outcomes from this Lab.