Chapter 6

Method Study/Motion Study

8 Steps in Method Study
Select the work to be studied and define its boundaries.
Record the relevant facts about the job by direct observation.
Examine the way the job is performed and challenge its purpose, place, sequence
and method of performance. Critical questioning technique. Primary and secondary
Develop the most practical, economic and effective method. (ideas developed)
Evaluate different alternatives to developing a new improved method.
Define the new method, as a result, in a clear manner and present it to those
concerned. Write a report to all stakeholders.
Install the new method as a standard practice and train workers.
Maintain the new method and introduce control procedures to prevent a drifting
back to previous methods.
Select Stage
Economic considerations
Questions always should be asked before an investigation begins is: “Will it pay to begin a method
study of this job?” or
“Will it pay to continue this study? ‘
The obvious choices for study are:
A] key profit generating or costly operations or ones with high scrap rates.
B] bottlenecks which are holding up other production operations.
C] Operations involving repetitive work using a great deal of labour.
D] Movements of material over long distances between workstations

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Technical considerations: (Equipment, machinery, computers)
 Management may have the desire to acquire more advanced technology
whether in equipment or in processes, thus management may want to
computerize its office paperwork or its inventory system.
 Before such steps are taken, a method study can point out the important
needs of the organisation.
 Method study acts as a scouting operation prior to the introduction of more
advanced technology.
The introduction of new technology should therefore constitute an important factor
in the choice of methods of work to be investigated.
HUMAN CONSIDERATIONS:
- Certain operations are often a cause of dissatisfaction by workers.
- They may induce fatigue or monotony.
- The level of satisfaction should point to a need for method study.
- Operations that are perceived as effective by management, may generate resentment by
workers.
- Such operations should be addressed by the work-study person, and the benefits of
workstudy can become more apparent to the workforce.
- If a job select causes unrest or ill-feelings, the advice is to leave it alone and tackle other
jobs, where workers can see the benefits of method study.

Record Stage of Method Study

 In Method Study charts and diagrams are used to record the facts on a job. Lengthy
sentences are not used when the description of a process is recorded. The
standardized set of Process Chart Symbols are used to Record the steps in a process.
Process Chart Symbols

О- OPERATION – indicates the main steps in the process.

□ - INSPECTION – indicates an inspection for quality and/or check for

quantity.

- TRANSPORT – indicates movement of workers, materials or equipment

from place to place.

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 D - DELAY – indicates a delay in the sequence of events.

- PERMANENT STORAGE – indicates a controlled storage in which material is received or

issued.
Combined operation and Inspection, used to denote the activities taking place simultaneously
Charts to be studied in this module
1. Outline process Chart – this chart only two process chart symbols are used i.e.
Operation and Inspection. This chart gives a “bird’s eye” view of the process.
2. Man Type Flow Process Chart – all process chart symbols are used to record only
what the worker/operator is doing.
3. Material Type Flow Process Chart – All process chart symbols are used to record
only how the material is transformed in the process.
4. Two handed Process Chart (Page 150 of Into to WS) – process chart symbols take on
slightly different definitions. The activities of the right hand is recorded in relation to
the activities of the left hand. The process chart symbols take on a slightly different
meaning.
O = used for activities of grasp, position, use, release of tool or product.

D = used to denote the hand is idle.

= used to denote the movement of the hand.

▼ = this symbol is re-designated as HOLD and is used to represent the hand is holding a
tool or part

5. Multiple Activity Chart – Records the activities of multiple subjects (machines &
workers) in relation to each other.
Practical class exercises of charts are on page 6, 9 and 10.

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Examine Stage of Method Study
The questioning technique is the means by which the critical examination is conducted, each
activity being subjected in turn to a systematic and progressive series of questions.
Combining the primary questions with the secondary questions under each heading, yields
the following list:
Purpose: What is done?
Why is it done?
What else might be done?
What should be done?

Place: Where is it done?

Why is done there?
Where else might it be done?
Where should it be done?

Sequence: When is it done?

Why is it done then?
When might it be done?
When should it be done?

Person: Who does it?

Why does that person do it?
Who else might do it?
Who should do it?

Means: How is it done?

Why is it done that way?
How else might it be done?
How should it be done?

Develop Stage of Method Study

Asking the right question is halfway towards finding the right answer. It is advised not to
rush into solutions before investigating other areas such as product design, proper use of
raw materials, proper layout and good material handling practices. More than one solution
should be developed. The question technique will give the work study practitioner a fairly
good idea about the shortcomings of the present method.

Practical: use a man type flow process chart complied in the class and apply the questioning

technique, find answers and use those answers to develop improved methods .

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Evaluate Stage of Method Study
The sponsors of the investigation normally the senior managers must take a decision on which
solution to implement. For them to take this decision, they need information on the alternate
methods.
The method study person should prepare a cost benefit analysis for each of the proposed methods.
This is done in stages. The first pass is carried out in which very broad costs and benefits are
associated with each potential change. It is important for the method study person to include
qualitative (Job satisfaction) and quantitative (direct financial savings).
Practical: use the alternative methods developed in develop stage and conduct a costing
on each alternative.

Define Stage of Method Study

For jobs that are performed on standard machine tools or specialized machines it is
desirable to prepare a written standard practice sheet also know as a work instruction.
This document serves the following purposes:-
a) It records the improved method for future reference.
b) It can be used to explain the new method to management, supervisors and workers.
c) I is an aid to training or retraining of workers and can be used by them for reference
until they are fully conversant with the new method.
d) It forms the basis on which time studies may be taken for setting standards

The work study practitioner must prepare a report at the define stage. The report must be
circulated to senior management, operations manager, supervisor, trade union representative and
the worker directly involved. The report should include the present method on a chart or diagram,
the proposed method on a chart or diagram, the implementation costs of the new method, the
alternative methods and their costs. The practitioner must also explain why he selected the new
method for implementation and show the cost savings to the organisation, improvement in
productivity and improvement in job satisfaction.
Practical: compile a report to management and supervisor.

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Install Stage of Method Study
It is at this point that the active support is required from management and trade
unions. It is here that the personal qualities of the work study person, his ability to
explain clearly and simply what he or she is trying to do and a gift for getting along
with other people and winning their trust become of the greatest importance.
Installation can be divided into 5 stages, namely:
Gaining acceptance of the change by management.

Gaining acceptance of change by the departmental supervision.

Gaining acceptance of the change by the workers and their representatives.

Preparing to make the changes.

Controlling the change over.

Maintain Stage of Method Study
The work study department is responsible for this task.

This department needs to do regular follow ups on the new process.

The work study officer must report any deviations in the method of working to the

Supervisor. The supervisor should take corrective action immediately by correcting

the worker under his supervision.
Workers should not be allowed to slip back to the old methods of working. Tools,
layout and elements of movement must be specified beyond any risk of
misinterpretation. If the method is properly maintained disputes over time standards
will not take place.

Record stage of method study examples (description of a process)

The following operation takes place in the Packaging Department of Tetra-Pak (PTY) Ltd..
Sbu’s job consists of labelling cartons. The unlabelled cartons are stacked to the left of the
workplace at an average distance of 2.8 metres from the workplace. The workplace consists
of a work- bench (1.3 metres high) on which the cartons are placed and worked on. On the
left hand side (LHS) of the bench and within arms reach are 3 different types of labels in
open boxes. On the right, also within arms reach, is a brush and a pot of glue.

The work procedure is as follows:

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Sbu walks to the cartons to be labelled, picks up 1 carton and walks back to the bench and
places it on the bench. He picks up the brush in his right hand, dips it into the pot of glue and
applies the glue onto the carton (average 3 strokes). He then picks up 2 labels with his left
hand (the right hand is still holding the brush), positions and affixes the first label onto one
part of the glued strip of the carton, then positions and affixes the second label at right angles
to the first. Sbu stands back and checks that the alignment of the labels are correct.

With the brush still in his right hand, he turns the case around (180 degrees) with both hands.
He picks up the last label with his left hand while simultaneously applying glue to the new
side of the cartoon (he does not re-dip the brush into the glue pot) and affixes this label onto
the cartoon. Once again he checks his work, places aside the brush in its position on the
table, then uses both hands to pick up the carton and conveys it to the right hand side (RHS)
of the workplace where the completed cartons are stacked. He places the completed carton
on a pallet that contains other cartons also, all awaiting despatch, then goes straight to pick up
a new carton from the LHS. The distance between the workplace and the completed cartons
is the same as that between the work bench and unlabelled cartons (in fact the work bench is
in the middle of the 2 stacks of cartons).

Exercises:
Compile the following charts using the above information
1. Outline process chart
2. Man Type Flow process chart
3. Two handed process Chart
Use the templates on pages 8, 9 and 10 to answer the above question

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Record stage of method study examples (description of a process)
The following operation takes place in the Packaging Department of Tetra-Pak (PTY) Ltd..
Sbu’s job consists of labelling cartons. The unlabelled cartons are stacked to the left of the
workplace at an average distance of 2.8 metres from the workplace. The workplace consists
of a work- bench (1.3 metres high) on which the cartons are placed and worked on. On the
left hand side (LHS) of the bench and within arms reach are 3 different types of labels in
open boxes. On the right, also within arms reach, is a brush and a pot of glue.

The work procedure is as follows:

Sbu walks to the cartons to be labelled, picks up 1 carton and walks back to the bench and
places it on the bench. He picks up the brush in his right hand, dips it into the pot of glue and
applies the glue onto the carton (average 3 strokes). He then picks up 2 labels with his left
hand (the right hand is still holding the brush), positions and affixes the first label onto one
part of the glued strip of the carton, then positions and affixes the second label at right angles
to the first. Sbu stands back and checks that the alignment of the labels are correct.

With the brush still in his right hand, he turns the case around (180 degrees) with both hands.
He picks up the last label with his left hand while simultaneously applying glue to the new
side of the cartoon (he does not re-dip the brush into the glue pot) and affixes this label onto
the cartoon. Once again he checks his work, places aside the brush in its position on the
table, then uses both hands to pick up the carton and conveys it to the right hand side (RHS)
of the workplace where the completed cartons are stacked. He places the completed carton
on a pallet that contains other cartons also, all awaiting despatch, then goes straight to pick up
a new carton from the LHS. The distance between the workplace and the completed cartons
is the same as that between the work bench and unlabelled cartons (in fact the work bench is
in the middle of the 2 stacks of cartons).

Exercises:
Compile the following charts using the above information
4. Outline process chart
5. Man Type Flow process chart
6. Two handed process Chart

Material type flow process chart

Sponge fish sweets are made in five different colours. These sweets are demoulded from
starch into plastic trays (5 kgs/tray)and 20 full trays are stacked on each pallet which is
stored in the product storage area in the Packing department. The process of mixing of
all five colours and removal of starch from the surface of the sponge fish sweets after
demoulding involves the use of a mixture containing vegetable oil and icing sugar. This

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process is carried out on a mixing table in the Packing department of Soft Sweets
division at Fishy Enterprises.

The operator pushes a trolley to the raw material storage area (100 metres away from the
mixing table) and collects 1 bag of icing sugar and a bucket of oil which he takes back to
the mixing table. On his return to the mixing table, he pushes a pallet jack to the product
storage area. (10 metres away from mixing table) which he uses to transfer a pallet of
each of five colours to the front end of the mixing table. (This involves 5 trips). He then
loads icing sugar and oil onto mixing table and prepares a “Drymix” by mixing these
ingredients together. He then loads 4 trays of each colour onto mixing table and places
empty trays on pallet situated on right hand side of mixing table. He then proceeds to
mix all five colours together with the icing sugar/oil mixture. The operator then carries
out a check to determine whether the sponge fish sweets are relatively free of starch and
adequately mixed. Having satisfied himself that this is the case, he proceeds to fill these
sweets into empty plastic trays and stacks these full trays on a pallet situated on the left
hand side of the mixing table. (A total of 20 plastic trays are filled). After clearing the
mixing table, he then uses a pallet jack to transfer the completed pallet of sponge fish
sweets to the machine on which it is wrapped and packed. (20 Metres away from mixing
table). The operator then returns to the mixing table.

Prepare a Material Type Flow Process Chart of the above work procedure as the present
method.

Use template on page 11 to answer the above question