K.L.

SENTHIL KUMAR, Assistant Professor/Mechanical

 Definition:

Work study is a generic term for the techniques of method study and work measurement. These techniques are used in the examination of human work in all its contexts. They lead systematically to the investigation of all the factors which affect the efficiency and economy at the work place in order to affect improvement.

Definition: Method study is the technique of systematic recording and critical examination of existing and proposed ways of doing work and developing an easier and economical method.

Objectives of Method Study 1. Improvement of manufacturing processes and procedures. 2. Improvement of working conditions. 3. Improvement of plant layout and work place layout. 4. Reducing the human effort and fatigue. 5. Reducing material handling 6. Improvement of plant and equipment design. 7. Improvement in the utility of material, machines and manpower. 8. Standardization of method. 9. Improvement in safety standard.

1. Select the work to be studied. 2. Record all facts about the method by direct observation. 3. Examine the above facts critically. 4. Develop the most efficient and economic method. 5. Define the new method. 6. Install the new method 7. Maintain the new method by regular checking.

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selecting a job for doing method study, the following factors are considered: (a) Economical factors. (b) Human factors. (c) Technical factors.

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money saved as a result of method study should be sufficiently more. Then only the study will be worthwhile. Based on the economical factors, generally the following jobs are selected. (a) Operations having bottlenecks (which holds up other production activities). (b) Operations done repetitively. (c) Operations having a great amount of manual work. (d) Operations where materials are moved for a long distance.

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method study will be successful only with the co-operation of all people concerned viz., workers, supervisor, trade unions etc. Workers may resist method study due to 1. The fear of unemployment. 2. The fear of reduction in wages. 3. The fear of increased work load.

then if they do not accept method study, the study should be postponed.

To improve the method of work all the technical details about the job should be available. Every machine tool will have its own capacity. Beyond this, it cannot be improved. For example, a work study man feels that speed of the machine tool may be increased and HSS tool may be used. But the capacity of the machine may not permit increased speed. In this case, the suggestion of the work study man cannot be implemented. These types of technical factors should be considered.

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the details about the existing method are recorded. This is done by directly observing the work. Symbols are used to represent the activities like operation, inspection, transport, storage and delay.

Different charts and diagrams are used in recording. They are: 1. Operation process chart: All the operations and inspections are recorded. 2. Flow process chart (a) Man type All the activities of man are recorded (b) Material type All the activities of the material are recorded (c) Equipment type All the activities of equipment or machine are recorded. 3. Two-handed process chart: Motions of both lands of worker are Right hand-Left hand chart recorded independently.

4. Multiple activity chart: Activities of a group of workers doing a single job or the activities of a single worker operating a number of machines are recorded. 5. Flow diagram: This is drawn to suitable scale. Path of flow of material in the shop is recorded. 6. String diagram: The movements of workers are recorded using a string in a diagram drawn to scale.

Critical examination is done by questioning technique. This step comes after the method is recorded by suitable charts and diagrams. The individual activity is examined by putting a number of questions. The following factors are questioned 1. Purpose To eliminate the activity, if possible. 2. Place To combine or re-arrange the activities. 3. Sequence -do 4. Person -do 5. Means To simplify the activity.

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following sequence of questions is used: 1. Purpose What is actually done? Why is it done? What else could be done? What should be done? 2. Place Where is it being done? Why is it done there? Where else could it be done? Where should it be done? 3. Sequence When is it done? Why is it done then? When could it be done? When should it be done?

4. Person Who is doing it? Why does that person do it? Who else could do it? Who should do it? 5. Means How is it done? Why is it done that way? How else could it be done? How should it be done? By doing this questioning Unwanted activities can be eliminated Number of activities can be combined or rearranged Method can be simplified. All these will reduce production time.

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answer to the questions given below will result in the development of a better method. 1. Purpose What should be done? 2. Place Where should it be done? 3. Sequence When should it be done? 4. Person Who should do it? 5. Means How should it be done?

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a complete study of a job has been made and a new method is developed, it is necessary to obtain the approval of the management before installing it. The work study man should prepare a report giving details of the existing and proposed methods. He should give his reasons for the changes suggested. The report should show (a) Brief description of the old method.

 (b)

Brief description of the new method. (c) Reasons for change. (d) Advantages and limitations of the new method. (e) Savings expected in material, labour and overheads. (f) Tools and equipment required for the new method.

(g) The cost of installing the new method including. 1. Cost of new tools and equipment. 2. Cost of re-layout of the shop. 3. Cost of training the workers in the new method. 4. Cost of improving the working conditions.

Before installing the new method, an operators instructions sheet called written standard practice is prepared. It serves the following purposes: 1. It records the improved method for future reference in as much detail as may be necessary. 2. It is used to explain the new method to the management foreman and operators. 3. It gives the details of changes required in the layout of machine and work places. 4. It is used as an aid to training or retraining operators. 5. It forms the basis for time studies.

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written standard practice will contain the following information: (a) Tools and equipment to be used in the new method. (b) General operating conditions. (c) Description of the new method in detail. (d) Diagram of the workplace layout and sketches of special tools, jigs or fixtures required.

This step is the most difficult stage in method study. Here the active support of both management and trade union is required. Here the work study man requires skill in getting along with other people and winning their trust. Install stage consists of (a) Gaining acceptance of the change by supervisor. (b) Getting approval of management. (c) Gaining the acceptance of change by workers and trade unions. (d) Giving training to operators in the new method. (e) To be in close contact with the progress of the job until it is satisfactorily executed.

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work study man must see that the new method introduced is followed. The workers after some time may slip back to the old methods. This should not be allowed.

The new method may have defects. There may be difficulties also. This should be rectified in time by the work study man. Periodical review is made. The reactions and suggestions from workers and supervisors are noted. This may lead to further improvement. The differences between the new written standard practice and the actual practice are found out. Reasons for variations are analyzed. Changes due to valid reasons are accepted. The instructions are suitably modified.