• Fundamentals of Work Study

• Procedures of work method

• Method /Motion study
• Time study
Definition
 Study on works done by human
 Systematic study to find the most efficient
work method and set standard for
performances
 Management method including
1. Method Study
2. Work measurement
Objective

 Standardized method on doing work

 Standard Time
 Minimize Production Cost
 Less of material and workers movement
 Elimination of unproductive movement
 Ensure efficiency on human, tools and
material utilization
 Method
Method Systematicrecording
recordingand
andcritical
critical
The systematic Systematic
The systematic
examination of the
Study
Study examinations of ways of doing
examinations of ways of doing
examination of the things in order to make improvement
methods on
methods on
(motionstudy)
(motion study) things in order to make improvement
carrying an
carrying an
activities so as to
activities so as to
improve the
improve the
effective use of the
Work
WorkStudy
Study
effective use of the
resources and to
resources and to
set up standard of
set up standard of Work
Work Applicationsofoftechniques
techniquesdesign
designtoto
performances for Applications
performances for
the activities being
the activities being
Measurement
Measurement establish the time for a qualified
establish the time for a qualified
worker to carry a task at a defined
carriedout
carried out (timestudy)
(time study) worker to carry a task at a defined
rate of working
rate of working

HIGHER
HIGHER OUTPUT
OUTPUT
PRODUCTIVITY
PRODUCTIVITY
INPUT
INPUT
 Basic
BasicProcedure ofWork
Procedureof Workmethod
method
Select the job or process to be studied

Record the relevant facts about the job by direct observation and collect such additional
data as may be needed from appropriate sources.

Examine the record critically and challenge everything that being done (its purpose,
place sequence and method of performance.)

Develop the most practical, economics and effective method

Evaluate different alternatives to developing a new improved method comparing the cost-
effectiveness of the selected new method with the current method with the current method of
performance.

Define the new method and the related time with documentation and present to those
concerned; ie supervisors, workers, management

Install the new method, training those involved

Maintain the standard practice by monitoring the results and introduce control procedures to
prevent a drifting back to the previous method of work.
 A job is selected such that the proposed method achieves one or more
of the following results
• (a) Improvement in quality with lesser scrap.
• (b) Increased production through better utilization of resources.
• (c) Elimination of unnecessary operations and movements.
• (d) Improved layout leading to smooth flow of material and a balanced production
line.
• (e) Improved working conditions.
Based on 3 Factors
 Economic – involving improvement of all the sources such as time, capital and
human energy that can contribute to company profit
 Technical – Consideration taken based on if involving change will effect the
quality of product cause of limitation on technical property
 Human – Is it going to affect the way in which the job is done
presently and is not fully accepted by workman and the union
» Must be accurate and based on description of actual situation
» Use CHARTS & DIAGRAMS
Records
RecordsTechniques
Techniques

Charts
Charts Diagrams
Diagrams

Movement
Movement
Macro
MacroMotion Micro
Motion
Chart MicroMotion
MotionChart
Chart •Flow
Chart •Flow
•SIMO •String
•Operation
•OperationProcess
ProcessChart
Chart •SIMOchart
chart •String
•Flow •Therblig
•FlowProcess
ProcessChart
Chart •Therblig
•Two
•TwoHanded
HandedProcess
ProcessChart
Chart
•Multiple
•MultipleActivity
ActivityChart
Chart
Operation Process Chart
• Also called outline process chart
• recording only the major activities and inspections involved in the
process.
• uses only two symbols, i.e., operation and inspection
Flow Process Chart
• gives the sequence of flow of work of a product or any part of it through the work
centre or the department recording the events using appropriate symbols
• operations; inspection, storage, delay and transportation are represented
• three types
(a) Material type—Which shows the events that occur to the materials.
(b) Man type—Activities performed by the man.
(c) Equipment type—How equipment is used.
• The flow process chart is useful:
(a) to reduce the distance travelled by men (or materials).
(b) to avoid waiting time and unnecessary delays.
(c) to reduce the cycle time by combining or eliminating operations.
(d) to fix up the sequence of operations.
(e) to relocate the inspection stages.
Two Handed Process Chart
• most detailed type of flow chart in which the activities of
the workers hands are recorded in relation to one another
• work carried out at a single workplace
• Use 4 symbols:
 Operations
 Transportation
 Delays
 Storage
Multiple Activity Chart
•activities of more than subject (worker or equipment) are each
recorded on a common time scale to show their inter-relationship
•Multiple activity chart is made
 to study idle time of the man and machines,
 to determine number of machines handled by one operator, and
 to determine number of operators required in teamwork to perform
the given job
Purpose:
To study the different layout plans and thereby; select the most optimal
layout.
To study traffic and frequency over different routes of the plant.
Identification of back tracking and obstacles during movements.
 Example

Figure : Flow Process Chart Figure :Two handed/ Right-

Hand Left-Hand
Flow Diagram
•Drawing of the working area, showing the location of the various activities
identified by their numbered symbols
•Associated with particular flow process chart either man type or machine type.
•Routes followed in transport are shown by joining the symbols in sequence by a
line which represents as nearly as possible the path or movement of the subject
concerned
•Procedures:
1. The layout of the workplace is drawn to scale.
2. Relative positions of the machine tools, work benches, storage, and inspection
benches
are marked on the scale.
3. Path followed by the subject under study is tracked by drawing lines.
4. Each movement is serially numbered and indicated by arrow for direction.
5. Different colours are used to denote different types of movements.
String Diagram
•A scale layout drawing on which, length of a string is used to record the
extent as well as the pattern of movement of a worker working within a
limited area during a certain period of time.
•Purpose: to produce a record of a existing set of conditions so that the job of
seeing what is actually taking place is made as simple as possible
•Procedures:
1. A layout of the work place of factory is drawn to scale on the soft board.
2. Pins are fixed into boards to mark the locations of work stations, pins are
also driven at the turning points of the routes.
3. A measured length of the thread is taken to trace the movements (path).
4. The distance covered by the object is obtained by measuring the
remaining part of the thread and subtracting it from original length.
Graphical method of recording originated by Gilbreth
Consists of symbols to represent process, methods or procedure
Symbols:
1.O = operation
2.□ = inspection
3.→= transportation
4.D = delay
5.▽ = storage
Motion study is part of method study where analysis of the motion of an
operator or work will be studied by following the prescribed methods.

Principles of Motion study

The principles are grouped into three headings:
(a) Use of the human body.
(b) Arrangement of workplace.
(c) Design of tools and equipment.
(A) USES OF HUMAN BODY
When possible:
1. The two hands should begin and complete their movements at the same time.
2. The two hands should not be idle at the same time except during periods of
rest.
3. Motions of the arms should be made simultaneously.
4. Hand and body motions should be made at the lowest classification at which it
is possible to do the work satisfactorily.
5. Momentum should be employed to help the worker, but should be reduced to a
minimum whenever it has to be overcome by muscular effort.
6. Continuous curved movements are to be preferred to straight line motions
involving sudden and changes in directions.
7. ‘Ballistic’ (i.e., 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. The work should be arranged to permit easy and natural rhythm
wherever possible.
9. Work should be arranged so that eye movements are confined to a comfortable
area, without the need for frequent changes of focus.
(B) ARRANGEMENT OF THE WORKPLACE

1.Definite and fixed stations should be provided for all tools and materials to
permit habit formation.

2. Tools and materials should be pre-positioned to reduce searching.

3. Gravity fed, bins and containers should be used to deliver the materials as
close to the point of use as possible.

4. Tools, materials and controls should be located within a maximum working

area and as near to the worker as possible.

5. Materials and tools should be arranged to permit the best sequence of

motions.

6. ‘Drop deliveries’ or ejectors should be used wherever possible, so that the

operative does not have to use his hands to dispose of finished parts.

7. Provision should be made for adequate lightning, and a chair of type and
height to permit good posture should be provided. The height of the workplace
and seat should be arranged to allow alternate standing and seating.
(C) DESIGN OF TOOLS AND EQUIPMENTS

1.The colour of the workplace should contrast with that of work and thus
reduce eye fatigue.

2. The hands should be relieved of all work of ‘holding’ the work piece where
this can be done by a jig or fixture or foot operated device.

3. Two or more tools should be combined where possible.

4. Where each finger performs some specific movement, as in typewriting, the

load should be distributed in accordance with the inherent capacities of the
fingers.

5. Handles such as those used on screw drivers and cranks should be

designed to permit maximum surface of the hand to come in contact with the
handle.

6. Levers, cross bars and wheel bars should be in such position that operator
can manipulate them with least body change and with greatest mechanical
advantage.
1.Operation O
An operation occurs when an object is intentionally changed in one or
more of its characteristics (physical or chemical). This indicates the main
steps in a process, method or procedure.
An operation always takes the object one stage ahead towards
completion.
Examples of operation are:
• Turning, drilling, milling, etc.
• A chemical reaction.
• Welding, brazing and riveting.
• Lifting, loading, unloading.
• Getting instructions from supervisor.
• Taking dictation.

2.Inspection □
An inspection occurs when an object is examined and compared with
standard for quality and quantity. The inspection examples are:
• Visual observations for finish.
• Count of quantity of incoming material.
• Checking the dimensions.
3.Transportation →
A transport indicates the movement of workers, materials or equipment
from one place to another.
Examples:
•Movement of materials from one work station to another.
•Workers travelling to bring tools.

4.Delay D: Delay (Temporary Storage)

A delay occurs when the immediate performance of the next planned
thing does not take place.
Example:
•Work waiting between consecutive operations.
•Workers waiting at tool cribs.
•Operators waiting for instructions from supervisor.

5.Storage ∇
Storage occurs when the object is kept in an authorized custody and
registered. For example, materials kept in stores to be distributed to
various work.
 Quiz

Develop a Process Chart for drilling a 10 mm diameter hole on a metal

workpiece

Steps:
1.Draft out the entire process
2.Decide the type of process
3.Determine if any distance involved
Activity:

1. Mark the measurement of the hole onto the work piece

2. Hammer and indenter on shelf
3. Reach for hammer and indenter
4. Make an indentation to guide the drill bit
5. Carry to drilling machine
6. Drill bit set on shelf
7. Select appropriate drill bit
8. Insert drill bit to spindle
9. Tighten the chuck
10. Rotate the chuck by hand to confirm that the drill bit is inserted properly and
not wobbling.
11. Clamp the work piece securely
12. Ensure safety measures: close down the protective lid, wear appropriate
PPE
13. Perform drilling
14. Inspect for burrs
15. Files set on shelf
16. Reach for files
17. Perform filing
18. Carry tools back to shelf
 Example

Develop a Multiple Activity Chart for doing three loads of laundry,

assume you will have access to one washing machine and one dryer.
Study all the record and identified
problems/weakness exist. Find Improvement can be achieve:
alternatives.
Question:
Elimination
WHAT & WHY
Combination
WHO & WHY
Rearrangement
WHERE & WHY
WHEN & WHY Simplification
HOW & WHY
examine
elimination
 All possible activities, jobs or motion
combination
 Combine the multiple activities/elements
rearrangement
 Improvement by rearrangement process/works
simplification
 Analysis each of the operation on process for
simplification or improvement
 develop

the most practical, economics and effective method

Development» :of alternatives
based on principles:

Single
SingleMinute
MinuteExchange
Exchangeof
ofDie
Die
SMED)
SMED)
Design
Designfor
forManufacture
Manufacture&&
Assembly
Assembly(DFMA)
(DFMA)
 Evaluate define
Involve
Involve22Aspect
Aspect
• All the alternative 1.1. Report
Reportof
ofMethod
Methodimplications
implications
 Cost, Savings and Action
efficiency need to be Cost, Savings and Action
taken.
taken.
measure and evaluate 2.2. Standard
StandardOperation
OperationProcedure
Procedure
so the decision can be (SOP)
(SOP)
 For the new Method
carry out based on For the new Method
 References, Explanation and
References, Explanation and
TIME STUDY guideline
guidelineononworkers
workerstraining.
training.
 Standard Practice explain
Standard Practice explain
tools,
tools,works
worksmethod
methodand
andwork
work
station
stationlayout.
layout.
install maintain

Divide on 3 section
a. Approval and support from Maintain the new
manager, supervisors &
workers
method as being fixed
b. Trained workers with new and all the workers
method utilization not allowed to use the
c. Monitor all the development
until achieve the original old method
target
DEFINITION
 Application of the techniques designed to
establish the time for a qualified worker to carry
out a task at a defined rate of working

OBJECTIVE
 INVESTIGATING , REDUCING AND SUBSEQUENTLY
ELIMININATING INEFFECTIVE TIME ( TIME DURING
NO EFFECTIVE WORK IS BEING PERFORMED,
WHATEVER THE CAUSE)
 The
TheUses
UsesofofWork
Workmeasurement
measurement
 Compare the efficiency of alternatives methods
 Balance the work of the member teams
 To determine in association with the worker and machine
multiple activity chart, the number of machine and operative
can run
 To provide the basis for production planning and control for
the choice of better layout and for process planning and
establishing just-in-time and inventory control system
 To provide information that can enable estimates to be made
for tenders, selling prices and delivery dates
 To set standards of machine utilization and labor performance
that can be used for any of the above purposes and as basis in
incentives scheme
 To provide information for labor cost control and to enable
standard costs to be fixed and maintained
 Techniques ofWork
Techniquesof Workmeasurement
measurement

Select, record, examine and measure quantity of

Select, record, examine and measure quantity of
work performed using either one of a combination
work performed using either one of a combination
of following method
of following method

Work
Work Structured
Structured Predetermined
Predetermined
Time
TimeStudy
Study Time
Sampling
Sampling Estimating
Estimating TimeStudy
Study

Compile Compile

With appropriate allowances to get

With appropriate allowances to get To establish standard data bank
started time of operations To establish standard data bank
started time of operations
 Definitions
Definitionsin
intime
timestudy
study
Normal time the time required for an average, trained operator to perform a task
under usual working condition and working at normal pace. (It not
include allowances for personal needs and delays that would be
necessary if the task were done 8 hours )
Normal pace the pace of an average, trained and conscientious operator working over
an 8 hour- day
Actual time the observed time required for an operator to perform task

allowances the amount of time added to the normal time to provide for personal
needs, unavoidable delays and fatigue.

Standard the total time in which the a job should be completed at a standard
time performances
 method
methodof
ofdetermining
determiningstandard
standardtimes
times

 DIRECT TIME STUDY

 TIME STUDY STANDARD DATA
 PREDETERMINED TIME SYSTEMS
 PREDETERMINED MOTION TIME STUDY
 WORK SAMPLING
 
DIRECT
DIRECTTIME
TIMESTUDY
STUDY
 Work measurement techniques in which a physical measurement is
made of the actual time required to do a task by using a watch or
some other device.
 Tools:
 Watch ( Stop watch )
 Time Study Form
 Observation Board
 Stop Watch Method
 Continuous Timing – Unstopping time recorded
 Repetitive Timing (Snap back) – The indicator of top watch back to zero
for each work element end.
 
DIRECT
DIRECTTIME
TIMESTUDY
STUDY

 PROCEDURE
 Collect and record all the information related to work and work situation
 Divided work that are studied into the elements with the description
 Fixed observation quantity using statistical method and assumption
 Do the observation and record the time taken by worker for each
elements and rating for each worker
 Define worker allowance
 Calculate Standard time

DIRECT
DIRECTTIME
TIMESTUDY
STUDY
 Average Time = Total Time
Quantity of Observation

 Normal Time = Average Time x Rating %

 Standard Time = Normal Time + ( Normal Time x Allowances %)

@

Normal Time x ( 100 / 100 - Allowances %)

 
DIRECT
DIRECTTIME
TIMESTUDY
STUDY

Observation of 4 cycle
Allowance 5% from Normal Time Qty Work elements Cycle 1 Cycle 2 Cycle 3 Cycle 4

Rating for workers 90%

1 Take the cloth 25 30 35 25
Data from stop watch snap back
2 Put in the washing machine 8 9 8 6
Work days per week = 6
Switch on and machine
3 10 10 10 10
Method operation

4 Take out the cloth 8 8 9 6

• Calculate
i. Average Process Time
ii. Normal Process Time
iii. Standard Process Time
iv. How many trip of washing cloth can be done if
working hours = 8 hour for one week
v. If salary is = RM1.50/hour what is labor cost for
each trip
 
DIRECT
DIRECTTIME
TIMESTUDY
STUDY

Qty Work elements Average Time Normal Time Standard Time

1 Take the cloth 28.8 25.9 27.2

2 Put in the washing machine 7.8 7 7.4
Switch on and machine
3 10 9 9.5
operation

4 Take out the cloth 7.8 7 7.4

Standard Time : 51.5

b) 6 x 8 x 60 x 60 / 51.5 = 3355.34 = 3355trip

c) 51.5 x 1.5 / 60 x 60 = RM 0.02/trip

 Assignment #1
Assuming that the total observed time for an operator to assemble a toy truck is
1.00 min. If the rating is 120%, find normal time. If an allowance of 10% is
allowed for the operation, determine the standard time.
 
Work
Worksampling
sampling

 Method of finding percentage occurrence of a

certain activity by statistical sampling and
random observation
 In order to obtain a complete and accurate
picture of the productive time and idle time of the
machine, production area or operator.
 Example : making a tours of the factory at random
intervals noting which machine are working and which
are stopped and noting the cause of stoppage.
 
Work
Worksampling
sampling
 PROCEDURE
 Identified study objective
 Things that needs to be achieve after the study
 Such as the percentage rating of operators or machine either productive,
busy or idle
 Do the early observation
 Randomize based on experience for estimation percentage idle time and
productive time
 Decide quantity of observations
 Based on confidence level and accuracy range chosen from statistical
method or nomogram
 Decide frequency of observations
 Random Number Table
 Do the observation and record on observation form prepared for
this study objective
 
Predetermined
Predeterminedtime
timeMOTION
MOTIONSTUDY
STUDY

• A work measurement technique whereby times

established for basic human motions (classified
according to the nature of the motion and
conditions under which it is made) are used to
build up the time for a job at the defined level
ofperformance. The most commonly used PMTS
is known as Methods Time Measurement
(MTM).
 
Predetermined
Predeterminedtime
timeMOTION
MOTIONSTUDY
STUDY

 PROCEDURE
 Jobs or task are broken down into finer and finer
elements
 Time values can be assigned to these elements
 The total time required to perform a task can be
determined by adding the appropriates elements
 
Predetermined
Predeterminedtime
timeMOTION
MOTIONSTUDY
STUDY

 Example
 Using MTM systems to identify standard time
 1 TMU = 0.0006 minutes
 Data must be extremely accurate, more
decimals places are necessary
 
Predetermined
Predeterminedtime
timeMOTION
MOTIONSTUDY
STUDY

 Example
 One Printed circuit board needed semiconductor to be push in the drilled
groove. Movement elements involve:

I. Hand move 6 inch to semiconductor 10.5TMU

II. Grasp semiconductor 8.0TMU
III. Bring semiconductor to the board 9.5TMU
IV. Adjust the position of semiconductor 20.1TMU
V. Push in the groove 20.3TMU
VI. Put the board aside 15.8TMU
TOTAL 84.2TMU
1 TMU = 0.0006 minutes
84.2TMU = 84.2 ( 0.0006)
= 0.05052 minutes
= 3.0312 second
 
Time
Timestudy
studystandard
standarddata
data
 Normal time value not obtained from direct time
measurement of the particular element but obtained from
direct time measurement of the element in a similar
operation earlier.
 Using time data to obtain standard time
 Often, elements of a task are repeated many times
throughout organization
 The organization already have time study and filed the
standard data for the elements
 Whenever the elements reappears the time could be
directly applied from the standard data file.
 
Time
Timestudy
studystandard
standarddata
data

Advantages Disadvantages
 Individual time study are  Time not accurate
quicker and less costly
 High development to obtain
 Consistently exists between the necessary data
time studies
 Less chance of error on a
study
 Fewer analysis may be
needed
 Good for cost estimating and
production planning before
jobs run