WORK STUDY

Unit 7

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 Work Study

It is that body of knowledge concerned with

the design of an optimum standardised work
method through analysis of the method and
equipment used in a present or proposed job.

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 Objectives of Work Study :
 To analyse the present method of doing a job systematically, and
to develop a new and/or better method.
 To establish a “Standard Time” of a job, through measurement of
the time required to perform it.
 To increase the productivity by ensuring the best possible use of
man, machine and material resources.
 To improve operational efficiency.
 To achieve the best quality Product / Service at the minimum
possible cost

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 Benefits of work study
Increased productivity

Reduced production costs

Better layout

Better manpower planning

Reduced handling costs

Better Morale and satisfaction of employees

Standard performance measurement and basis for incentive

schemes
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 Steps involved in work Study
Work Measurement
Method Study Work Study

Select the work to be studied

Select the work to be studied

Record the effective and ineffective time under existing working

Record the present method, using
conditions

Operation Examine to reduce / eliminate ineffective time

Flow Motion Charts Film
Process Charts
Process Analysis
Charts Charts Define method to be used

Examine the facts critically, considering the purpose, place, Break down job into elements
sequence, person and means

Develop the best method under prevailing circumstances Measure quantity of work involved in that method by:

Define the new method

Time Study Synthesis Analytical Work
(PMTS) Estimation Sampling
Install and maintain the new method

Estimate Normal Time and Standard Time

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 Method study

Method study is a technique of observing,

recording and examining the present method
of performing the work with a view to develop
a cheaper and productive method.
It covers work processes, working conditions,
equipments and tools used to carry out the job.

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 When method study is conducted:
High operating cost
Heavy rejections
Excessive movement of materials and men
Production bottle necks
Quality problems
Poor working conditions
Excessive overtime
Poor delivery performance

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 Advantages of Method study:
Work simplification
Improved method(cheaper and productive)
Better quality product
Improved layout
Better material handling
Better work flow
Less fatigue to operator
Shorter production time
Job satisfaction

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 Method Study Procedure
1. Selection of work based on present
problems and scope for improvement
2. Record relevant facts and information on
existing method , use appropriate charts and
diagrams
3. Examining recorded facts ( use what,
when , how, who, where, why type of
questioning on collected facts)

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 4. Developing improved method by
Eliminating wasteful tasks
Simplifying tasks
Combining tasks
Evaluating alternatives with respect to cost,
savings, feasibility , reaction of employees, short
term and long term implications etc.
5. Installing improved method ( plan, schedule,
coordinate, involve all concerned)
6. Maintaining the new method ( feed back on
performance towards objectives)

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 Recording Charts and diagrams used in
method study:
# Chart type Usage
1 Outline process chart Covers only main operations and
Inspections
2 Operations process chart Includes operations, inspections
and material inputs
3 Flow process charts Includes sequence of operations,
transportation, inspections, delays
and storages.

· For Material or product

· For Man
· For Machine
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 # Chart type Usage
4 Two handed Depicts the activities of both hands or limbs
process charts
5 Multiple activity For more than one worker/ machine or
chart equipment
6 Man- machine · Worker and machine on common time scale
chart · Worker and two machines on common time
scale
7 Flow diagram Actual paths followed by materials. Diagram
drawn to scale
8 String diagram String used to trace the path of materials or
workmen in a scale plan or a Model. To measure
distances travelled.
9 SIMO chart Simultaneous motion cycle chart used for very
small cycle time operations .

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 Symbols used in process charts:

Operation Movement /
Transportation
( conversion)

Delay / waiting
Inspection

Combined
Storage activity

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 Motion Study : A component of method study that aims to find
and install the method for a task, job or process with the least
wasteful method of labour.
Work Measurement : A Work study technique of measuring
the Work Content of a job. It usually succeeds method study
and/or method establishment. Two main Work measurement
techniques are time study and Work Sampling, apart from the
approach of time synthesis.
Time Study : A Work measurement technique for recording the
times and rates of working for elements of a specified job under
specified conditions and for analysing the data to determine the
time necessary to carry out the job at a defined level of
performance.

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 Objectives of Work Measurement
Improved planning and control
Basis for sound incentive schemes
Better utilization of manpower
Better labour productivity
Better labour cost control

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 Types of Work Measurement
1. Time Study
2. Synthesis Method
3. Analytical estimation
4. Predetermined motion time system (PMTS)
5. Work Sampling

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 Time Study :
A Work measurement technique for
recording the times and rates of working for
elements of a specified job under specified
conditions and for analysing the data to
determine the time necessary to carry out
the job at a defined level of performance.

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 Time Study Procedure : Theory of “Standard
Time : Start by selecting an operator with a known
“Rating”, and observe his performance over a number
of cycles

Step 1 : Record the observed time(s)

Step 2 : Determine the Central tendency, Usually the

Mean, or, for a large number of observations, the
Mode.

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 Step 3 : Multiply the Average Observed Time
with Operator Rating. This gives the Normal
Time.

Step 4 : Add on the approved allowances

(Personal and non-personal) to the Normal
Time. This gives the STANDARD TIME,
which is the basis of the final agreement of
productivity between Management and Unions.

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 Synthesis method
Synthesis method takes values of normal time for
each element from the data base developed and
available. Data base has elemental times for all
similar job elements e.g. loading, unloading,
clamping, checking etc.
Advantages: less time to establish, reliable, good
for estimation for new jobs

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 Analytical estimation
Takes data from elemental time data base as far
as possible. Estimation of time is made for
remaining elements based on experience
Advantages : good for non-repetitive jobs and
for estimation for new jobs

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 Predetermined motion time systems
(PMTS)

Times for basic motions ( Therbligs ) are

established in TMUs ( time measurement
units) . 1 TMU =0.036 sec. Times for reach,
move , grasp etc are available in TMUs.

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 Work sampling

Work sampling is based on statistical theory of

random sampling and probability of Normal
distribution.
Normally used for determining fraction of time the
machines are idle or the operators are idle. More
the number of samples taken less are the error.

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 No. of observations n= pqz2 / a2
p= percentage of observations where machine
was idle
q= 1- p ( percentage machine not idle)
z= desired confidence level ( z=1 for 68.3%, 2
for 95.4%, 3 for 99%)
a= desired accuracy or error (in percentage)

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 Important Formulae on Work Study
1.a) Observed Time per unit : OT = Ʃxi / n

1. b) Observed Time for ‘n’ Units: OT

= Working time – Idle time

Where xi – Recorded time of an observation,

n – No. of Observations

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 2. Normal time (Basic Time): NT = OT x PR
Where OT – Observed time,
PR – Performance Rating (Rating Factor)

3. Standard Time: ST = NT + AF
Or ST = NT x AFR
Where NT – Normal Time,
AF – Allowance factor
AFR –Allowance factor rating

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 Problems on Standard Time Calculation

The following information is available from a work sampling study

carried out over 48 hours of work in a week :
Total Units produced – 300; Average performance rating – 90%;
Idle Time – 18%; Total Allowances – 20% of basic time.
Determine the Standard Time per Unit.

Solution: Idle Time – 18% of 48 Hrs = 8.64 Hrs.

Available working time = 48 – 8.64 Hrs. = 39.36 Hrs. = 2361.6 mins
Þ Time taken to produce one job = 2361.6/300 = 7.87 Mins.
Þ Normal Time = 7.87  0.9 = 7.08 mins.
Þ Standard time = 7.08 mins  1.20 = 8.50 Mins Answer.

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 Work Study – Method study and Work Measurement
Problem - Following data were recorded in a Time Study :
Element Observed Rating Relaxation Frequ Normal Normal Standard
Time Allowance ency/ Time, Time per Time, mins
(Mins.) (%) Cycle mins. Cycle
a b c d e f g h
B  c / 100 Fe [1+d/100]  g
1 0.15 120 15 1 0.18 0.18 0.207
2 0.07 110 20 3 0.77 2.31 2.772
3 1.25 90 20 2 1.125 2.25 2.700
4 0.50 100 18 1 0.50 0.50 0.590

Standard time per Work Cycle = 6.269 mins.

= 6.3 mins.
Calculate the standard time per work Cycle.

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 Work Study – Method study and Work Measurement
A job has been divided into elements 1, 2, 3 and 4. The element time in minutes for the first five
cycles are shown in the following table with a performance rating for each element:
a. Compute an estimated normal time for the job based on the data available;
b. Compute standard time if the permissible allowance total is 25% of normal time .

Elem Observed Time ( mins), for cycle No. Performa Average Normal
ent 1 2 3 4 5 nce rating Obs. Time
% Time** (mins.)
1 1.51 1.63 1.48 1.55 1.72 100 1.58 1.58
2 2.46 2.34 2.33 2.36 2.30 90 2.36 2.12
3 1.79 3.02 1.84 1.78 1.77 95 1.80 1.71
4 1.25 1.11 1.40 1.15 1.29 115 1.24 1.43

Total Normal time for the job = 6.84 mins. Standard Time = 6.84  1.25 = 8.55 = 8.6 mins. Ans.
**
Cycle No.2 of element No.3 is ignored, as the timing seems to indicate some abnormality during
operation.

Observed timings of Element 4 are quite erratic. Though we have used the available data, further
numbers of observations should give a more accurate picture.
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