Semester-III, BBA, 2014-17

MOTION & TIME STUDY

Prof. Biranchi Prasad Panda

CoMES, UPES, Dehradun.
Motion & Time Study

• Productivity
• Method Study
• Motion Study
• Time Study
• Ergonomics
 Productivity
Productivity is an attitude of mind. It is the mentality of progress, of the constant
improvements of that which exists. It is the certainty of being able to do better today than
yesterday and continuously. It is the constant adaptation of economic and social life to
changing conditions. It is the continual effort to apply new techniques and methods. It is
the faith in progress. - European Productivity Agency (EPA) -

• Mathematically, Productivity is the efficiency of production.

• It is a quantitative relation between what we produce and how much resource we consume for this.

Output (..) ↑ . ↑ ↑↑ ↑
Productivity (↑)= Input (..) . ↓ ↓ ↑ ↓↓

• Therefore, higher productivity (↑) refers to a higher production in lesser time, cost, effort …. etc.

– Economists see it from Gross National Product view

– Managers see it from cost cutting and speed up view

– Engineers see it from output per hour view

• Productivity refers to the efficiency of a production system

• Factors/resources of production can be land, man, machine, materials, money/capital, energy, time, ..
Factors of Productivity
• Controllable factors (internal)
– Product
– Plant & Equipment
– Technology
– Materials
– Energy
– Human
– Methods/Process
– Management style

• Un-controllable factors (external)

– Structural adjustments
– Natural resources
– Government (policy, infrastructure)
 Measuring Productivity
Total productivity measure (TPM) Partial productivity measure (PPM)
Total productivity *
= Total tangible output / Total tangible input Partial productivity *
= Total output / Individual input
Total tangible output = value of FG produced +
value of partial units produced + dividends Labor productivity = Total output / labor input
from securities + interest + other income
Capital productivity = Total output / capital input
Total tangible input = value of (human + material +
capital + energy + other inputs) used. The Material productivity = Total output / material input
tangibility refers to measurability.
Energy productivity = Total output / Energy
input
* The output and input must be expressed in a common
measurable unit, preferably in rupee value * The output and input must be expressed in a common
measurable unit, preferably in rupee value
 Productivity improvement techniques
• Technology based
– CAD, CAM, CIM, CAPP, MRP, CRP, Robotics, FMS, modern technologies etc.

• Employee base
– Individual/group incentives, promotion, job design/rotation/enrichment/ enlargement,
participation, QC, group technology etc.

• Material based
– Planning, selecting, purchasing, storage, retrieval, waste reduction, control etc.

• Process based
– Methods, simplification, job design, safety, ergonomics etc.

• Product based
– Value, diversification, standardization, simplification, reliability, product mix, promotion etc.

• Task based
– Mgt. style, communication, work culture, motivation, promoting group activity.
 Work Study
• Work-study
– The basis for work-system design
– Identifies the most effective means of achieving functions
– Aims to improve the existing and proposed ways of doing work
– Establishes standard times for work performance
– An accurate and systematic technique
– Better manager-worker relation at workplace
– Better workplace layout

• Two major techniques of work-study to improve productivity:

– Method study (or motion study)
Method study is the systematic recording and critically examining the present and proposed ways of
doing work as a means of developing and applying easier and more effective methods and reducing
costs.

– Time study (or work measurement)

Work measurement is the application of techniques designed to establish the time for a qualified
worker to carry out a specified job at a defined level or performance.

– Link between
Method study standardizes the operations and work measurement standardizes the time for them.
 Work Study
• Work-study
– The basis for work-system design
– Identifies the most effective means of achieving functions
– Aims to improve the existing and proposed way ways of doing work
– Establishes standard times for work performance

• Two major techniques of work-study are:

– Method study (or motion study)
– Time study (or work measurement)
 Method Study
Method study is the systematic recording and critical examination of existing and
proposed ways of doing work as a means of developing and applying easier and
more effective methods and reducing cost. – British Standard Institute (BS: 3138) –

• Method study analyzes the operations systematically

• Also called as methods engineering or work-design
• Improves work methods by
– Understanding the human factors involved in a production
– Understanding and effectively utilizing all the resources – men, machines,
materials, tools, etc.
– Designing the facility locations, work stations and work environment
– Understanding the movements of man and material movement
– Designing better products and processes
– Establishing the best sequence of doing work
– Elimination of waste of material, time and all kinds of efforts so as to reduce the
cycle time of operations
• Steps in Method study: Select, Record, Examine, Develop, Evaluate, Define, Install,
Maintain
 Steps in Method study
Select a job for method study with
– Economic considerations for
• Critical operations, labor intensive operations, operations resulting scrap
and rejections, over/un(der)utilized resources

– Technical considerations for

• Jobs with inconsistent quality, operations resulting scrap and rejections,
high maintenance of m/c-equipment

– Human consideration for

• Discomfort/ tiresome at workplace, safety, inconsistent earning
 Steps in Method study
Record all facts about the Job/operation
– Record in the form of charts, diagrams and datasheets
Charts, may or may not be scaled, often use the symbols for different
movements (ref. motion study)
– Macro-motion charts – operation/outline process chart (shows operations
and inspections only), flow process chart (of material/man/equipment type,
shows operation, inspection, storage, delay, and transportation), 2-handed
process chart (shows the loading pattern of two-hands), multiple-process
chart (man/machine, material/machine, ...
– Micro-motion charts (for doing job analysis by studying the micro-motions of
body parts), ex-SIMO (simultaneous motion )chart
Diagrams used in method study are
– Flow diagram (man/machine type, shows the locations through which process
flows), string diagram (a scaled layout indicating the amount of movement in
the shop-floor)
 Steps in Method study
1. Examine the facts critically
– The purpose, place, sequence, and method of performance
2. Develop a record and alternative methods
– A most practical, economic and effective method
3. Evaluate the alternative methods
– By comparing the cost-effectiveness
4. Define the method and production resources
– Present it to the management, supervisors and workers
5. Install the improved method and supports
– Train accordingly the involved persons
6. Maintain the installed set-up and method
– Elimination of waste of material, time and all kinds of efforts so as to
reduce the cycle time of operations
 Motion Study
Motion study as a part of method study analyses the motion of an operator or work.

• The principles of motion study, laid by Gilbreth are grouped into

three headings:
– Use of the human body
• In rhythm, simultaneous/combination, swinging
– Arrangement of workplace
• Materials, tools, workstations arranged in a definite way to reduce
search
• Use of gravity (drop delivery) and ejectors for motion economy
• Light, air, height of workplace (seating/standing/moving) need to be
well organized to keep the people productive
– Design of tools and equipment
• Use of symbols, color codes, jigs and fixtures to run fool-proof
• Use of levers, handles, wheels at workplace for mechanical advantage
 Time Study (or Work Measurement)
The application of techniques designed to establish the time for a qualified worker to carry out a specified job at a
defined level of performance. - British Standard Institute -

• Work measurement helps in planning, scheduling and controlling

• Helps in determining the capacity of facilities, rate of production, labor utilization, efficiency,
wage incentive plan, standard costing and budget control
• A basis for scheduled delivery
• Work Measurement done in terms of - Repetitive works and Non-repetitive works

• Time study does under direct observations and analysis,

– Time study: for recording the times and rates of working for a job using stop
watch.
– Synthetic data: for building up the time for a job or pans at a defined level of
performance .
– Work sampling: a large number of observations are made over a period for
one/group of machines, processes or workers.
– Predetermined motion time study (PMTS): whereby times are established for
basic human motions to build up the time for a job at a defined level of
performance. A very common PMTS is Methods Time Measurement (MTM).
– Analytical estimating: to develop time elements of a job at a defined level of
performance. This is done by own knowledge and experience.
 Computing the Standard Time

Standard time may be defined as the, amount of time required to complete a unit of work:
(a) under existing working conditions,
(b) using the specified method and machinery,
(c) by an operator, able to the work in a proper manner, and
(d) at a standard pace.

Thus basic constituents of standard time are:

1. Elemental (observed time)
2. Performance rating to compensate for difference in pace of working
3. Relaxation allowance
4. Interference and contingency allowance
5. Policy allowance.
Ergonomics (or Human Engineering)
Examples
Answer:
A B C
Men 1000 2000 3000

Prodn. 10 15 25
(per month)

Prodn./yr 10x12=120 15x12=180 25x12=300

Productivity 10/1000=1/100 15/2000=3/400 25/3000=1/120

Answer:
Previous Now
Production/yr = 120 140
HR used = 20,000 21,000
Productivity = 120/20000=0.006 140/21000=0.0067

% increase in Production = [(140-120)/120] x 100 = 16.67%

% increase in Productivity = [(0.0067-0.006)/0.006] x 100 = 11.67%

Answer:
Cycle time for an operation = 1.14 min.
Production time available in a day = 405 min.
But,
Total time available in a day = 480 min.

Therefore,
Standard time of the product = 480/355 = 1.35 min. ……………………………… (1)

Production in a standard hour = 60/1.35 = 44.44 = 44/hr. ………………………. (2)

Answer:
Observed time for a work = 15 min.
Rating factor of a worker = 80%
So, Basic time = 15 x 0.8 = 12 min. …………………………………………………………………. (1)
Fatigue allowance = 2%
Contingency work allowance = 1%
Contingency delay allowance = 2%
Process allowance = other than personal allowance = (2+1+2)% = 5%
So, Normal time of work = Basic time + 5% = 12 + (12 x 0.05) = 12.6
Personal allowance = 5%
So, Standard time of work = Normal time + 5%
= 12.6 + (12.6 x 0.05) = 12.6 + 0.63 = 13.23 ………… (3)
Work content = No. of works done in an average day
= 480/13.23 = 36.28 = 36 ………………………………………………….. (2)