Methods and Value

Engineering
Chapter Four:
Method study
 Introduction to Method Study
According to British Standards Institution (BS 3138):
“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.”
Fundamentally method study involves the breakdown of an operation
or procedure into it component elements and their systematic analysis.
In carrying out the method study, the right attitude of mind is
important.
 Cont’d

Method study enables the industrial engineer to subject each operation

to systematic analysis.
Method study is also called methods engineering or work design.
Method engineering is used to describe collection of analysis techniques
which focus on improving the effectiveness of labor and machines.
Method study is essentially concerned with finding better ways of doing
things. It adds value and increases the efficiency by eliminating
unnecessary operations, avoidable delays and other
forms of waste.
 Cont’d
The method study Person should have:
1. The desire and determination to produce results.
2. Ability to achieve results.
3. An understanding of the human factors involved.
 Cont’d
The objectives of method study techniques are:
Present and analyze true facts concerning the situation.
To examine those facts critically.
To develop the best answer possible under given
circumstances based on critical examination of facts
 Cont’d
The scope of method study is not restricted to only manufacturing
industries.
Method study techniques can be applied effectively in service
sector as well. It can be applied in offices, hospitals, banks and other
service organizations.
 Cont’d
Method study can be applied successfully in manufacturing for the following
reasons:

To improve work methods and procedures.

To determine the best sequence of doing work.
To smoothen material flow with minimum of back tracking and to improve
layout.
To improve the working conditions and hence to improve labor efficiency.
To reduce monotony in the work.
To improve plant utilization and material utilization.
Elimination of waste and unproductive operations.
To reduce the manufacturing costs through reducing cycle time of
operations
 Steps or Procedure Involved in Method Study
The basic approach to method study consists of the following eight
steps.

Figure: Method Study Procedure

 Cont’d

1. SELECT the work to be studied and define its boundaries.

2. RECORD the relevant facts about the job by direct observation
and collect such additional data as may be needed from
appropriate sources.
3. EXAMINE the way the job is being performed and challenge its
purpose, place sequence and method of performance.
4. DEVELOP the most practical, economic and effective method,
drawing on the contributions of those concerned.
 Cont’d
5. EVALUATE different alternatives to developing a new improved
method comparing the cost-effectiveness of the selected new method
with the current method of performance.
6. DEFINE the new method, as a result, in a clear manner and
present it to those concerned, i.e., management, supervisors and
workers.
7. INSTALL the new method as a standard practice and train the
persons involved in applying it.
8. MAINTAIN the new method and introduce control procedures to
prevent a drifting back to the previous method of work.
 Selection of the Job for Method Study

The job should be selected for the method study based upon the
following considerations:
1. Economic aspect
2. Technical aspect and
3. Human aspect.
 Cont’d
A. Economic Aspects
The method study involves cost and time. If sufficient returns are not
attained, the whole exercise will go waste. Thus, the money spent
should be justified by the savings from it. The following guidelines can
be used for selecting a job:
 Bottleneck operations which are holding up other production
operations.
Operations involving excessive labor.
Operations producing lot of scrap or defectives.
Operations having poor utilization of resources.
Backtracking of materials and excessive movement of materials.
 Cont’d
B. Technical Aspects
The method study man/women should be careful enough to select a
job in which he/she has the technical knowledge and expertise.
A person selecting a job in his/her area of expertise is going to do full
justice.
Other factors which favor selection in technical aspect are:
1. Job having in consistent quality.
2. Operations generating lot of scraps.
3. Frequent complaints from workers regarding the job.
 Cont’d
C. Human Considerations
Method study means a change as it is going to affect the way in
which the job is done presently and is not fully accepted by workman
and the union.
Human considerations play a vital role in method study. These are
some of the situations where human aspect should be given due
importance:
1. Workers complaining about unnecessary and tiring work.
2. More frequency of accidents.
3. Inconsistent earning.
 Information Collection and Recording
Information Collection Techniques:
The accuracy of data about the method study problem is important for
the development of improved method.
Determine the sequence of operations
 Note down all snags and difficulties and suggestions during interview
and observation.
Get all possible information from informal records
Information needed: the object of the operation, the means, the place,
time and date, the volume and frequency
The following techniques are used for the collection of information /
data about the task under consideration.
 Cont’d
A. Observation.
It is a common technique used for collecting information about the
present method or the existing problem.
The method study person visits the site where the work is
currently being done and observes various steps in the method being
followed.
There are many instances where all the data needed is obtained by
only observing the work or work site.
 Cont’d
B. Discussion.
Discussion with those who do or who supervise the work can
frequently provide information not obtainable by observation.
The discussion technique is commonly used where irregular work is
involved or where one is trying to analyze past work in order to improve
efficiency of work to be done in future.
Even where observation by itself may accomplish the data collection
task, discussion may be used for developing good human relations.
 Cont’d
C. Records.
Valuable information can be obtained from past records concerning
production, cost, time, inventory and sub-contracts. For certain type of
information concerning the past practice, sometimes this is the only
way to obtain authentic data.
 Cont’d
D. Motion Pictures or video Films.
 Accurate and most detailed information can be obtained by taking
motion pictures or video film.
Information obtained by this procedure can easily be transmitted /
forwarded to all levels in the organization and if needed, can be used
directly for training purposes.
The film can be used to focus attention at particular point or motion in an
operation.
For obtaining information concerning those types of work that involve
large crew size, it is probably the only procedure.
 Cont’d
Information Recording Techniques:
There are three main types of information recording techniques. These
are
 Process Charts
Diagrams
Templates
 Cont’d
A. Process Chart
A Process Chart is a graphic means of representing the activities that
occur during a manufacturing or servicing job.
Process charts are the graphical representation or diagrams of pictures
which gives overall view of a process.
Thus a chart indicates the process with the help of symbols and aids for
better understanding with a purpose of improvement and identification of
facts.
Process charts are denoted by symbols.
The symbols give a better understanding of the facts
 Cont’d
Process Chart Symbols
The following are the various symbols to record various events
(elements of Work):
Cont’d
Cont’d
 Cont’d

Types of process Charts can be divided into two groups.

A. Those which are used to record a process sequence (i.e. series of
events in the order in which they occur) but do not depict the
events to time scale.
 This category includes: Operation process chart, Flow
process chart – (man / material / equipment type) and
Operator chart (also called Two Handed Process Chart)
B. Those which record events in the sequence in which they occur
on a time scale so that the interaction of related events can be more
easily studied.
 This category includes: Multiple activity chart
 Cont’d
The Operation Process Chart (OPC)
This is also known as outline process chart and it provides a compact
over all view of the whole system of operations involved in the
production of a product.
This chart has been used for long time to display the operations,
inspections, and their sequence for manufacture of a complete product in
one figure. Operation includes all work performed by a worker or a crew
at one location at one time.
In this chart only the main activities (i.e. operations and inspections)
carried out to complete a job are recorded in the sequence of their
occurrence but irrespective of where they are performed and who
performs them.
Thus only symbols of process chart are used in preparing it.
 Cont’d
Some times a brief note about the nature of each activity (may be
operation and inspection) and the time allowed are mentioned by the side
of symbols.
The processing of material i.e. various activities are shown vertically on
the entry or purchase of material by horizontal lines as shown in the figure
in the next slide.
The operation process chart for the fabrication of riveted assembly.
 Cont’d
Operation Process Chart
Part Name: Washer Assembly
Order No.: A 384/98
Drg. No.: AOC594 C
Method: Present Chart by Mr. Tariku Date: May,11, 2016
Part B Part A Part C

Turn and Face 3 1 Cut to size 6 Turn

Drill Turn and

4 2 7 Thread
bore

1 Inspect
2 8 Mill
5 Assembly
3 Inspect
Final
9
Assembly
Final
4
Inspection
 Cont’d
An operation process chart has following advantages:
i. To improve shop/plant layout
ii. Helps in specifying the basic manufacturing system
iii. Helps in determining sequence of assembly and the scheduling
activities regarding dates of purchased material and completion
dates for fabricated parts.
iv. To introduce the new technical personal with the manufacturing
system.
 Cont’d

Figure: An example of the outline process chart of plywood manufacture

 Cont’d
Flow Process Chart (FPC)
Is a chart showing the sequence of the flow of a product by way of
recording all activities/events under review with appropriate symbols.
In case of OPC, attention was paid only to operations, the flow process
chart (FPC) includes additional components like transports or moves,
delays and storages occurring during production.
This also gives the information regarding the distance moved and time
required for different items such as transportation, delays, and inspection,
etc.
It is usually prepared for one component of an assembly at a time.
 Cont’d
Storage indicates that the product has come out of production’s
control, and is under the control of another entity (e.g., the stockroom
or warehouse).
Delay implies that the product remains under production’s direct
control.
The flow process chart is particularly effective in tracing the
incredible distance traveled by apart in plant specially if the plant is
not designed scientifically.
 Cont’d
There are three types of Flow process charts: Man, Machine and
Material
1. The man type flow process chart shows the process from the points of
view of man/operator. This is a graphic representation of different
steps a person performs when doing a job and his movements from one
place to another in performing that job.
• It indicates the activities of man through out the process.
2. The machine type flow process chart shows the activities from the
point of view of machines involved.
 Cont’d
3. The material type (Product type) flow process chart shows the
process from the materials point of view utilized during the
process. This is a graphic representation of different steps involved in
performing the work required to pass a product from one stage to
another.
• It shows the introduction of all materials whether raw material or
finished components and represents all information regarding
operations and inspections carried out on the during process
diagrammatically.
Example: 1:A portion of the flow process chart (material type ) showing flow of material
Operations Distance moved Time
(m) (min)
Activity
Steel plates in store
Moved to gas cutting M/c 20 6
Wait cutting M/c being set 20
Plates cut to size 40
Moved to M/c Shop 15 12
Inspected before Machining 10

35
 Cont’d
Example:2: A flow process chart is shown below for vulcanizing for
tires.
Vulcanizing means treating rubber under heat with sulfur or some
compound to increase elasticity and durability. The symbols are short
hand tools and serve as sign posts to wake critical areas for
improvement. In this way by making flow process chart, a process or
job can be analyzed step by step. Activity can be eliminated in some
cases, combined in others or rearranged for effective processing.
Cont’d
 Cont’d
Summary
 Cont’d
Benefits of Flow Process Chart
It helps to improve a work method by:
i. Simplification of operations.
ii. Simplification of inspection required
iii. Reduction in distance moved by men and materials in shops
iv. Reduction in waiting time
v. Reduction in periods of temporary storage so reduces work in
process time
 Cont’d
Multiple Activity Charts (MAC)
There will be various situations wherein the combined and 'inter-
related efforts of a group of· workers and machines would be
necessary for the performance of the job.
The charts described so far can be used to record only one subject in
anyone particular chart.
Whenever a process involves the co-ordination of various activities it
may be required to study the relationship between these activities.
Such an inter-relationship is provided by the multiple activity charts.
A multiple activity chart is used to record the activities of one subject
in relation to others.
 Cont’d
Multiple activity chart brings out the comparative utilization of men
and machines very clearly and helps to synchronies the various
activities and improve the situation.
It is a useful tool for planning team work and determining the staffing
pattern.
These charts graphically depict the relationship of two or more
simultaneous sequences of activity against a time scale.
A multiple activity chart may be any of the following types:
i. Man-Machine Chart
ii. Man-Man Chart
iii. Simo Chart
 Cont’d
Procedures for constructing Multiple activity Charts
Separate vertical bars are attached to each worker and/or machine to be charted.
A time scale is entered along side in a convenient place, usually on the left hand side.
The activities are then plotted in sequence against the time scale within their own
particular bar in the chart.
Brief descriptions of the activities are also given along side.
In getting the time for activities very fine accuracy may not be needed. But it may
become necessary sometimes to obtain the time values by one of the work
measurement techniques.
The contract between working and non-working is brought out by suitable hatching
of the respective boxes.
A summary showing the times and percentage use of all the subjects is made at the
end of the chart.
 Similar summary for the proposed method provides a comparison.
 Cont’d
1. Man-Machine Chart
It is a diagram which describes the activity of a man and machines
he is attending against a time scale.
The general approach in such analysis is to try to use the resources in
optimal manner. The focus of the analysis is to minimize the cycle
time of man or the operator.
Based on this study, one can propose a better method.
Efforts are directed to reduce the idle times of man and machine.
A Man-Machine Chart is illustrated in Figure below:
Cont’d
 Cont’d
Summary
 Cont’d
Example: The operating characteristics of the two operations are
indicated in the following table:

Operation 1 Operation 2
Upload 0.13 min 0.12 min
Load 0.18 min 0.14 min
Mill 0.40 min 0.49 min
Total 0.71 min 0.75 min

The diagram is shown in the next slide.

 Operation 1 On Operation 2 On
Operator
M/C1 M/C 2
0.0 _
0.1 _
0.2 _ S1 S IDLE
0.3 _ 0.31 0.31
0.4 _
MINUTES

S2 S S = indicates setting period

0.5 _ R
0.6 _ 0.57 R = Running period
IDLE
0.7 _ 0.71 Sectioned Portion is idle period
0.8 _ R
0.9 _ S1 S
1.0 _ 1.02
IDLE 1.06
1.1 _
1.2 _ S2 S
R
1.3 _ -
1.4 _ IDLE R

 In this diagram it is indicated that one man can operate two machines in both the cases
with cycle times of 0.71min and 0.75min.
 Each operator is operating two machines performing operations 1 and 2.
47
Cont’d
 Cont’d
Job: Turn Edge-present method
Subject of Chart: Operator, Lathe I, Lathe II
Chart Begins: Operator near Machine I-unloading & loading
Chart Ends: Operator near Machine II
 Cont’d
2. Man-Man Chart
It depicts graphically the simultaneous activities of two or more
operators/ workers against a time scale.
The purpose of this chart is utilize two or more workers on the same
job without loss of time by any one of them thus improving production
or increasing productivity of the system.
Example: for the early morning concurrent activities of three persons in
apartment. The chart is shown in the next slide.
 Cont’d

Control Activities Times

Making all the beds 5 Minutes
Preparing Breakfast 14 Minutes
Bath and Shave 8 Minutes
Dress Up 10 Minutes
Wash Dishes 14 Minutes
Eat or Take Break Fast 13 Minutes
Close Apartment 5 Minutes
 1 2 3 Cont’d
BEDS (7) PREPARE
BATH (8)
BREAK FAST
BATH (8) (14) DRESS (10)
EAT (13) EAT (13)
EAT (13)
DRESS (10) BATH (8)
WASH
CLOSE (7) DRESS (10) DISHES (14)

Total Time Total Time Total Time

(45min) (45min) (45min)

Each of the common activities such as preparing breakfast for all,

taking breakfast, washing all the dishes, dressing up closing the
apartment are performed simultaneously.
It may be seen that all of them take same time of 45 minutes and get
ready at the same time.
3. SIMO Chart Cont’d
This chart was devised by the Gilberth and it shows graphically the separable
steps of each pertinent limb of the worker under study.
It is rather an extremely detailed left and right-hand operation chart.
It indicates on a common time scale the simultaneous movements performed by
the two hands of the worker.
SIMO chart is generally utilized for micro motion analysis of:
i. Short cycle repetitive jobs.
ii. High order skill jobs.
 Cont’d
B. Diagrams.
It gives pictorial view of the layout of workplace or floor on which
locations of different equipment, machines, etc. are indicated.
Indicates the movement of man or material by a line or a string.
The diagrams are valuable in highlighting the movement so that
analyst can take steps to simplify or reduce it and thus effect saving in
time or reduction in collisions / accidents.
Two common types of diagrams are : Flow diagram and string
diagram.
 Cont’d
Flow Diagram
Is a pictorial layout of buildings and floors on which locations of all the activities
as given on the flow lines representing the movement of men and materials are
shown.
Is valuable in incorporating improvements in the method.
Example: Q P

2 2 1

1 3
R

STORE

4
S
 Cont’d
Flow process chart and flow diagrams are very simple and effective
tools of methods study. They are very useful in establishing the overall
sequence of operations and in determining the best layout.
 Cont’d
String Diagram
This diagram is a layout drawing on which a length of string is
utilized to record the extent as well as the pattern of movement of
operators, materials and machines working in a limited area during a
certain period of time.
It is a special type of flow diagram generally drawn when the paths are
many and repetitive and a flow diagram becomes crowded and it is
neither easy to trace it nor to understand.
String diagram is a scale plan of the shop, in which every machine or
work bench is marked and a peg is struck in the area representing a
facility.
A continuous colored string traces the path traced/adopted by the
operator or materials or machines while performing particular activity.
 Cont’d

M-4 M-3 STORE

ROOM

M-1

Inspection
Section
M-2
M-5

STORE

String Diagram
 Cont’d
Benefits of String Diagram
1. A string diagram represents the record of an existing set of conditions
and thus helps the methods engineer in visualizing the actual
situation.
2. It indicates complex movements, back tracking, overcrowding, bottle
necks and over and under utilized paths on the shop floor.
3. It is an aid for comparison between different layouts or the methods
of doing a job as far as the distances moved are involved.
4. It helps in tracing existing paths of movement for incorporating
necessary modifications if any.
5. It is preferred when movements are not regular as far as frequency
and distance moved are concerned.
6. Indicates the pattern of movements and thus helps in deciding the
most economical routes to perform a particular operation.
 Critical Examination

Critical examination of the information recorded about the process

in charts / diagrams is the most important phase of the method study.
In this, each element of the work, as presently being done and
recorded on the chart is subjected to a systematic and progressive
series of questions with the purpose of determining true reasons for
which it is done. Based on the reasons, improvements are found and
adopted into a new method, called better method.
The use of questioning technique reduces the possibility of missing
any information which may be useful for the development of better
method.
 Cont’d
A popular procedure of carrying out critical examination uses two sets
of questions: Primary questions (answers to these show up the
necessity of carrying out the activity), and Secondary questions
(answers to these allow considerations to alternative methods of doing
the activity).
 Cont’d
Primary Questions:
It’s main purpose is to make sure that the reasons for every aspect of
the presently used method are clearly understood.
The answers to these questions should clearly bring out any part of the
work which is unnecessary or inefficient in respect of means,
sequence, person or place.
 Cont’d
1. Purpose. The need of carrying out the activity is challenged by the questions-
What is achieved? Is it necessary? Why? The answers to these questions
determine whether the particular activity will be included in the proposals of
new method for the process.
2. Means. The means of carrying out the activity are challenged by the
questions- 'How is it done?' and 'Why that way'?
3. Place. The location of carrying out the activity is challenged by the questions-
'Where is it done'? and 'Why there'?
4. Sequence. The time of carrying out the activity is challenged by the
questions- 'When is it done'? And 'Why then'?
5. Person. The level of skill and experience of the person performing the activity
is challenged by the questions- 'Who does it'? and 'Why that person'?
 Cont’d
Secondary Questions:
The aim of secondary questions is to arrive at suitable alternatives to the
presently used method:
1. Purpose. If the answer to the primary question 'Is the activity necessary"? is
convincingly 'Yes', alternatives to achieve the object of carrying nut the
activity are considered by the question— 'What else could be done'?
2. Means. All the alternative means to achieve the object are considered by the
question— 'How else could it be done'?
3. Place. Other places for carrying out the activity are considered by the
question— 'Where else could it be done'?
4. Sequence. The secondary question asked under this heading is— 'When
else could it be clone'?
5. Person. The possibilities for carrying out the activity by other persons are
considered by asking the question- 'Who else should do it' ?
 Developing Better Method
With the present method or procedure for the job in mind, the
application of ‘critical analysis' highlights the essential part of the job,
for which alternative ways for its carrying out are developed .
When developing alternative ways for doing a task the following may
be considered.
• Where and how to use ‘Person' in the process?
• What better work procedure be adopted?
• What better equipment be used?
• What better layout of work station, shop or factory be used?
 Cont’d
In deciding whether a particular element of work (operation,
inspection, or transportation) be carried out manually or with the
help of a device, method study engineer must be well aware of things
which Person cannot do or does in inferior fashion than machine.
Examples of such things are:
• Exert large amount of force, as needed in metal cutting.
• Exert force precisely or smoothly at a fixed rate as needed in
metal forming.
• Do high speed computations of complex nature.
• Perform repetitive tasks without suffering from side effects like
boredom, fatigue, etc.
 Cont’d
• Move at high speeds for hours together.
• Carry out several tasks simultaneously.
• Respond fast to frequently changing control signals.
• Perform satisfactorily in an environment where conditions
relating to cold, heat, noise, dampness, etc. are extreme.
 Evaluation
The answers to the following questions are then required through
evaluation of the alternatives.
• 'What should be done'?
• 'How should it be done'?
• 'Where should it be done'?
• 'When should it be done'? and
• 'Who should do it'?
 Cont’d
The evaluation phase requires the work study Person to consider all the
possibilities with respect to the four factors—
 Economic ( refers determination of 'How much will it cost'? and
'How much will it save'?)
Safety (is to ensure that the alternative selected shall not make the
work less safe.)
Work quality (The evaluation of quality factor shall determine
whether the alternative selected shall make for better product quality
or quality control.) and
Human factors (human factors considerations shall ensure that the
new method will be interesting, easy to learn, safe, less monotonous
and less fatiguing to the operator.)
 Defining The Improved Method
The report should show:
1.     Relative costs in material, labor and overheads of the two methods, and
savings expected.
2. The cost of installing the new method, including the cost of new
equipment and of re-laying out shops or working areas
3.  Executive actions required to implement the new method.  It should also
give details regarding :
1. The tools and equipment to be used
2.  A description of the method
A diagram of the work place layout, jigs/fixtures etc
 Installation of Improved Method
The activities of the installation phase include:
1. Gaining acceptance of the change by the workers involved and their
representatives.
2. Retraining the workers. The extent to which workers need retraining will depend
on the nature of the job and the changes involved.
3. Arranging the requirements of the new method. This involves -
Arranging the necessary plant, tools and equipment at all the workplaces,
Arranging building-up of necessary stocks of new raw materials, and
running-down of old stocks,
Checking up the availability and continuity of all supplies and services, and
Arranging any clerical records which may be required for purposes of
control and comparison.
4. Taking other necessary actions.
5. Giving a trial run to the new method
 Standard Performance
Is the rate of output which qualified workers will naturally achieve
without over-exertion as an average over the working day or shift,
provided that they know and adhere to the specified method and
provided that they are motivated to apply themselves to their work.