1. Manual Work & Worker-Machine
Systems
Sections:
1. Manual Work Systems
2. Worker-Machine Systems
3. Automated Work Systems
4. Determining Worker and Machine
Requirements
5. Machine Clusters
Chapter 2
2. Three Categories of Work Systems
1. Manual work system
Worker performing one or more tasks
without the aid of powered tools
2. Worker-machine system
Human worker operates powered
equipment
3. Automated work system
Process performed without the direct
participation of a human worker
6. Some Definitions
Work unit – the object that is processed by the work
system
Workpiece being machined (production work)
Material being moved (logistics work)
Customer in a store (service work)
Product being designed (knowledge work)
Unit operations – tasks and processes that are
treated as being independent of other work
activities
7. Manual Work Systems
Human body accomplishing some physical task
without an external source of power
With or without hand tools
When hand tools are used, the power to
operate them is derived from the strength of a
human worker
Other human faculties are required, such as hand-
eye coordination and mental effort
8. Pure Manual Work
Involves the physical and mental capabilities of the
human worker, and no machines, tools, or other
implements are employed in performing the task.
Material handler moving cartons in a warehouse
Workers loading furniture into a moving van without
the use of dollies
Dealer at a casino table dealing cards
Office worker filing documents
Assembly worker snap-fitting two parts together
9. Manual Work with Hand Tools
Manual tasks are commonly improved by the use of
hand tools. A tool is a device or implement for
making changes to some object (e.g., the work
unit), such as cutting, grinding, striking, squeezing,
or other process. A hand tool is a small tool that is
operated by the strength and skill of the human
user. Examples of manual tasks involving the use of
hand tools include the following:
Machinist filing a part
Assembly worker using screwdriver
Painter using paintbrush to paint door trim
QC inspector using micrometer to measure a shaft
diameter
10. Repetitive vs. Nonrepetitive Tasks
Repetitive Task
Relatively short duration (usually a few
minutes or less)
High degree of similarity from one cycle to
the next
Nonrepetitive Task
Takes a long time
Work cycles are not similar
11. Cycle Time Variations
A main objective in work design is to determine the one
best method for a task, and then to standardize its use
Once the method has been standardized, the actual time
to perform the task is a variable because of:
Differences in worker performance
differences in hand and body motions
Mistakes by worker
Variations in starting work units
The learning curve phenomenon
Differences in the physical and cognitive attributes
among workers performing the task
Variations in the methods used by different workers to
perform the task
12. Worker Performance
Defined as the pace or relative speed of working
As worker performance increases, cycle time
decreases
From the employer’s viewpoint, it is desirable for
worker performance to be high
What is a reasonable pace to expect from a
worker?
13. Normal Performance
A pace of working that can be maintained by a
properly trained average worker throughout an
entire work shift without injurious effect on the
worker’s health or physical well-being
The work shift is usually 8 hours, during which
periodic rest breaks are allowed
Normal performance = 100% performance
Common benchmark of normal performance:
Walking at 3 miles/hr
14. Normal Time
The time to complete a task when working at
normal performance
Actual time to perform the cycle depends on
worker performance
Tc = Tn / Pw
where Tc = cycle time, Tn = normal time, and
Pw = worker performance or pace
15. Example: Normal Performance
Given: A man walks in the early morning for health
and fitness. His usual route is 1.85 miles. A typical
time is 30 min. The benchmark of normal
performance = 3 miles/hr.
Determine: (a) how long the route would take at
normal performance and (b) the man’s performance
when he completes the route in 30 min.
16. Example: Solution
(a) At 3 miles/hr, time = 1.85 miles / 3 miles/hr
= 0.6167 hr = 37 min
(b) Rearranging equation, Pw = Tn / Tc
Pw = 37 min / 30 min = 1.233 = 123.3 %
Alternative approach in (b):
Using velocity = 1.85 miles / 0.5 hr = 3.7 miles/hr
Pw = 3.7 miles/hr / 3.0 miles/hr = 1.233 %
17. Standard Performance
Same as normal performance, but acknowledges
that periodic rest breaks must be taken by the
worker
Periodic rest breaks are allowed during the work
shift
Federal law requires employer to pay the
worker during these breaks
Other interruptions and delays also occur during
the shift
18. PFD Allowance
To account for the delays due to:
Personal time (P)
Bathroom breaks, personal phone calls
Fatigue (F)
Rest breaks are intended to deal with fatigue
Delays (D)
Interruptions, equipment breakdowns
19. Standard Time
Defined as the normal time but with an allowance
added in to account for losses due to personal
time, fatigue, and delays
Tstd = Tn (1 + Apfd)
where Tstd = standard time, Tn = normal time, and
Apfd = PFD allowance factor
Also called the allowed time
20. Irregular Work Elements
Elements that are performed with a frequency of
less than once per cycle
Examples:
periodic changing of tools (e.g., changing a
knife blade)
Irregular elements are prorated into the regular
cycle according to their frequency
21. Example: Determining Standard
Time
Given: The normal time to perform the regular work
cycle is 3.23 min. In addition, an irregular work
element with a normal time = 1.25 min is performed
every 5 cycles. The PFD allowance factor is 15%.
Determine (a) the standard time and (b) the number of
work units produced during an 8-hr shift if the worker's
pace is consistent with standard performance.
22.
23.
24.
25. Standard Hours and Worker
Efficiency
Two common measures of worker productivity used in
industry to assess a worker’s productivity are standard
hours and worker efficiency
Standard hours – represents the amount of work actually
accomplished
Hstd = Q Tstd
Hstd = standard hours accomplished; Q = quantity of work
units completed; Tstd = standard time per work unit
Worker efficiency – work accomplished as a proportion of
shift hours
Ew = Hstd / Hsh
Ew = worker efficiency; Hstd = # of standard hours of work
accomplished; Hsh = # of shift hours (8 hr)
26.
27.
28. Worker efficiency
Worker efficiency is commonly used to evaluate
workers in industry.
In many incentive wage payment plans, the worker’s
earnings are based on his or her efficiency or the
number of standard hours accomplished.
Worker efficiency and standard hours are easily
computed, because the number of hours in the shift
and the standard time are known, and the number of
work units produced can be readily counted.
29. Worker-Machine Systems
When worker operates a powered equipment we
refer to the arrangement as a worker-machine
system.
Examples:
Machinist operating a milling machine
Factory worker loading and unloading parts at
a machine tool.
Truck driver driving an 18-wheel tractor-trailer
Worker crew operating a rolling mill that
converts hot steel blocks into flat plates.
Clerical worker entering data into a PC
30. Types of Powered Equipment
Distinguished from hand tools by the fact that a source of power
other than human strength is used to operate it. Common power
sources are electric, pneumatic, hydraulic, and fossil fuel motors
1. Portable power tools are light enough in weight
portable power drills, rotary saws, chain saws, and electric
hedge trimmers.
2. Mobile powered equipment are generally heavy pieces of
equipment
Transportation equipment, agricultural and lawn-keeping,
forklift trucks, electric power generator at construction site
3. Stationary powered machines stand on the floor or ground
and cannot be moved while they are operating
Machine tools (e.g., turning, drilling, milling); office
equipment (personal computers, photocopiers, telephones,
fax machines); cash registers, heat treatment furnaces
32. Numbers of Workers and Machines
Means of classifying worker-machine systems is according to
whether there are one or more workers and one or more machines
One worker and
One machine
Taxicab driver and
taxi
One worker & Multiple
machines
A worker tending
several production
machines
Multiple workers and
One machine
Ship's crew
Multiple workers and
Multiple machines
Emergency repair
crew responding to
machine breakdowns
in a factory
33. One Worker and One Machine
Good work design attempts to achieve the following
objectives:
Design the controls of the machine to be logical and
easy to operate for the worker.
Design the work sequence so that as much of the
worker’s task as possible can be accomplished
while the machine is operating, thereby minimizing
worker idle time.
Minimize the idle times of both the worker and the
machine.
Design the task and the machine to be safe for the
worker.
34. Level of Operator Attention
Full-time attention
Welders performing arc welding
Part-time attention during each work cycle
Worker loading and unloading a production
machine on semi-automatic cycle
Periodic attention with regular servicing
Crane operator in steel mill
Periodic attention with random servicing
Firefighters responding to alarms
36. Cycle Time Analysis in Worker
Machine System
In terms of cycle time analysis, worker-machine
systems fall into two categories:
(1) systems in which the machine time depends on
operator control, the task can be either repetitive or
nonrepetitive
(2) systems in which the machine time is constant and
independent of operator control, and the work cycle is
repetitive.
37. Cycle Time with no Overlap between
Worker and Machine
If there is no overlap in work elements between the worker
and the machine, then the normal time for the cycle is
simply the sum of their respective normal times:
Normal time for cycle
Tn = Tnw + Tm
Where Tnw = normal time for the worker-controlled portion of the cycle,
min: and Tm = machine cycle time (assumed constant).
Standard time for cycle
Tstd = Tnw (1 + Apfd) + Tm (1 + Am)
where Tnw = normal time of the worker, min; Tm = constant time for the
machine cycle, min; Am = machine allowance factor, used in the
equation as a decimal fraction
38.
39.
40.
41. Worker-Machine Systems with
Internal Work Elements
In the operation of a worker-machine system, it is
important to distinguish between the operator’s work
elements that are performed in succession with the
machine’s work elements and those that are
performed simultaneously with the machine elements.
Operator elements that are performed sequentially
are called external work elements while those that
are performed simultaneously with the machine cycle
are called internal work elements.
42. Example 2.10 Internal Versus External
Work Elements in Cycle Time Analysis
The work cycle in a worker-machine system
consists of the elements and associated times
given in the table below.
All of the operator’s work elements are external
to the machine time.
Can some of the worker’s elements be made
internal to the machine cycle, and if so, what is
the expected cycle time for the operation?
43.
44.
45. Comment
Although the total times for the worker and the machine are
the same as before, element 4 in the revised cycle (which
Consists of elements 1, 2, and 6 from the original work
cycle) is performed simultaneously with the machine time,
resulting in the following new cycle time:
Tc = 0.10 + 0.12 + 0.75 = 0.97 min
This represents a 34% reduction in cycle time, which
translates into a 53% increase in production rate.
When internal elements are present in the work cycle, it
must then be determined whether the machine cycle time
or the sum of the worker’s internal elements take longer.
46. Automated Work Systems
Automation is the technology by which a process
or procedure is accomplished without human
assistance
Implemented using a program of instructions
combined with a control system that executes
the instructions
Power is required to drive the process and
operate the control system
47. Levels of Automated Systems
Semiautomated machine
Performs a portion of the work cycle under
some form of program control
Human worker tends the machine for the
remainder of the cycle, by loading and
unloading it
Operator must be present every cycle
Fully automated machine
Operates for extended periods of time with
no human attention