PRODUCTION PLANNING AND CONTROL

1. WORK STUDY
UNIT - II

2. WORK STUDY
 Today’s competitive market industry must be
aware of latest developments for new
technology.
1. By improving the process of manufacture
2. By improving the operation of existing
facilities( Plant and Human)

3. DEFINITION OF WORK
STUDY
 Study of human work in all aspects in order to
increase the effectiveness with which work is
done.
 Work study aimed to achieving higher
productivity
 By finding the most efficient use of available
resource to create output.

4. ELEMENTS OF WORK STUDY
 Work study = Method study + Work measurement
 Method study = Developing easier and more
effective method.
 Work measurement = Time for a qualified worker to
carry out a specific job at different level of
peformance
 Work study gives higher productivity.

5. OBJECTIVES OF
WORK STUDY
 Most economical way for work
 To simplify and standardise the methods,
materials and tools.
 Time required for a qualified worker
 To plan training program for the worker for
new method.

6. PURPOSE OF WORK STUDY
 Raising productivity
 Increase productivity without capital
expenditure
 It helps to eliminate / reduce waste
 Better quality of product at reasonable price

7. Work study procedure (13 mark)
1. Select (job or process selected)
2. Record (record by various techniques)
3. Examine (asking questions who,when)
4. Develop (Economical method)
5. Measure (amount of work involved)
6. Define (new method)
7. Install (new method standard pratice)
8. Maintain (proper control the above pratice)

8. METHOD STUDY
 Systematic analysis for the better utilisation of
resources
 It is developing better method for doing a
job.
 Other wise called as method engineering,
Method analysis, Work improvement

9. Objectives of Method study
 To improve process and procedures
 To improve design plant and equipment
 Improve plant layout
 Improve men , material.
 Standardise methods
 Improve safety methods

10. Basic procedure for method
study (13 Mark)
1. Select (job or process selected)
2. Record (record by various techniques)
3. Examine (asking questions who,when)
4. Develop (Economical method)
5. Define (new method)
6. Install (new method standard pratice)
7. Maintain (proper control the above pratice)

12.  1) SELECTION OF JOB FOR METHOD STUDIES
 1) Economic considerations:
 Waste of time for long investigation
 Operations involved excess man power
 By tracking materials
 Repetative work
 Operations having poor utilisation of resources
 2) Techinical consideration:
 To ensure adequate technology is available to carry out
the study successfully.
 3) Human reactions:
 All concern persons accept the method study for
improve.

13.  2) RECORD
 After selection the job record the Relevant facts of
existing methods.
 RECORDONG METHODS
 CHARTS
 Outline process chart
 Flow process chart
 Multiple activity chart wth time scale
 Simo chart
 CHARTS AND DIAGRAMS
 Flow diagram
 String diagram

14.  3) EXAMINE
 Relevant informations and procedures are recorder
next stem examine that.
 CRITICAL QUESTIONS
1. PRIMARY QUESTIONS
2. SECONDARY QUESTIONS
4) DEVELOP
Evaluate successfully the four step formula are
1. Eliminate all un necessary operations
2. Combine two or more operations
3. Sequence of various activities

15.  5) DEFINE NEW METHOD
 By analysing the above methods We Define newer
method by agreeing the various workers and
management.
 6) INSTALL NEW METHOD
 Install new method
 Train the workers for the new method
 The proposed method was accepted by supervisors, etc.
7) MAINTAIN THE PROPOSED METHOD
 Adopting various monitoring techniques
 Data collection and interruption
 Feed back from evaluated reports

16. RECORDING TECHNIQES
(13 mark)1. CHARTS
1. METHOD STUDY
2. PROCESS CHARTS
1. OUTLINE PROCESS CHARTS
2. FLOW PROCESS CHARTS
3. TWO HANDED PROCESS CHARTS
2. DIAGRAMS
1. FLOW DIAGRAM
2. STRING DIAGRAM
3. TRAVEL CHART
4. CYCLE GRAPH

17. METHOD STUDY( PROCESS
CHART SYMBOLS)
CIRCLE is used for operation
RECTANGLE is used for inspection

18. TRANSPORT (movement of workers, equipments )
DELAY (Temporary storage)
STORAGE (PERMANENT STORAGE)

19. PROCESS CHART
 1) OUTLINE PROCESS CHART
 It is otherwise called as operation process chart
 Overall view of the whole process
 INPUT- OPERATION- OUTPUT

21. 2) FLOW PROCESS CHART
 It includes graphical representation of ALL
OPERATIONS, INSPECTIONS, DELAYS,
STORAGES etc.,
 DEF: Sequence of flow of product or
procedure
 TYPES OF FLOW CHART
 Flow process chart (Man type)
 Flow process chart (Material type)
 Flow process chart (Equipment type)

22. FLOW PROCESS CHART
EXAMPLE

25. TWO HANDED PROCESS
CHART
 Other wise called as left and right handed process
chart
 Activities of the worker’s hand are recorded
 To eliminate the unwanted motion to minimum
 ADV:
 Balance the motion and reduce fatigue
 To eliminate and reduce motions
 Train new operations in ideal method

28. CHARTS USING TIME SCALE
 1) MULTIPLE ACTIVITY CHART:
 It is a chart more than one subject(men, machine, item)
are recorded on a common time scale
 USES OF MULTIPLE ACTIVITY CHART:
 To analyses ideal time of men and machine.
 Determine number of machines handle by an operator
 IMPORTANT TYPES OF MULTI ACTIVITY CHART:
1. Man machine activity(1 operator, 1 machine)
2. Multi man activity(many operators, 1 machine)
3. Man-multi machine activity(1 operator, many machine)
4. Multi machine activity chart (group of operators
,central machine)

29.  2) SIMO chart (SIMULTANEOUS MOTION
CYCLE CHART)
 Record the activities, of two hands or other parts.
 SIMO chart constructed from Data collected motion flim
analysis
 THERBLINGS
 Therblings are the symbols used to denote various
activities and movements done for different purpose.

30. THERBLINGS

32. DIAGRAMS
 1) FLOW DIAGRAMS:
 Plan drawing in a working area, showing a
location of various activities by symbols.
 CONSTRUCTION PROCEDURE:
 Draw the work area
 Mark the positions of tools, benches
 Trace the path
 Indicate the direction of movement
 Different colours for the different type of movement

33. FLOW DIAGRAM

35. STRING DIAGRAM
 It is a scale plan or model THREAD is used to
trace and measure the path of materials ,
machine in define path.

36. TRAVEL CHART
 A travel chart is a tabular record for presenting
quantitative data about the movement of
workers , materials or equipment between any
number of places over any given period of
time.

38. CYCLE GRAPH
 The techniques are developed by Gilberth.
 It is the record of path movement , Usually
traced by continuous source of light on
photograph.
 For these small electric bulb is attached to the
hand or finger, the motion can be recorded.

39. CHRONOCYCLE graph is a special form of
cycle graph in which light source is suitable
interrupted so thet path appears peer- dot
shaped.

40. PRINCIPLES OF MOTION
ECONOMY
 These principles are developed from improved
methods
 These principles are groped in to THREE
headings
1. Use of human body
2. Arrangement of workplace
3. Design of tools and equipment.

41. Principles with the use of HUMAN BODY
 Two hands should began and end their movements in same
time.
 Two hands should not be ideal at same time
 Hand motions should symmetrically opposite direction
 Momentum should be help of the worker during work
 Countineous curved movements preferred to straight line
motions during sudden changes in direction.
 Free swinging movements are faster for controlling
movements
 Work should be arranged to eye comfort for easier work

42. PRINCIPLES OF THE ARRANGEMENT
OF WORKPLACE
 Fixed station to provide all tools
 Pre position of tools to reduce searching
 Scrap bins are closer to the working area
 Tools should be arranged permit for the best
sequence
 Ejectors should provide whenever possible for
disposal purpose.

43. PRINCIPLES OF TOOLS AND EQUIPMENTS
 Equipments are fixed by using jigs and fixtures.
 Two or more tools should be combined whenever
possible
 Load should be distributed accordingly for the
type writing purpose
 Handles such as large screw drivers are designed
for easy handling purpose
 Levers , crossbars , handwheels are places for a
mechanical advantage.

44. MICRO MOTION STUDY
(8mark)
 It is a detailed motion study employing either
video taps, or motion pictures operating in a
constant speed.
 Picture camera is utilized for study, then the
procedure is known micro motion study

45. MICRO MOTION STUDY
PROCEDURE
1. Filming the operation to be studied
2. Analysing the films
3. Recordings/ presenting the data.
 Filming the operation
 16mm movie camera
 Other equipments like, reflectors, exposure meter

46.  2)ANALYSING THE FILMS
 Once the operation over film is viewed through
projector.
1. Film is run at normal speed to get the movement
involved
2. A regular work cycle( process) is selected among
the film
3. Film is run at very slowly for backward purpose.
3) RECORDING / PRESENTING THE DATA
 Once the film analysis over
 Next to prepare SIOM chart for the micro
motion of limbs

47. PURPOSE OF MICRO MOTION AND ITS
ADVANTAGES
 To study the nature and path of movements
 To study the activities of the machine and operator
 To keep permanent record of most efficient way of
performing task
 Carry out research in the field of method and time
study
ADVANTAGES:
 It gives very accurate time for operation
 Fast, short , repetitive cycles by this process
 Easy comparison of present method and proposed
method

48. MEMO MOTION
(8 mark)
 It is developed by Marvin Mudrel
 It is special type of micro motion,
ACTIVITIES ARE FLIMED AT SLOWER
SPEED 60 or 100 frames per second.
 It is best suited for many activities
 For quantity checking purpose in continues
production activity in company.

49. PROCEDURE OF MEMO MOTION STUDY
1. Study of operations to be filmed
2. Obtain the film
3. Analysis the film
4. Construct a suitable chart depending up on the
nature of the film
5. Improve the methods by using the motion
economy

50. PURPOSE OF MEMO MOTION STUDY AND
ADVANTAGES
 To study job involving cycles
 To study team work and create activities
 To study flow of material
 Analyses the material handling
 For collecting motion time data
ADVANTAGES:
 More economical than micro motion study
 Consumes less film
 Film analyses in smaller time than micro motion stud

51. WORK MEASUREMENT
 It is also known as TIME STUDY
 Time for a specific job for a worker
USES OF WORK MEASUREMENT:
 To determine time standards
 Alternate method for doing a job
 Eliminate in effective time
 Estimate the cost of the product
 To determine staff and product requirements

52. TECHNIQUES OF WORK MEASUREMENT
1. Stop watch time study(It deals with time and
rate of working)
2. Work sampling( Large number of
observations from random samples)
3. Pre determined time standards
(PTS)(Basic human motion for increase in
peformance)
4. Standard data.( Time for a job in
countineous process )

53. Stop watch time study
 It is a measurement technique
 Records the time and rates of working for the
elements of a specified job.
 TIME STUDY EQUIPMENT
 Stop watch
 Electronic devices
 Motion picture camera

54.  STOP WATCH
 To measure the elemental timings
 It has two hands
 i) Small hand (one revolution in 30 min)
 Ii) Large hand (One revolution in one minute)
 TYPES OF STOPWATCH
 Non-fly back
 Fly back

55.  Non-fly back (continuous )
 First pressure on winding knob Starts the long
hand
 Second pressure stops the long hand
 Third pressure returns hand to Zero position
 Fly back
 Start and stop with the help of slide
 Pressuring the wind knob brings the hand back to zero.

56. Stop watch

57. BASIC TIME STUDY
PROCEDURE
 SELECT (The job to be studied)
 OBTAIN & RECORD (All the details about the job
and operator)
 BREAK DOWN (the job into suitable elements)
 MEASURE (Time duration for each element and
assess the rating)
 EXTEND ( Observed time into normal time)
 DETERMINE (The allowances to be made)
 COMPUTE (The standard time by adding allowances
to normal time)

58. Breaking the job in to elements
 After collecting the data, breaking the job in to
elements
 REASON
 Ensure that production work is efficient
 Better and accurate performance rating.
 To identify different types of elements
 To checking the method

59. Types of elements
1. Repetitive elements (Start, loading , stop the
machine)
2. Occasional elements (Not doing every time
Eg: cleaning)
3. Constant elements (checking by using things ;
gauging diameters)
4. Variable elements ( It varies not a constant)
5. Manual elements ( Performed by worker)

60. 6. Machine elements (performed automatically)
7. Governing elements (Major working eg:
Turning dismeter)
8. Foreign elements (Not in a regular activity,
Eg: talking to his friends)

61. METHOD OF TIMING WITH
THE STOP WATCH
1. FLYBACK TIMING
1. Complete the time for element.
2. The work finish watch stops
3. Repeat the process.
2. COUNTINEOUS TIMING
1. Start the beginning in the first element and ends
with the last of the process.

62. PERFORMANCE RATING
 Process of adjusting the actual time of working of
an operator by the normal speed.
ALLOWANCES:
It is an amount of time added to the normal time to provide for
personal delays
TYPES OF ALLOWANCES:
1. Relaxation allowances
1. Personal need allowances
2. Fatigue allowances
2. Contingency allowances (Unavoidable delays)
3. Process allowances
4. Interference allowances (Two or more work doing)

63. CALCULATION OF STANDARD TIME

65. WORK SAMPLING
 Analyising work performance and machine
utilization
 Large number of observations at random
intervals for a specified group of workers.

66. WORK SAMPLING
PROCEDURE
1. Preparing the work sampling
2. Performing the work sampling
3. Evaluate and present results of work sampling
USES OF WORK SAMPLING
1. Determination and time standards
2. Aid of job evaluation
3. Aid of manpower

67. ADVANTAGES OF WORK
SAMPLING
 Studies of several operations and machines
continuously
 Analyst can study the many activities
 Any interruption during study
LIMITATIONS:
 Not economical of short job duration
 Not provide a complete break down elements
during time study

68. SYNTHETIC DATA
(SYNTHESIS FROM STANDRD DATA)
 SYNTHETICS:
 Level of performance
 From previously time studies
 SYNTHETIC DATA:
 Analysis of the work measurement in the form of
tables and formulas

69. PROCEDURE FOR
SYNTHESIS DATA
1. Collect all the details
2. Analyise job in elements
3. Select appropriate time for covering factors
4. Detailed analysis of a job
5. Total time , ratings, allowances for a standard
job

70. PREDETERMINED MOTION
TIME STANDARDS (PMTS)
 Set of time data observed from a workers
performance
 Human task can be sub divides in to various
performance and motions
 By arranging the basic motions existing task
can be analyses.

71. TYPES OF PMTS
1. METHOD TIME ANALYSIS ( It is relation
ship between time and motion )
2. WORK FORCE SYSTEM ANALYSIS
(Manual task by the pre determined data)
3. METHOD TIME MEASUREMENT
(Acceptable data for scientific measurement
of human effort)

72. PURPOSE OF (PTMS)
 Useful method analysis
 Modifying and improving works before work
start
 Set time standards for different job
 Basic wages and labor cost estimation