SlideShare a Scribd company logo
1 of 105
July 16, 2015 Sri Sai Ram Institute of Technology 1
UNIT-I
Work Study and Ergonomics
Outline
July 16, 2015 Sri Sai Ram Institute of Technology 3
1. Work Study1. Work Study
2. Method Study2. Method Study
3. Various Charts3. Various Charts
Work Study
 Work Study is a generic term for management services and
system engineering techniques, used to investigate:
– Methods of performing work (Method Study).
– The time taken to do it (Work Measurement).
July 16, 2015 Sri Sai Ram Institute of Technology 4
Work Study (Cont.)
July 16, 2015 Sri Sai Ram Institute of Technology 5
Method Study
 Method study is a technique to reduce the work content
mainly by eliminating unnecessary movements by workers,
materials, or equipments.
 However, even after that, there could be substantial
unnecessary time taken for the process because of lack of
management control or inaction of worker.
 Method Study approaches and tools of Method Analyst:
– Flow Diagrams & Process Charts etc.
– Critical questioning techniques.
July 16, 2015 Sri Sai Ram Institute of Technology 6
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 costs.
 Used to analyze
 Movement of body, people, or material
 Activities of people & machines
July 16, 2015 Sri Sai Ram Institute of Technology 7
Method Study Objectives
 Improvement of processes and procedures.
 Improvement in the design of plant and equipment.
 Improvement of layout.
 Improvement in the use of men, materials and machines.
 Economy in human effort and reduction of unnecessary
fatigue.
 Development of better working environment.
July 16, 2015 Sri Sai Ram Institute of Technology 8
Method study - Methodology
 Procedure to accomplish method study, called "SREDIM" shall
be as follow:
1. Select: the job or operation that needs improvement,
2. Record: all facts, how work is done by chart methods,
3. Examine: every aspect of the job by asking; what, why,
where, when, who and how
4. Develop: review ideas, eliminate, simplify, combine, re-
arrange, make new method which more safe, chart new
method, submit for approval,
5. Install: the new method, consider best time to introduce,
convince all, train users,
6. Maintain: check frequently, match results, correct deviations.
July 16, 2015 Sri Sai Ram Institute of Technology 9
Methodology (Cont.)
July 16, 2015 Sri Sai Ram Institute of Technology 10
Select
Record
Examine
OK?
Develop
Install
Maintain
Method Study Tools
 Exploratory Tools
– Pareto Analysis
– Fish & Bone Diagrams
– Gantt and PERT charts
 Recording and Analysis Tools
– Operation Process Chart
– Flow process chart
– Flow diagram
– Worker and Machine Process Charts
– Gang Process charts
– Synchronous Servicing
July 16, 2015 Sri Sai Ram Institute of Technology 11
Method Study Applications
 The need for methods analysis can come
from a number of different sources :
 Changes in tools and equipment.
 Changes in product design or new products.
 Changes in materials or procedures
 Other factors (e.g. accidents, quality problems)
July 16, 2015 Sri Sai Ram Institute of Technology 12
Recording Techniques
 Charts
1. Outline process chart.
2. Flow process chart (man-type, material-type and equipment-
type): This is the use of symbols and description to chart the
sequence of work. The process, then, show what is
happening at different stages. The distances and time may be given.
3. Two hands process charts.
4. Multiple activity charts: This technique is used to solve problems
where a number of items are dependent on each other. The aim is
to reduce idle times by using the optimum number of each item. It
depicts the occupied times-broken down into the number of
different activities and the idle times both for the original and
proposed methods of doing the job.
July 16, 2015 Sri Sai Ram Institute of Technology 13
Recording Techniques (Cont.)
 Diagrams and models (2-D and/or 3-D)
1. Flow diagrams, which is the use of symbols for flow process
charts, superimposed on drawings and the "descriptions" are
not necessary.
2. String diagrams, which is used for solving movement
problems since it shows congestions and excessive distances.
3. Cut-out templates (2-D models).
4. 3-D models.
 Photography
1. Photographs,
2. Films,
3. Video.
July 16, 2015 Sri Sai Ram Institute of Technology 14
Assembly Chart
 It is an analog model of the assembly process.
 Circles with a single link denote basic components,
circles with several links denote assembly
operations/subassemblies, and squares represent
inspection operations.
 The easiest method to constructing an assembly
chart is to begin with the original product and to
trace the product disassembly back to its basic
components.
July 16, 2015 Sri Sai Ram Institute of Technology 15
Assembly Chart (Cont.)
Assembly Chart for producing Cheese
July 16, 2015 Sri Sai Ram Institute of Technology 16
Assembly Chart (Cont.)
July 16, 2015 Sri Sai Ram Institute of Technology 17
Operation Process Chart
 The operation process chart shows the chronological
sequence of all operations, inspections, time
allowances, and materials used in a manufacturing or
business process, from the arrival of raw material to
the packaging of the finished product.
 The chart depicts the entrance of all components
and subassemblies to the main assembly.
 Two symbols are used in constructing the operation
process Chart : an operation and an inspection.
July 16, 2015 Sri Sai Ram Institute of Technology 18
Operation Process Chart (Cont.)
 Operations charts show the introduction of raw
materials at the top of the chart on a horizontal line.
 Some parts require no fabrication steps. These parts
are called buyouts. Buyouts are introduced above
the operation
July 16, 2015 Sri Sai Ram Institute of Technology 19
Tape
Carton
Operation
Number
Pieces / Hr
Hours / 1000
Operations Chart Steps
 Step by Step Procedures For Preparing an
Operations Chart:
 Identify the parts to be manufactured and purchased
 Determine the operations required to fabricate each part and
sequence them
 Determine the sequence or assembly for buyouts and
fabricated parts
 Draw the operations chart as explained
 Put time standards, operation numbers and descriptions
 Calculate and write down the total hours required per 1,000
units
July 16, 2015 Sri Sai Ram Institute of Technology 20
Operation Process Chart
Operation Process Chart for Refrigera
July 16, 2015 Sri Sai Ram Institute of Technology 21
Operation Process Chart
July 16, 2015 Sri Sai Ram Institute of Technology 22
Flow Diagrams
 A flow diagram is essentially a flow process chart drawn to:
1. Show the layout of a facility.
2. Show the flow of work through that area
3. Show overcrowding areas, crossing worker paths, total travel.
4. Identify how layout can be redesigned to reduce travel,
motion, collisions, etc.
5. Store materials near where they are used.
6. Increase efficiency and safety.
 Usually, the objective is to look for spatial relationships.
 It depicts the probable movement of materials in the floor
plant. The movement is represented by a line in the plant
drawing.
July 16, 2015 Sri Sai Ram Institute of Technology 23
Flow Diagram (Cont.)
July 16, 2015 Sri Sai Ram Institute of Technology 24
Buyer
You
75 ft.75 ft.
Flow Diagram (Cont.)
July 16, 2015 Sri Sai Ram Institute of Technology 25
Flow Process Charts
 A flow process chart is a chart of all the activities
involved in a process.
 It is similar to an operations process chart, except that
more detail is shown by including transportations and
delays as well as operations, inspections, and storages.
 Not usually used for entire assemblies, it is used for just
one component (or operator)
 Add in information on:
 Operation duration (time to complete)
 Distance traveled (for transport operations)
 Good for showing savings of a new method.
July 16, 2015 Sri Sai Ram Institute of Technology 26
Flow Process Charts (Cont.)
 Process charts summarizes the whole process
 They are used to compare the existing and the
proposed methods
 Process is observed, who, what, where, when, and
how questions are asked
 Every detail is understood and the chart of the
existing situation is drawn
July 16, 2015 Sri Sai Ram Institute of Technology 27
Flow Process Charts (Cont.)
 Quantity:
 Operations: Pieces per hour
 Transportation: How many are moved at a time
 Inspection: How many pieces per hour if under
time standard and/or frequency of inspection
 Delays: How many pieces in a container
 Storage: How many pieces per storage unit
July 16, 2015 Sri Sai Ram Institute of Technology 28
Flow Process Charts (Cont.)
 Time in Hours per Unit
 If 250 pieces are processed in an hour then 1 unit
is processed in 0.00400 hours. Record 400
 If 200 units are moved in 1 minute, then 1/200 =
0.005 minutes per part, and 0.005/60 hours/part
=0.00008 hrs/part. Record 8.
July 16, 2015 Sri Sai Ram Institute of Technology 29
 Flow Process Types:
 Product or Material type
 Worker (Man) type
 Machine type
July 16, 2015 Sri Sai Ram Institute of Technology 30
July 16, 2015 Sri Sai Ram Institute of Technology 31
Flow Process Chart Symbols
July 16, 2015 Sri Sai Ram Institute of Technology 32
Operation
Transportation
Inspection
Delay
Storage
 Occurs when an object is intentionally changed in
one or more of its characteristics
 Usually occurs at a machine or a work station
 Drilling, Painting, Data Entry, Cutting, Sorting, etc.
July 16, 2015 Sri Sai Ram Institute of Technology 33
Operation
 Occurs when an object is moved from one place to
another
 except when the movement is part of an operation
or an inspection
 Using elevator, carrying, moving with material
handling devices
July 16, 2015 Sri Sai Ram Institute of Technology 34
Transportation
 Occurs when an object is examined for identification
or is compared with a standard as to quantify or
quality
 Examine the quantity or quality, read steam gauge
on boiler, detect the defectives
July 16, 2015 Sri Sai Ram Institute of Technology 35
Inspection
 Occurs when the immediate performance or the next
planned action does not take place
 Work In Process inventory waiting to be processed,
Employee waiting for an elevator, Waiting for
accumulation of a certain quantity for packaging
July 16, 2015 Sri Sai Ram Institute of Technology 36
Delay
 Occurs when an object is kept under control such
that its withdrawal requires authorization
 Bulk storage of raw material, finished products
inventory, archived documents
July 16, 2015 Sri Sai Ram Institute of Technology 37
Storage
Combined Symbols
 Two symbols may be combined when two activities
are performed concurrently.
July 16, 2015 Sri Sai Ram Institute of Technology 38
Operation and Inspection
Flow Process Chart-An Example
Flow Process Chart Example
July 16, 2015 Sri Sai Ram Institute of Technology 39
Flow Process Chart-An Example
July 16, 2015 Sri Sai Ram Institute of Technology 40
1 X Enter emergency room, approach patient window
2 X Sit down and fill out patient history
3 X Nurse escorts patient to ER triage room
4 X Nurse inspects injury
5 X Return to waiting room
6 X Wait for available bed
7 X Go to ER bed
8 X Wait for doctor
9 X Doctor inspects injury and questions patient
10 X Nurse takes patient to radiology
11 X Technician x-rays patient
12 X Return to bed in ER
13 X Wait for doctor to return
14 X Doctor provides diagnosis and advice
15 X Return to emergency entrance area
16 X Check out
17 X Walk to pharmacy
18 X Pick up prescription
19 X Leave the building
0.50 15
10.0 -
0.75 40
3.00 -
0.75 40
1.00 -
1.00 60
4.00 -
5.00 -
2.00 200
3.00 -
2.00 200
3.00 -
2.00 -
1.00 60
4.00 -
2.00 180
4.00 -
1.00 20
Process: Emergency room admission
Subject: Ankle injury patient
Beginning: Enter emergency room
Ending: Leave hospital
Step
no.
Time
(min)
Distance
(ft)
Summary
Number
of stepsActivity
Time
(min)
Distance
(ft)
Step description
Insert Step
Append Step
Remove Step
Transport 9 11 815
Operation 5 23 —
Inspect 2 8 —
Store — — —
Delay 3 8 —
Material Type - Example
July 16, 2015 Sri Sai Ram Institute of Technology 41
Man Type - Example
July 16, 2015 Sri Sai Ram Institute of Technology 42
Left-Hand-Right-Hand Charts
 Useful in analyzing the work performed by one
person at one specific workstation. As the name
implies, the chart follows the motion of the left and
right hands of one operator .
 Each hand of the worker is treated as an activity.
 Each hand’s activities are broken into work elements
and plotted side by side on a time scale.
July 16, 2015 Sri Sai Ram Institute of Technology 43
Left-Hand-Right-Hand Charts (Cont.)
Lists the work performed simultaneously by
each hand
– To assist in finding a better method of performing
the task and
– To train the operator in the preferred method.
July 16, 2015 Sri Sai Ram Institute of Technology 44
Symbols
 Two symbols are used in this chart:
– Transportation (either an arrow or a small circle)
– Action (e.g., grasp, position, use, release)
 A sketch of the workplace is drawn, indicating the
contents of the bins and the location of tools and
materials.
– Record the motions of one hand at a time
– Usually necessary to redraw the chart
July 16, 2015 Sri Sai Ram Institute of Technology 45
Left-Hand-Right-Hand Chart (An Example)
July 16, 2015 Sri Sai Ram Institute of Technology 46
L-R Hand Chart of Signing a Letter
LEFT HAND RIGHT HAND
Hold Letter
Reach for pen
Grasp pen
Carry pen to
paper
Sign letter
Return pen to
holder
Release pen in
holder
Move hand back
to letterJuly 16, 2015 Sri Sai Ram Institute of Technology 47
LEFT HAND RIGHT HAND
Reach for
bolt in bin 1
Grasp bolt
Carry bolt to
work area
Position bolt
Hold Bolt
Carry
assembly to
bin 3
Reach for nut
in bin 2
Grasp nut
Carry nut to
work area
Position nut
Assemble nut
Release nut
July 16, 2015 Sri Sai Ram Institute of Technology 48
Man-machine chart
 The worker and machine process chart (Man-machine chart)
is used to study, analyze, and improve one workstation at a
time.
 The chart shows the exact time relationship between the
working cycle of the person and operating cycle of the
machine.
 These facts can lead to utilization of both worker and
machine time, and a better balance of the work cycle.
July 16, 2015 Sri Sai Ram Institute of Technology 49
Worker-Machine Chart for a Gourmet Coffee Store
July 16, 2015 Sri Sai Ram Institute of Technology 50
Worker-Machine Chart for a Gourmet Coffee Store
July 16, 2015 Sri Sai Ram Institute of Technology 51
The customer, the clerk, and the coffee grinder (machine) are involved in this
operation. It required 1 minute and 10 seconds for the customer to purchase a pound
of coffee in this particular store. During this time the customer spent 22 seconds, or
31 percent of the time, giving the clerk his order, receiving the ground coffee, and
paying the clerk for it. He was idle during the remaining 69 percent of the time. The
clerk worked 49 seconds, or 70 percent of the time, and was idle 21 seconds, or 30
percent of the time. The coffee grinder was in operation 21 seconds, or 30 percent of
the time, and was idle 70 percent of the time.
Multiple Activity Charts
 Also known as Gang Process Charts
 Used when several workers operate a single
machine or render a single service
 Used when a single worker is operating several
machines
 Used to show the exact relationship between idle
and operating times of both workers and machines
July 16, 2015 Sri Sai Ram Institute of Technology 52
Multiple Activity Charts (Cont.)
 An operation performed by one member of the
group may continue while another member is
performing more than one operation.
 The chart should cover the complete cycle for the
longest performing member.
July 16, 2015 Sri Sai Ram Institute of Technology 53
Activity Chart
July 16, 2015 Sri Sai Ram Institute of Technology 54
Subject: Semi-Auto Machine
Operator MachineTime
1
2
3
4
5
6
Load machine Being loaded
Idle Run
Unload Being Unloaded
Present
Activity Chart for Two-Person
July 16, 2015 Sri Sai Ram Institute of Technology 55
Activity Chart of Emergency Tracheotomy
July 16, 2015 Sri Sai Ram Institute of Technology 56
Principles of Motion Economy
As Related To The Use Of The Human Body
1. The two hands should begin as well as complete
their motions at the same time.
2. The two hands should not be idle at the same
time except during rest periods.
3. Motions of the arms should be made in opposite
and symmetrical directions, and should be made
simultaneously.
4. Hand and body motions should be confined to
the lowest classification with which it is possible
to perform the work satisfactorily.
July 16, 2015 Sri Sai Ram Institute of Technology 57
July 16, 2015 Sri Sai Ram Institute of Technology 58
5. Momentum should be employed to assist the
worker whenever possible, and it should be
reduced to a minimum if it must be overcome
by muscular effort.
6. Smooth continuous curved motions of the
hands are preferable to straight-line motions
involving sudden and sharp changes in
direction.
July 16, 2015 Sri Sai Ram Institute of Technology 59
7. Ballistic movements are faster, easier, and
more accurate than restricted (fixation) or
“controlled” movements.
8. Work should be arranged to permit easy and
natural rhythm wherever possible.
9. Eye fixations should be as few and as close
together as possible.
July 16, 2015 Sri Sai Ram Institute of Technology 60
As Related To The Work
Place
10.There should be a definite and fixed place for
all tools and materials.
11.Tools, materials, and controls should be
located close to the point of use.
July 16, 2015 Sri Sai Ram Institute of Technology 61
July 16, 2015 Sri Sai Ram Institute of Technology 62
12.Gravity feed bins and containers
should be used to deliver material close
to the point of use.
July 16, 2015 Sri Sai Ram Institute of Technology 63
13. Drop deliveries should be used whenever
possible.
14. Materials and tools should be located to
permit the best sequence of motions.
15. Provision should be made for adequate
conditions for seeing. Good illumination is the
first requirement for satisfactory visual
perception.
July 16, 2015 Sri Sai Ram Institute of Technology 64
July 16, 2015 Sri Sai Ram Institute of Technology 65
16.The height of the work place and the chair should preferably
be arranged so that alternate sitting and standing at work are
easily possible.
July 16, 2015 Sri Sai Ram Institute of Technology 66
17. A chair of the type and height to permit
good posture should be provided for every
worker.
July 16, 2015 Sri Sai Ram Institute of Technology 67
As Related To The Design Of Tools
And Equipment
18.The hands should be relieved of all work that
can be done more advantageously by a jig, a
fixture, or a foot-operated device.
19.Two or more tools should be combined
wherever possible.
20.Tools and materials should be prpositioned
whenever possible.
21.Where each finger performs some specific
movement, such as in typewriting, the load
should be distributed in accordance with the
inherent capacities of the fingers.
July 16, 2015 Sri Sai Ram Institute of Technology 68
22. Levers, hand wheels and other controls
should be located in such positions that the
operator can manipulate them with the least
change in body position and with the greatest
speed and ease.
July 16, 2015 Sri Sai Ram Institute of Technology 69
Work measurement
71
Introduction
• Work measurement is the application of techniques designed
to establish the time for a qualified worker to carry out
specified jobs at a defined level of performance.
• We have seen how total time to manufacture a product is
increased by:
 adding undesirable features to product,
 bad operation of the processes, and
 ineffective time added because of worker and management.
• All this leads to decreased productivity.
72
Introduction
• Method study is one of principal techniques by which work
content in the product manufacture or process could be
decreased.
• It is a systematic method of investigating and critically
examining the existing methods, to develop the improved
ones.
• Method study is, then, a technique to reduce the work content
mainly by eliminating unnecessary movements by workers
and/or materials and/or equipments.
• However, even after that, there could be substantial
unnecessary time taken for the process because of lack of
management control and/or inaction of worker.
73
Introduction
• Work measurement (WM) is concerned with investigating,
reducing and eliminating ineffective time, whatever may be
the cause.
• WM is the means of measuring the time taken in the
performance of an operation or series of operations in such a
way that the ineffective time is shown up and can be separated
out.
• In practice, proving existence of the ineffective time is the
most difficult task.
• After existence is proved, nature and extent is easy to see!
74
Introduction
• WM is also used to set standard times to carry out the work, so
that any ineffective time is not included later.
• Any addition the standard time would show up as excess time
and thus can be brought to attention.
• Since, standard times are set for all the activities through WM,
it has earned bad reputation amongst workers.
• Major reason for that has been the initial focus of the WM
methods, which essentially targeted only the worker
controllable ineffective times.
• Management controllable ineffective times were ignored
traditionally.
75
Introduction
Two critical issues in work study:
1. Method study should precede the work measurement,
always.
2. Elimination of management controllable ineffective time
should precede the elimination of the ineffective time within
the control of the workers.
76
Purpose of WM
• To reveal the nature and extent of ineffective time, from
whatever cause,
• So that action can be taken to eliminate it; and then,
• To set standards of performance that are attainable only if all
avoidable ineffective time is eliminated and work is performed
by the best method available.
77
Uses of WM
• To compare the efficiency of alternative methods. Other
conditions being equal, the method which takes the least time
will be the best method.
• To balance the work of members of teams, in association with
the multiple activity charts, so that, as far as possible, each
member has tasks taking an equal time.
• To determine, in association with man and machine multiple
activity charts, the number of machines an worker can run.
78
Uses of time standards
• To provide information on which the planning and scheduling
of production can be based, including the plant and labor
requirements for carrying out the program of work and
utilization of resources.
• To provide information on which estimates for tenders, selling
prices and delivery promises can be based.
• To set standards of machine utilization and labor performance
which can be used for incentive scheme.
• To provide information for labor-cost control and to enable
standard costs to be fixed and maintained.
79
TECHNIQUES OF WORK MEASUREMENT
The different techniques used in work measurement are
1. Stop watch time study.
2. Production study.
3. Work sampling or Ratio delay study.
4. Synthesis from standard data.
5. Analytical estimating.
6. Predetermined motion time system.
Procedure for conducting stop watch time study
The following procedure is followed in conducting stop watch
time study:
1. Selecting the job.
2. Recording the specifications.
3. Breaking operation into elements.
4. Examining each element.
5. Measuring using stop watch.
6. Assessing the rating factor.
7. Calculating the basic time.
8. Determining the allowances.
9. Compiling the standard time.
July 16, 2015 Sri Sai Ram Institute of Technology 80
Stop watch time study
Measuring Time with a Stop Watch
There are two methods of timing using a stop
watch. They are
1. Fly back or Snap back method.
2. Continuous or Cumulative method.
July 16, 2015 Sri Sai Ram Institute of Technology 81
1. Fly back method
• Here the stop watch is started at the beginning of the
first element. At the end of the element the
• reading is noted in the study sheet (in the WR column).
At the same time, the stop watch hand is
• snapped back to zero. This is done by pressing down
the knob, immediately the knob is released.
• The hand starts moving from zero for timing the next
element. In this way the timing for each
• element is found out. This is called observed time
(O.T.) .
July 16, 2015 Sri Sai Ram Institute of Technology 82
2. Continuous method
• Here the stop watch is started at the beginning of
the first element. The watch runs continuously
• throughout the study. At the end of each
element the watch readings are recorded on the
study
• sheet. The time for each element is calculated by
successive subtraction. The final reading of the
• stop watch gives the total time. This is the
observed time (O.T.).
July 16, 2015 Sri Sai Ram Institute of Technology 83
CALCULATION OF STANDARD TIME
• Standard time or allowed time is the total time in which a job should be completed at standard
performance. It is the sum of normal time (basic time) and allowances. Policy allowance is
notincluded.Standard time is worked out in a stop watch time study in the following manner.
Observed time
• This is the actual time observed by using a stop watch. The observed time of an operation is the
total of the elemental times. The time study for the same job is conducted for a number of times.
The average of the Observed times is calculated.
Basic or normal time
• Basic time is the time taken by a worker with standard performance. Basic time is calculated from
• the observed time by applying the rating factor.
• Basic time orNormal time = Observed time ×(Rating of the operator/Standard rating 100)
Allowed time or standard time
• The standard time is obtained by adding the following allowances with the basic or normal time.
• 1. Rest and personal allowance or relaxation allowance.
• 2. Process allowance or unavoidable delay allowance.
• 3. Contingency allowance.
• 4. Special allowance.
• Policy allowance may be added to the standard time if the management wants.
July 16, 2015 Sri Sai Ram Institute of Technology 84
85
Factors affecting rate of working
Factors outside the control of workers include:
• Variation in the quality or other characteristics of the material
used, although they be within the prescribed tolerance limit.
• Changes in the operating efficiency of tools or equipment
within their normal life.
• Minor and unavoidable changes in methods or conditions of
operations.
• Variation in the mental attention for the performance of
elements.
• Changes in the climatic and other conditions.
86
Factors affecting rate of working
Factors within worker’s control:
• Acceptable variation in the quality of the process/product.
• Variation due to worker’s ability.
• Variation due to ability of mind, specifically attitude.
Optimum pace at which the worker will work depends on –
• The physical effort demanded by the work.
• The care required on the part of the worker.
• Training and experience.
87
Rating factor
• The figure 100 represents standard performance.
• If the operator is apparently performing with less effective
speed, than the assigned factor is less than 100.
• If, on the other hand, the effective rate of working is above
standard, the operator gets a factor above hundred.
• Essential idea being:
Observed time x Rating = Constant
88
Rating factor
• This constant is known as the basic time:
• So, depending on the rating assigned for the operator, the
basic time can either be less than or greater than the
observed time.
TimeBasic
RatingStandard
Rating
timeObserved =x
89
Selected time
• The selected time is the time chosen as being representative of
a group of times for which an element or group of elements.
• These times may be either observed or basic times; and should
be denoted as selected observed or selected basic times.
• Theoretically, the results of all the computations of the basic
time for any single constant element should be same.
• However, because of inherent process variations, it happens
rarely!
90
Selected time
• It becomes necessary to select a representative time for each
element from all the basic times which have been entered into
the time study.
• Multiple ways to pick a representative selected time from the
available ones.
• Statistics suggests….. Taking averages!
• There are other ways though!
• Before the selected time is decided, the anomalies in the
sample should be noted.
• Exceptionally high or low points should get some attention.
91
Selected time
Constant element
• A very high or short observed time for a given element of job
should be treated with caution.
• An exceptionally high observed time could be due to incorrect
recording, but most common reason is material or environment
variation.
• In such as case, it should be checked whether such a variation
is frequent or rare.
• Excess observed time because of rarely occurring events is
typically not included as a representative.
92
Selected time
• The average time calculations should exclude this observation.
But, the excess-over-average time is added to the contingency
allowance.
• Frequent large variations indicate that the element is not a
constant one but a variable element.
• Excessively large time for this element could be detected by
corresponding reduction in time for the immediate element.
• Exceptionally short times could be due to human error.
• A rare reason of observation of such short times could also be
a last-minute-process-improvement. In such as case, the job
should be studied again with more detailed attention.
93
Selected time
Variable element
• In general more observations will be necessary of a variable
element than of a constant element before reliable
representative basic times can be established.
• The analysis of factors affecting the time to complete the
element should be closely studied.
• Some relationship should be established between the observed
time and the variable factors.
• Multiple factors could be affecting the observed time variation
and establishing relationships amongst multiple factors is
difficult
94
Work content
• The work content of a job or operation is defined as: basic
time+ relaxation allowance+ any allowance for additional
work (e.g. the part of relaxation allowance that is work
related).
• Standard time is the total time in which a job should be
completed at standard performance – i.e. work content,
contingency allowance for delay, unoccupied time and
interference allowance.
• Allowance for unoccupied time and interference may not be
frequently included in the standard time calculations; however,
the relaxation allowance is.
95
Standard time constituents
• A contingency allowance is a small allowance of time which
may be included in a standard time to meet legitimate and
expected items of work or delays, precise measurement of
which is uneconomical because of their infrequent or irregular
occurrence.
• Contingency allowance for work should include fatigue
allowance; whereas the allowance for delay should be
dependent on the workers.
• Typically contingency allowances are very small and are
generally expressed as percentage of the total repetitive
minutes of the job.
96
Standard time constituents
• Contingency allowance should not be more than 5%, and
should only be given where the contingencies cannot be
eliminated and are justified.
97
Standard time constituents
• Relaxation allowance is an addition to the basic time intended
to provide the worker with the opportunity to recover from the
physiological and psychological effects of carrying out
specified work under specified conditions and to allow
attention to personal needs.
• The amount of the allowance will depend on the nature of the
job.
• One of the major additions to the basic time.
• Industrial fatigue allowance, in turn, forms a major portion of
the relaxation allowance.
• Relaxation allowances are also given as percentages of the
basic times.
98
Standard time constituents
• Typical values of relaxation allowance are 12-20%.
• In addition to including relaxation allowances, short rest
pauses could be added over the period of work for an operator.
99
Other allowances
• Start-up / shut-down allowance
• Cleaning allowance
• Tooling allowance
• Set-up / change-over allowance
• Reject / excess production allowance
• Learning / training allowance
• Policy allowance is an increment, other than the bonus
increment, applied to standard time to provide a satisfactory
level of earning for certain level of performances under
exceptional conditions.
100
Standard time
• Now, we can add all the constituents to arrive at the standard
time for a job.
Standard time = observed time + rating factor + relaxation
allowance + work related contingency allowance + delay
related contingency allowance.
ERGONOMICS
• Ergons means ‘work’ and Nomos means ‘Natural
laws’. Ergonomics or its American equivalent
• ‘Human Engineering may be defined as the
scientific study of the relationship between man
and
• his working environments.
• Ergonomics implies ‘Fitting the job to the
worker’. Ergonomics combines the knowledge of
a
• psychologist, physiologist, anatomist, engineer,
anthropologist and a biometrician.
July 16, 2015 Sri Sai Ram Institute of Technology 101
Objectives
The objectives of the study of ergonomics is to optimize the
integration of man and machine inorder to increase work
rate and accuracy. It involves
• The design of a work place befitting the needs and
requirements of the worker.
• The design of equipment, machinery and controls in such a
manner so as to minimize mental and physical strain on the
worker thereby increasing the efficiency, and
• The design of a conductive environment for executing the
task most effectively. Both work study and Ergonomics are
complementary and try to fit the job to the workers;
however Ergonomics adequately takes care of factors
governing physical and mental strains.
July 16, 2015 Sri Sai Ram Institute of Technology 102
Applications
• In practice, ergonomics has been applied to a
number of areas as discussed below
1. Working environments 2. The work place
and 3. Other areas.
July 16, 2015 Sri Sai Ram Institute of Technology 103
1. Working environments
(a) The environment aspect includes considerations
regarding light, climatic conditions (i.e., temperature,
humidity and fresh air circulation), noise, bad odour,
smokes, fumes, etc., which affect the health and
efficiency of a worker.
(b) Day light should be reinforced with artificial lights,
depending upon the nature of work.
(c) The environment should be well-ventilated and
comfortable.
(d) Dust and fume collectors should preferably be
attached with the equipments giving rise to them.
July 16, 2015 Sri Sai Ram Institute of Technology 104
2. Work place layout
Design considerations
(a) Materials and tools should be available at their predetermined places
and close to the worker.
(b) Tools and materials should preferably be located in the order in which
they will be used.
(c) The supply of materials or parts, if similar work is to be done by each
hand, should be duplicated. That is materials or parts to be assembled by
right hand should be kept on right hand side and those to be assembled
by the left hand should be kept on left hand side.
(d) Gravity should be employed, wherever possible, to make raw materials
reach the operator and to deliver material at its destination (e.g.,
dropping material through a chute).
(e) Height of the chair and work bench should be arranged in a way that
permits comfortable work posture.
July 16, 2015 Sri Sai Ram Institute of Technology 105

More Related Content

What's hot (19)

Method study
Method studyMethod study
Method study
 
Unit 2
Unit 2Unit 2
Unit 2
 
Recording techniques in method study
Recording techniques in method studyRecording techniques in method study
Recording techniques in method study
 
Problem solving tools 112411
Problem solving tools 112411Problem solving tools 112411
Problem solving tools 112411
 
Work study
Work studyWork study
Work study
 
Method study
Method studyMethod study
Method study
 
Chronocycle graph
Chronocycle graphChronocycle graph
Chronocycle graph
 
Indutrual engieneering
Indutrual engieneeringIndutrual engieneering
Indutrual engieneering
 
How I Improve and Manage a Production Area
How I Improve and Manage a Production AreaHow I Improve and Manage a Production Area
How I Improve and Manage a Production Area
 
Work Study- Methods Study
Work Study- Methods StudyWork Study- Methods Study
Work Study- Methods Study
 
Ergonomics and its application
Ergonomics and its applicationErgonomics and its application
Ergonomics and its application
 
Therbligs details
Therbligs detailsTherbligs details
Therbligs details
 
Work study IEM unit v for MEs2
Work study   IEM unit v  for MEs2Work study   IEM unit v  for MEs2
Work study IEM unit v for MEs2
 
UNIT 2 - WORK STUDY
UNIT 2 -  WORK STUDYUNIT 2 -  WORK STUDY
UNIT 2 - WORK STUDY
 
Cumulative and flyback timing
Cumulative and flyback timingCumulative and flyback timing
Cumulative and flyback timing
 
Micro-Macro Motion Study
Micro-Macro Motion StudyMicro-Macro Motion Study
Micro-Macro Motion Study
 
Method study
Method studyMethod study
Method study
 
Work Study Part- I
Work Study Part- IWork Study Part- I
Work Study Part- I
 
REDUCTION OF WASTAGES THROUGH PPC TECHNIQUES
REDUCTION OF WASTAGES THROUGH    PPC TECHNIQUESREDUCTION OF WASTAGES THROUGH    PPC TECHNIQUES
REDUCTION OF WASTAGES THROUGH PPC TECHNIQUES
 

Similar to Mareeswaran

Method study(abhishekkumar)
Method study(abhishekkumar)Method study(abhishekkumar)
Method study(abhishekkumar)Abhishek Kumar
 
PRODUCTION PLANNING AND CONTROL-WORK STUDY
PRODUCTION  PLANNING AND CONTROL-WORK STUDYPRODUCTION  PLANNING AND CONTROL-WORK STUDY
PRODUCTION PLANNING AND CONTROL-WORK STUDYAttiMurugan
 
02 Method Study part_2.pdf
02 Method Study part_2.pdf02 Method Study part_2.pdf
02 Method Study part_2.pdfSugumarSarDurai
 
Unit 2-IE6605 & PRODUCTION PLANNING AND CONTROL
Unit 2-IE6605 & PRODUCTION PLANNING AND CONTROLUnit 2-IE6605 & PRODUCTION PLANNING AND CONTROL
Unit 2-IE6605 & PRODUCTION PLANNING AND CONTROLMohanumar S
 
PRODUCTION PLANNING AND CONTROL UNIT 2
PRODUCTION PLANNING AND CONTROL UNIT 2PRODUCTION PLANNING AND CONTROL UNIT 2
PRODUCTION PLANNING AND CONTROL UNIT 2SIVASHANKAR N
 
PRODUCTION PLANNING AND CONTROL-Unit 2
PRODUCTION PLANNING AND CONTROL-Unit 2PRODUCTION PLANNING AND CONTROL-Unit 2
PRODUCTION PLANNING AND CONTROL-Unit 2prakash0712
 
Productivity Improvement by Optimum Utilization of Plant Layout: A Case Study
Productivity Improvement by Optimum Utilization of Plant Layout: A Case StudyProductivity Improvement by Optimum Utilization of Plant Layout: A Case Study
Productivity Improvement by Optimum Utilization of Plant Layout: A Case StudyIRJET Journal
 
Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...
Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...
Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...viveksangwan007
 
Work Study, Method Study
Work Study, Method StudyWork Study, Method Study
Work Study, Method StudyDr. Mohit Sahu
 
UNIT-II.ppt
UNIT-II.pptUNIT-II.ppt
UNIT-II.pptmahe49
 
PPC-Unit II- WORK STUDY
PPC-Unit II- WORK STUDYPPC-Unit II- WORK STUDY
PPC-Unit II- WORK STUDYDr.PERIASAMY K
 

Similar to Mareeswaran (20)

Work methods
Work methodsWork methods
Work methods
 
Method study(abhishekkumar)
Method study(abhishekkumar)Method study(abhishekkumar)
Method study(abhishekkumar)
 
PRODUCTION PLANNING AND CONTROL-WORK STUDY
PRODUCTION  PLANNING AND CONTROL-WORK STUDYPRODUCTION  PLANNING AND CONTROL-WORK STUDY
PRODUCTION PLANNING AND CONTROL-WORK STUDY
 
PPC_UNIT - II.pptx
PPC_UNIT - II.pptxPPC_UNIT - II.pptx
PPC_UNIT - II.pptx
 
02 Method Study part_2.pdf
02 Method Study part_2.pdf02 Method Study part_2.pdf
02 Method Study part_2.pdf
 
Unit 2 PPC
Unit 2 PPCUnit 2 PPC
Unit 2 PPC
 
Unit 2-IE6605 & PRODUCTION PLANNING AND CONTROL
Unit 2-IE6605 & PRODUCTION PLANNING AND CONTROLUnit 2-IE6605 & PRODUCTION PLANNING AND CONTROL
Unit 2-IE6605 & PRODUCTION PLANNING AND CONTROL
 
Unit 2
Unit 2Unit 2
Unit 2
 
PRODUCTION PLANNING AND CONTROL UNIT 2
PRODUCTION PLANNING AND CONTROL UNIT 2PRODUCTION PLANNING AND CONTROL UNIT 2
PRODUCTION PLANNING AND CONTROL UNIT 2
 
unit 2.pptx
unit 2.pptxunit 2.pptx
unit 2.pptx
 
PRODUCTION PLANNING AND CONTROL-Unit 2
PRODUCTION PLANNING AND CONTROL-Unit 2PRODUCTION PLANNING AND CONTROL-Unit 2
PRODUCTION PLANNING AND CONTROL-Unit 2
 
PPC -UNIT-II.ppt
PPC -UNIT-II.pptPPC -UNIT-II.ppt
PPC -UNIT-II.ppt
 
Unit 2
Unit 2Unit 2
Unit 2
 
Productivity Improvement by Optimum Utilization of Plant Layout: A Case Study
Productivity Improvement by Optimum Utilization of Plant Layout: A Case StudyProductivity Improvement by Optimum Utilization of Plant Layout: A Case Study
Productivity Improvement by Optimum Utilization of Plant Layout: A Case Study
 
Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...
Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...
Facility Layout/Production Planning & Control(PPC)/ Method Study/ Capacity Pl...
 
Work study
Work studyWork study
Work study
 
Work Study, Method Study
Work Study, Method StudyWork Study, Method Study
Work Study, Method Study
 
method Study.pptx
method Study.pptxmethod Study.pptx
method Study.pptx
 
UNIT-II.ppt
UNIT-II.pptUNIT-II.ppt
UNIT-II.ppt
 
PPC-Unit II- WORK STUDY
PPC-Unit II- WORK STUDYPPC-Unit II- WORK STUDY
PPC-Unit II- WORK STUDY
 

Recently uploaded

The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13Steve Thomason
 
Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111Sapana Sha
 
Introduction to AI in Higher Education_draft.pptx
Introduction to AI in Higher Education_draft.pptxIntroduction to AI in Higher Education_draft.pptx
Introduction to AI in Higher Education_draft.pptxpboyjonauth
 
भारत-रोम व्यापार.pptx, Indo-Roman Trade,
भारत-रोम व्यापार.pptx, Indo-Roman Trade,भारत-रोम व्यापार.pptx, Indo-Roman Trade,
भारत-रोम व्यापार.pptx, Indo-Roman Trade,Virag Sontakke
 
Employee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptxEmployee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptxNirmalaLoungPoorunde1
 
Pharmacognosy Flower 3. Compositae 2023.pdf
Pharmacognosy Flower 3. Compositae 2023.pdfPharmacognosy Flower 3. Compositae 2023.pdf
Pharmacognosy Flower 3. Compositae 2023.pdfMahmoud M. Sallam
 
Presiding Officer Training module 2024 lok sabha elections
Presiding Officer Training module 2024 lok sabha electionsPresiding Officer Training module 2024 lok sabha elections
Presiding Officer Training module 2024 lok sabha electionsanshu789521
 
Sanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdfSanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdfsanyamsingh5019
 
Science 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsScience 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsKarinaGenton
 
Biting mechanism of poisonous snakes.pdf
Biting mechanism of poisonous snakes.pdfBiting mechanism of poisonous snakes.pdf
Biting mechanism of poisonous snakes.pdfadityarao40181
 
History Class XII Ch. 3 Kinship, Caste and Class (1).pptx
History Class XII Ch. 3 Kinship, Caste and Class (1).pptxHistory Class XII Ch. 3 Kinship, Caste and Class (1).pptx
History Class XII Ch. 3 Kinship, Caste and Class (1).pptxsocialsciencegdgrohi
 
Final demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptxFinal demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptxAvyJaneVismanos
 
A Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy ReformA Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy ReformChameera Dedduwage
 
Enzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdf
Enzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdfEnzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdf
Enzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdfSumit Tiwari
 
Blooming Together_ Growing a Community Garden Worksheet.docx
Blooming Together_ Growing a Community Garden Worksheet.docxBlooming Together_ Growing a Community Garden Worksheet.docx
Blooming Together_ Growing a Community Garden Worksheet.docxUnboundStockton
 
Paris 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activityParis 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activityGeoBlogs
 
Hybridoma Technology ( Production , Purification , and Application )
Hybridoma Technology  ( Production , Purification , and Application  ) Hybridoma Technology  ( Production , Purification , and Application  )
Hybridoma Technology ( Production , Purification , and Application ) Sakshi Ghasle
 
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdfssuser54595a
 

Recently uploaded (20)

The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13
 
Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111
 
Introduction to AI in Higher Education_draft.pptx
Introduction to AI in Higher Education_draft.pptxIntroduction to AI in Higher Education_draft.pptx
Introduction to AI in Higher Education_draft.pptx
 
भारत-रोम व्यापार.pptx, Indo-Roman Trade,
भारत-रोम व्यापार.pptx, Indo-Roman Trade,भारत-रोम व्यापार.pptx, Indo-Roman Trade,
भारत-रोम व्यापार.pptx, Indo-Roman Trade,
 
Model Call Girl in Tilak Nagar Delhi reach out to us at 🔝9953056974🔝
Model Call Girl in Tilak Nagar Delhi reach out to us at 🔝9953056974🔝Model Call Girl in Tilak Nagar Delhi reach out to us at 🔝9953056974🔝
Model Call Girl in Tilak Nagar Delhi reach out to us at 🔝9953056974🔝
 
Employee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptxEmployee wellbeing at the workplace.pptx
Employee wellbeing at the workplace.pptx
 
Pharmacognosy Flower 3. Compositae 2023.pdf
Pharmacognosy Flower 3. Compositae 2023.pdfPharmacognosy Flower 3. Compositae 2023.pdf
Pharmacognosy Flower 3. Compositae 2023.pdf
 
Presiding Officer Training module 2024 lok sabha elections
Presiding Officer Training module 2024 lok sabha electionsPresiding Officer Training module 2024 lok sabha elections
Presiding Officer Training module 2024 lok sabha elections
 
Sanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdfSanyam Choudhary Chemistry practical.pdf
Sanyam Choudhary Chemistry practical.pdf
 
Science 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsScience 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its Characteristics
 
Biting mechanism of poisonous snakes.pdf
Biting mechanism of poisonous snakes.pdfBiting mechanism of poisonous snakes.pdf
Biting mechanism of poisonous snakes.pdf
 
History Class XII Ch. 3 Kinship, Caste and Class (1).pptx
History Class XII Ch. 3 Kinship, Caste and Class (1).pptxHistory Class XII Ch. 3 Kinship, Caste and Class (1).pptx
History Class XII Ch. 3 Kinship, Caste and Class (1).pptx
 
Final demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptxFinal demo Grade 9 for demo Plan dessert.pptx
Final demo Grade 9 for demo Plan dessert.pptx
 
A Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy ReformA Critique of the Proposed National Education Policy Reform
A Critique of the Proposed National Education Policy Reform
 
Enzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdf
Enzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdfEnzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdf
Enzyme, Pharmaceutical Aids, Miscellaneous Last Part of Chapter no 5th.pdf
 
Blooming Together_ Growing a Community Garden Worksheet.docx
Blooming Together_ Growing a Community Garden Worksheet.docxBlooming Together_ Growing a Community Garden Worksheet.docx
Blooming Together_ Growing a Community Garden Worksheet.docx
 
Paris 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activityParis 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activity
 
Hybridoma Technology ( Production , Purification , and Application )
Hybridoma Technology  ( Production , Purification , and Application  ) Hybridoma Technology  ( Production , Purification , and Application  )
Hybridoma Technology ( Production , Purification , and Application )
 
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
18-04-UA_REPORT_MEDIALITERAСY_INDEX-DM_23-1-final-eng.pdf
 
9953330565 Low Rate Call Girls In Rohini Delhi NCR
9953330565 Low Rate Call Girls In Rohini  Delhi NCR9953330565 Low Rate Call Girls In Rohini  Delhi NCR
9953330565 Low Rate Call Girls In Rohini Delhi NCR
 

Mareeswaran

  • 1. July 16, 2015 Sri Sai Ram Institute of Technology 1
  • 3. Outline July 16, 2015 Sri Sai Ram Institute of Technology 3 1. Work Study1. Work Study 2. Method Study2. Method Study 3. Various Charts3. Various Charts
  • 4. Work Study  Work Study is a generic term for management services and system engineering techniques, used to investigate: – Methods of performing work (Method Study). – The time taken to do it (Work Measurement). July 16, 2015 Sri Sai Ram Institute of Technology 4
  • 5. Work Study (Cont.) July 16, 2015 Sri Sai Ram Institute of Technology 5
  • 6. Method Study  Method study is a technique to reduce the work content mainly by eliminating unnecessary movements by workers, materials, or equipments.  However, even after that, there could be substantial unnecessary time taken for the process because of lack of management control or inaction of worker.  Method Study approaches and tools of Method Analyst: – Flow Diagrams & Process Charts etc. – Critical questioning techniques. July 16, 2015 Sri Sai Ram Institute of Technology 6
  • 7. 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 costs.  Used to analyze  Movement of body, people, or material  Activities of people & machines July 16, 2015 Sri Sai Ram Institute of Technology 7
  • 8. Method Study Objectives  Improvement of processes and procedures.  Improvement in the design of plant and equipment.  Improvement of layout.  Improvement in the use of men, materials and machines.  Economy in human effort and reduction of unnecessary fatigue.  Development of better working environment. July 16, 2015 Sri Sai Ram Institute of Technology 8
  • 9. Method study - Methodology  Procedure to accomplish method study, called "SREDIM" shall be as follow: 1. Select: the job or operation that needs improvement, 2. Record: all facts, how work is done by chart methods, 3. Examine: every aspect of the job by asking; what, why, where, when, who and how 4. Develop: review ideas, eliminate, simplify, combine, re- arrange, make new method which more safe, chart new method, submit for approval, 5. Install: the new method, consider best time to introduce, convince all, train users, 6. Maintain: check frequently, match results, correct deviations. July 16, 2015 Sri Sai Ram Institute of Technology 9
  • 10. Methodology (Cont.) July 16, 2015 Sri Sai Ram Institute of Technology 10 Select Record Examine OK? Develop Install Maintain
  • 11. Method Study Tools  Exploratory Tools – Pareto Analysis – Fish & Bone Diagrams – Gantt and PERT charts  Recording and Analysis Tools – Operation Process Chart – Flow process chart – Flow diagram – Worker and Machine Process Charts – Gang Process charts – Synchronous Servicing July 16, 2015 Sri Sai Ram Institute of Technology 11
  • 12. Method Study Applications  The need for methods analysis can come from a number of different sources :  Changes in tools and equipment.  Changes in product design or new products.  Changes in materials or procedures  Other factors (e.g. accidents, quality problems) July 16, 2015 Sri Sai Ram Institute of Technology 12
  • 13. Recording Techniques  Charts 1. Outline process chart. 2. Flow process chart (man-type, material-type and equipment- type): This is the use of symbols and description to chart the sequence of work. The process, then, show what is happening at different stages. The distances and time may be given. 3. Two hands process charts. 4. Multiple activity charts: This technique is used to solve problems where a number of items are dependent on each other. The aim is to reduce idle times by using the optimum number of each item. It depicts the occupied times-broken down into the number of different activities and the idle times both for the original and proposed methods of doing the job. July 16, 2015 Sri Sai Ram Institute of Technology 13
  • 14. Recording Techniques (Cont.)  Diagrams and models (2-D and/or 3-D) 1. Flow diagrams, which is the use of symbols for flow process charts, superimposed on drawings and the "descriptions" are not necessary. 2. String diagrams, which is used for solving movement problems since it shows congestions and excessive distances. 3. Cut-out templates (2-D models). 4. 3-D models.  Photography 1. Photographs, 2. Films, 3. Video. July 16, 2015 Sri Sai Ram Institute of Technology 14
  • 15. Assembly Chart  It is an analog model of the assembly process.  Circles with a single link denote basic components, circles with several links denote assembly operations/subassemblies, and squares represent inspection operations.  The easiest method to constructing an assembly chart is to begin with the original product and to trace the product disassembly back to its basic components. July 16, 2015 Sri Sai Ram Institute of Technology 15
  • 16. Assembly Chart (Cont.) Assembly Chart for producing Cheese July 16, 2015 Sri Sai Ram Institute of Technology 16
  • 17. Assembly Chart (Cont.) July 16, 2015 Sri Sai Ram Institute of Technology 17
  • 18. Operation Process Chart  The operation process chart shows the chronological sequence of all operations, inspections, time allowances, and materials used in a manufacturing or business process, from the arrival of raw material to the packaging of the finished product.  The chart depicts the entrance of all components and subassemblies to the main assembly.  Two symbols are used in constructing the operation process Chart : an operation and an inspection. July 16, 2015 Sri Sai Ram Institute of Technology 18
  • 19. Operation Process Chart (Cont.)  Operations charts show the introduction of raw materials at the top of the chart on a horizontal line.  Some parts require no fabrication steps. These parts are called buyouts. Buyouts are introduced above the operation July 16, 2015 Sri Sai Ram Institute of Technology 19 Tape Carton Operation Number Pieces / Hr Hours / 1000
  • 20. Operations Chart Steps  Step by Step Procedures For Preparing an Operations Chart:  Identify the parts to be manufactured and purchased  Determine the operations required to fabricate each part and sequence them  Determine the sequence or assembly for buyouts and fabricated parts  Draw the operations chart as explained  Put time standards, operation numbers and descriptions  Calculate and write down the total hours required per 1,000 units July 16, 2015 Sri Sai Ram Institute of Technology 20
  • 21. Operation Process Chart Operation Process Chart for Refrigera July 16, 2015 Sri Sai Ram Institute of Technology 21
  • 22. Operation Process Chart July 16, 2015 Sri Sai Ram Institute of Technology 22
  • 23. Flow Diagrams  A flow diagram is essentially a flow process chart drawn to: 1. Show the layout of a facility. 2. Show the flow of work through that area 3. Show overcrowding areas, crossing worker paths, total travel. 4. Identify how layout can be redesigned to reduce travel, motion, collisions, etc. 5. Store materials near where they are used. 6. Increase efficiency and safety.  Usually, the objective is to look for spatial relationships.  It depicts the probable movement of materials in the floor plant. The movement is represented by a line in the plant drawing. July 16, 2015 Sri Sai Ram Institute of Technology 23
  • 24. Flow Diagram (Cont.) July 16, 2015 Sri Sai Ram Institute of Technology 24 Buyer You 75 ft.75 ft.
  • 25. Flow Diagram (Cont.) July 16, 2015 Sri Sai Ram Institute of Technology 25
  • 26. Flow Process Charts  A flow process chart is a chart of all the activities involved in a process.  It is similar to an operations process chart, except that more detail is shown by including transportations and delays as well as operations, inspections, and storages.  Not usually used for entire assemblies, it is used for just one component (or operator)  Add in information on:  Operation duration (time to complete)  Distance traveled (for transport operations)  Good for showing savings of a new method. July 16, 2015 Sri Sai Ram Institute of Technology 26
  • 27. Flow Process Charts (Cont.)  Process charts summarizes the whole process  They are used to compare the existing and the proposed methods  Process is observed, who, what, where, when, and how questions are asked  Every detail is understood and the chart of the existing situation is drawn July 16, 2015 Sri Sai Ram Institute of Technology 27
  • 28. Flow Process Charts (Cont.)  Quantity:  Operations: Pieces per hour  Transportation: How many are moved at a time  Inspection: How many pieces per hour if under time standard and/or frequency of inspection  Delays: How many pieces in a container  Storage: How many pieces per storage unit July 16, 2015 Sri Sai Ram Institute of Technology 28
  • 29. Flow Process Charts (Cont.)  Time in Hours per Unit  If 250 pieces are processed in an hour then 1 unit is processed in 0.00400 hours. Record 400  If 200 units are moved in 1 minute, then 1/200 = 0.005 minutes per part, and 0.005/60 hours/part =0.00008 hrs/part. Record 8. July 16, 2015 Sri Sai Ram Institute of Technology 29
  • 30.  Flow Process Types:  Product or Material type  Worker (Man) type  Machine type July 16, 2015 Sri Sai Ram Institute of Technology 30
  • 31. July 16, 2015 Sri Sai Ram Institute of Technology 31
  • 32. Flow Process Chart Symbols July 16, 2015 Sri Sai Ram Institute of Technology 32 Operation Transportation Inspection Delay Storage
  • 33.  Occurs when an object is intentionally changed in one or more of its characteristics  Usually occurs at a machine or a work station  Drilling, Painting, Data Entry, Cutting, Sorting, etc. July 16, 2015 Sri Sai Ram Institute of Technology 33 Operation
  • 34.  Occurs when an object is moved from one place to another  except when the movement is part of an operation or an inspection  Using elevator, carrying, moving with material handling devices July 16, 2015 Sri Sai Ram Institute of Technology 34 Transportation
  • 35.  Occurs when an object is examined for identification or is compared with a standard as to quantify or quality  Examine the quantity or quality, read steam gauge on boiler, detect the defectives July 16, 2015 Sri Sai Ram Institute of Technology 35 Inspection
  • 36.  Occurs when the immediate performance or the next planned action does not take place  Work In Process inventory waiting to be processed, Employee waiting for an elevator, Waiting for accumulation of a certain quantity for packaging July 16, 2015 Sri Sai Ram Institute of Technology 36 Delay
  • 37.  Occurs when an object is kept under control such that its withdrawal requires authorization  Bulk storage of raw material, finished products inventory, archived documents July 16, 2015 Sri Sai Ram Institute of Technology 37 Storage
  • 38. Combined Symbols  Two symbols may be combined when two activities are performed concurrently. July 16, 2015 Sri Sai Ram Institute of Technology 38 Operation and Inspection
  • 39. Flow Process Chart-An Example Flow Process Chart Example July 16, 2015 Sri Sai Ram Institute of Technology 39
  • 40. Flow Process Chart-An Example July 16, 2015 Sri Sai Ram Institute of Technology 40 1 X Enter emergency room, approach patient window 2 X Sit down and fill out patient history 3 X Nurse escorts patient to ER triage room 4 X Nurse inspects injury 5 X Return to waiting room 6 X Wait for available bed 7 X Go to ER bed 8 X Wait for doctor 9 X Doctor inspects injury and questions patient 10 X Nurse takes patient to radiology 11 X Technician x-rays patient 12 X Return to bed in ER 13 X Wait for doctor to return 14 X Doctor provides diagnosis and advice 15 X Return to emergency entrance area 16 X Check out 17 X Walk to pharmacy 18 X Pick up prescription 19 X Leave the building 0.50 15 10.0 - 0.75 40 3.00 - 0.75 40 1.00 - 1.00 60 4.00 - 5.00 - 2.00 200 3.00 - 2.00 200 3.00 - 2.00 - 1.00 60 4.00 - 2.00 180 4.00 - 1.00 20 Process: Emergency room admission Subject: Ankle injury patient Beginning: Enter emergency room Ending: Leave hospital Step no. Time (min) Distance (ft) Summary Number of stepsActivity Time (min) Distance (ft) Step description Insert Step Append Step Remove Step Transport 9 11 815 Operation 5 23 — Inspect 2 8 — Store — — — Delay 3 8 —
  • 41. Material Type - Example July 16, 2015 Sri Sai Ram Institute of Technology 41
  • 42. Man Type - Example July 16, 2015 Sri Sai Ram Institute of Technology 42
  • 43. Left-Hand-Right-Hand Charts  Useful in analyzing the work performed by one person at one specific workstation. As the name implies, the chart follows the motion of the left and right hands of one operator .  Each hand of the worker is treated as an activity.  Each hand’s activities are broken into work elements and plotted side by side on a time scale. July 16, 2015 Sri Sai Ram Institute of Technology 43
  • 44. Left-Hand-Right-Hand Charts (Cont.) Lists the work performed simultaneously by each hand – To assist in finding a better method of performing the task and – To train the operator in the preferred method. July 16, 2015 Sri Sai Ram Institute of Technology 44
  • 45. Symbols  Two symbols are used in this chart: – Transportation (either an arrow or a small circle) – Action (e.g., grasp, position, use, release)  A sketch of the workplace is drawn, indicating the contents of the bins and the location of tools and materials. – Record the motions of one hand at a time – Usually necessary to redraw the chart July 16, 2015 Sri Sai Ram Institute of Technology 45
  • 46. Left-Hand-Right-Hand Chart (An Example) July 16, 2015 Sri Sai Ram Institute of Technology 46
  • 47. L-R Hand Chart of Signing a Letter LEFT HAND RIGHT HAND Hold Letter Reach for pen Grasp pen Carry pen to paper Sign letter Return pen to holder Release pen in holder Move hand back to letterJuly 16, 2015 Sri Sai Ram Institute of Technology 47
  • 48. LEFT HAND RIGHT HAND Reach for bolt in bin 1 Grasp bolt Carry bolt to work area Position bolt Hold Bolt Carry assembly to bin 3 Reach for nut in bin 2 Grasp nut Carry nut to work area Position nut Assemble nut Release nut July 16, 2015 Sri Sai Ram Institute of Technology 48
  • 49. Man-machine chart  The worker and machine process chart (Man-machine chart) is used to study, analyze, and improve one workstation at a time.  The chart shows the exact time relationship between the working cycle of the person and operating cycle of the machine.  These facts can lead to utilization of both worker and machine time, and a better balance of the work cycle. July 16, 2015 Sri Sai Ram Institute of Technology 49
  • 50. Worker-Machine Chart for a Gourmet Coffee Store July 16, 2015 Sri Sai Ram Institute of Technology 50
  • 51. Worker-Machine Chart for a Gourmet Coffee Store July 16, 2015 Sri Sai Ram Institute of Technology 51 The customer, the clerk, and the coffee grinder (machine) are involved in this operation. It required 1 minute and 10 seconds for the customer to purchase a pound of coffee in this particular store. During this time the customer spent 22 seconds, or 31 percent of the time, giving the clerk his order, receiving the ground coffee, and paying the clerk for it. He was idle during the remaining 69 percent of the time. The clerk worked 49 seconds, or 70 percent of the time, and was idle 21 seconds, or 30 percent of the time. The coffee grinder was in operation 21 seconds, or 30 percent of the time, and was idle 70 percent of the time.
  • 52. Multiple Activity Charts  Also known as Gang Process Charts  Used when several workers operate a single machine or render a single service  Used when a single worker is operating several machines  Used to show the exact relationship between idle and operating times of both workers and machines July 16, 2015 Sri Sai Ram Institute of Technology 52
  • 53. Multiple Activity Charts (Cont.)  An operation performed by one member of the group may continue while another member is performing more than one operation.  The chart should cover the complete cycle for the longest performing member. July 16, 2015 Sri Sai Ram Institute of Technology 53
  • 54. Activity Chart July 16, 2015 Sri Sai Ram Institute of Technology 54 Subject: Semi-Auto Machine Operator MachineTime 1 2 3 4 5 6 Load machine Being loaded Idle Run Unload Being Unloaded Present
  • 55. Activity Chart for Two-Person July 16, 2015 Sri Sai Ram Institute of Technology 55
  • 56. Activity Chart of Emergency Tracheotomy July 16, 2015 Sri Sai Ram Institute of Technology 56
  • 57. Principles of Motion Economy As Related To The Use Of The Human Body 1. The two hands should begin as well as complete their motions at the same time. 2. The two hands should not be idle at the same time except during rest periods. 3. Motions of the arms should be made in opposite and symmetrical directions, and should be made simultaneously. 4. Hand and body motions should be confined to the lowest classification with which it is possible to perform the work satisfactorily. July 16, 2015 Sri Sai Ram Institute of Technology 57
  • 58. July 16, 2015 Sri Sai Ram Institute of Technology 58
  • 59. 5. Momentum should be employed to assist the worker whenever possible, and it should be reduced to a minimum if it must be overcome by muscular effort. 6. Smooth continuous curved motions of the hands are preferable to straight-line motions involving sudden and sharp changes in direction. July 16, 2015 Sri Sai Ram Institute of Technology 59
  • 60. 7. Ballistic movements are faster, easier, and more accurate than restricted (fixation) or “controlled” movements. 8. Work should be arranged to permit easy and natural rhythm wherever possible. 9. Eye fixations should be as few and as close together as possible. July 16, 2015 Sri Sai Ram Institute of Technology 60
  • 61. As Related To The Work Place 10.There should be a definite and fixed place for all tools and materials. 11.Tools, materials, and controls should be located close to the point of use. July 16, 2015 Sri Sai Ram Institute of Technology 61
  • 62. July 16, 2015 Sri Sai Ram Institute of Technology 62
  • 63. 12.Gravity feed bins and containers should be used to deliver material close to the point of use. July 16, 2015 Sri Sai Ram Institute of Technology 63
  • 64. 13. Drop deliveries should be used whenever possible. 14. Materials and tools should be located to permit the best sequence of motions. 15. Provision should be made for adequate conditions for seeing. Good illumination is the first requirement for satisfactory visual perception. July 16, 2015 Sri Sai Ram Institute of Technology 64
  • 65. July 16, 2015 Sri Sai Ram Institute of Technology 65
  • 66. 16.The height of the work place and the chair should preferably be arranged so that alternate sitting and standing at work are easily possible. July 16, 2015 Sri Sai Ram Institute of Technology 66
  • 67. 17. A chair of the type and height to permit good posture should be provided for every worker. July 16, 2015 Sri Sai Ram Institute of Technology 67
  • 68. As Related To The Design Of Tools And Equipment 18.The hands should be relieved of all work that can be done more advantageously by a jig, a fixture, or a foot-operated device. 19.Two or more tools should be combined wherever possible. 20.Tools and materials should be prpositioned whenever possible. 21.Where each finger performs some specific movement, such as in typewriting, the load should be distributed in accordance with the inherent capacities of the fingers. July 16, 2015 Sri Sai Ram Institute of Technology 68
  • 69. 22. Levers, hand wheels and other controls should be located in such positions that the operator can manipulate them with the least change in body position and with the greatest speed and ease. July 16, 2015 Sri Sai Ram Institute of Technology 69
  • 71. 71 Introduction • Work measurement is the application of techniques designed to establish the time for a qualified worker to carry out specified jobs at a defined level of performance. • We have seen how total time to manufacture a product is increased by:  adding undesirable features to product,  bad operation of the processes, and  ineffective time added because of worker and management. • All this leads to decreased productivity.
  • 72. 72 Introduction • Method study is one of principal techniques by which work content in the product manufacture or process could be decreased. • It is a systematic method of investigating and critically examining the existing methods, to develop the improved ones. • Method study is, then, a technique to reduce the work content mainly by eliminating unnecessary movements by workers and/or materials and/or equipments. • However, even after that, there could be substantial unnecessary time taken for the process because of lack of management control and/or inaction of worker.
  • 73. 73 Introduction • Work measurement (WM) is concerned with investigating, reducing and eliminating ineffective time, whatever may be the cause. • WM is the means of measuring the time taken in the performance of an operation or series of operations in such a way that the ineffective time is shown up and can be separated out. • In practice, proving existence of the ineffective time is the most difficult task. • After existence is proved, nature and extent is easy to see!
  • 74. 74 Introduction • WM is also used to set standard times to carry out the work, so that any ineffective time is not included later. • Any addition the standard time would show up as excess time and thus can be brought to attention. • Since, standard times are set for all the activities through WM, it has earned bad reputation amongst workers. • Major reason for that has been the initial focus of the WM methods, which essentially targeted only the worker controllable ineffective times. • Management controllable ineffective times were ignored traditionally.
  • 75. 75 Introduction Two critical issues in work study: 1. Method study should precede the work measurement, always. 2. Elimination of management controllable ineffective time should precede the elimination of the ineffective time within the control of the workers.
  • 76. 76 Purpose of WM • To reveal the nature and extent of ineffective time, from whatever cause, • So that action can be taken to eliminate it; and then, • To set standards of performance that are attainable only if all avoidable ineffective time is eliminated and work is performed by the best method available.
  • 77. 77 Uses of WM • To compare the efficiency of alternative methods. Other conditions being equal, the method which takes the least time will be the best method. • To balance the work of members of teams, in association with the multiple activity charts, so that, as far as possible, each member has tasks taking an equal time. • To determine, in association with man and machine multiple activity charts, the number of machines an worker can run.
  • 78. 78 Uses of time standards • To provide information on which the planning and scheduling of production can be based, including the plant and labor requirements for carrying out the program of work and utilization of resources. • To provide information on which estimates for tenders, selling prices and delivery promises can be based. • To set standards of machine utilization and labor performance which can be used for incentive scheme. • To provide information for labor-cost control and to enable standard costs to be fixed and maintained.
  • 79. 79 TECHNIQUES OF WORK MEASUREMENT The different techniques used in work measurement are 1. Stop watch time study. 2. Production study. 3. Work sampling or Ratio delay study. 4. Synthesis from standard data. 5. Analytical estimating. 6. Predetermined motion time system.
  • 80. Procedure for conducting stop watch time study The following procedure is followed in conducting stop watch time study: 1. Selecting the job. 2. Recording the specifications. 3. Breaking operation into elements. 4. Examining each element. 5. Measuring using stop watch. 6. Assessing the rating factor. 7. Calculating the basic time. 8. Determining the allowances. 9. Compiling the standard time. July 16, 2015 Sri Sai Ram Institute of Technology 80
  • 81. Stop watch time study Measuring Time with a Stop Watch There are two methods of timing using a stop watch. They are 1. Fly back or Snap back method. 2. Continuous or Cumulative method. July 16, 2015 Sri Sai Ram Institute of Technology 81
  • 82. 1. Fly back method • Here the stop watch is started at the beginning of the first element. At the end of the element the • reading is noted in the study sheet (in the WR column). At the same time, the stop watch hand is • snapped back to zero. This is done by pressing down the knob, immediately the knob is released. • The hand starts moving from zero for timing the next element. In this way the timing for each • element is found out. This is called observed time (O.T.) . July 16, 2015 Sri Sai Ram Institute of Technology 82
  • 83. 2. Continuous method • Here the stop watch is started at the beginning of the first element. The watch runs continuously • throughout the study. At the end of each element the watch readings are recorded on the study • sheet. The time for each element is calculated by successive subtraction. The final reading of the • stop watch gives the total time. This is the observed time (O.T.). July 16, 2015 Sri Sai Ram Institute of Technology 83
  • 84. CALCULATION OF STANDARD TIME • Standard time or allowed time is the total time in which a job should be completed at standard performance. It is the sum of normal time (basic time) and allowances. Policy allowance is notincluded.Standard time is worked out in a stop watch time study in the following manner. Observed time • This is the actual time observed by using a stop watch. The observed time of an operation is the total of the elemental times. The time study for the same job is conducted for a number of times. The average of the Observed times is calculated. Basic or normal time • Basic time is the time taken by a worker with standard performance. Basic time is calculated from • the observed time by applying the rating factor. • Basic time orNormal time = Observed time ×(Rating of the operator/Standard rating 100) Allowed time or standard time • The standard time is obtained by adding the following allowances with the basic or normal time. • 1. Rest and personal allowance or relaxation allowance. • 2. Process allowance or unavoidable delay allowance. • 3. Contingency allowance. • 4. Special allowance. • Policy allowance may be added to the standard time if the management wants. July 16, 2015 Sri Sai Ram Institute of Technology 84
  • 85. 85 Factors affecting rate of working Factors outside the control of workers include: • Variation in the quality or other characteristics of the material used, although they be within the prescribed tolerance limit. • Changes in the operating efficiency of tools or equipment within their normal life. • Minor and unavoidable changes in methods or conditions of operations. • Variation in the mental attention for the performance of elements. • Changes in the climatic and other conditions.
  • 86. 86 Factors affecting rate of working Factors within worker’s control: • Acceptable variation in the quality of the process/product. • Variation due to worker’s ability. • Variation due to ability of mind, specifically attitude. Optimum pace at which the worker will work depends on – • The physical effort demanded by the work. • The care required on the part of the worker. • Training and experience.
  • 87. 87 Rating factor • The figure 100 represents standard performance. • If the operator is apparently performing with less effective speed, than the assigned factor is less than 100. • If, on the other hand, the effective rate of working is above standard, the operator gets a factor above hundred. • Essential idea being: Observed time x Rating = Constant
  • 88. 88 Rating factor • This constant is known as the basic time: • So, depending on the rating assigned for the operator, the basic time can either be less than or greater than the observed time. TimeBasic RatingStandard Rating timeObserved =x
  • 89. 89 Selected time • The selected time is the time chosen as being representative of a group of times for which an element or group of elements. • These times may be either observed or basic times; and should be denoted as selected observed or selected basic times. • Theoretically, the results of all the computations of the basic time for any single constant element should be same. • However, because of inherent process variations, it happens rarely!
  • 90. 90 Selected time • It becomes necessary to select a representative time for each element from all the basic times which have been entered into the time study. • Multiple ways to pick a representative selected time from the available ones. • Statistics suggests….. Taking averages! • There are other ways though! • Before the selected time is decided, the anomalies in the sample should be noted. • Exceptionally high or low points should get some attention.
  • 91. 91 Selected time Constant element • A very high or short observed time for a given element of job should be treated with caution. • An exceptionally high observed time could be due to incorrect recording, but most common reason is material or environment variation. • In such as case, it should be checked whether such a variation is frequent or rare. • Excess observed time because of rarely occurring events is typically not included as a representative.
  • 92. 92 Selected time • The average time calculations should exclude this observation. But, the excess-over-average time is added to the contingency allowance. • Frequent large variations indicate that the element is not a constant one but a variable element. • Excessively large time for this element could be detected by corresponding reduction in time for the immediate element. • Exceptionally short times could be due to human error. • A rare reason of observation of such short times could also be a last-minute-process-improvement. In such as case, the job should be studied again with more detailed attention.
  • 93. 93 Selected time Variable element • In general more observations will be necessary of a variable element than of a constant element before reliable representative basic times can be established. • The analysis of factors affecting the time to complete the element should be closely studied. • Some relationship should be established between the observed time and the variable factors. • Multiple factors could be affecting the observed time variation and establishing relationships amongst multiple factors is difficult
  • 94. 94 Work content • The work content of a job or operation is defined as: basic time+ relaxation allowance+ any allowance for additional work (e.g. the part of relaxation allowance that is work related). • Standard time is the total time in which a job should be completed at standard performance – i.e. work content, contingency allowance for delay, unoccupied time and interference allowance. • Allowance for unoccupied time and interference may not be frequently included in the standard time calculations; however, the relaxation allowance is.
  • 95. 95 Standard time constituents • A contingency allowance is a small allowance of time which may be included in a standard time to meet legitimate and expected items of work or delays, precise measurement of which is uneconomical because of their infrequent or irregular occurrence. • Contingency allowance for work should include fatigue allowance; whereas the allowance for delay should be dependent on the workers. • Typically contingency allowances are very small and are generally expressed as percentage of the total repetitive minutes of the job.
  • 96. 96 Standard time constituents • Contingency allowance should not be more than 5%, and should only be given where the contingencies cannot be eliminated and are justified.
  • 97. 97 Standard time constituents • Relaxation allowance is an addition to the basic time intended to provide the worker with the opportunity to recover from the physiological and psychological effects of carrying out specified work under specified conditions and to allow attention to personal needs. • The amount of the allowance will depend on the nature of the job. • One of the major additions to the basic time. • Industrial fatigue allowance, in turn, forms a major portion of the relaxation allowance. • Relaxation allowances are also given as percentages of the basic times.
  • 98. 98 Standard time constituents • Typical values of relaxation allowance are 12-20%. • In addition to including relaxation allowances, short rest pauses could be added over the period of work for an operator.
  • 99. 99 Other allowances • Start-up / shut-down allowance • Cleaning allowance • Tooling allowance • Set-up / change-over allowance • Reject / excess production allowance • Learning / training allowance • Policy allowance is an increment, other than the bonus increment, applied to standard time to provide a satisfactory level of earning for certain level of performances under exceptional conditions.
  • 100. 100 Standard time • Now, we can add all the constituents to arrive at the standard time for a job. Standard time = observed time + rating factor + relaxation allowance + work related contingency allowance + delay related contingency allowance.
  • 101. ERGONOMICS • Ergons means ‘work’ and Nomos means ‘Natural laws’. Ergonomics or its American equivalent • ‘Human Engineering may be defined as the scientific study of the relationship between man and • his working environments. • Ergonomics implies ‘Fitting the job to the worker’. Ergonomics combines the knowledge of a • psychologist, physiologist, anatomist, engineer, anthropologist and a biometrician. July 16, 2015 Sri Sai Ram Institute of Technology 101
  • 102. Objectives The objectives of the study of ergonomics is to optimize the integration of man and machine inorder to increase work rate and accuracy. It involves • The design of a work place befitting the needs and requirements of the worker. • The design of equipment, machinery and controls in such a manner so as to minimize mental and physical strain on the worker thereby increasing the efficiency, and • The design of a conductive environment for executing the task most effectively. Both work study and Ergonomics are complementary and try to fit the job to the workers; however Ergonomics adequately takes care of factors governing physical and mental strains. July 16, 2015 Sri Sai Ram Institute of Technology 102
  • 103. Applications • In practice, ergonomics has been applied to a number of areas as discussed below 1. Working environments 2. The work place and 3. Other areas. July 16, 2015 Sri Sai Ram Institute of Technology 103
  • 104. 1. Working environments (a) The environment aspect includes considerations regarding light, climatic conditions (i.e., temperature, humidity and fresh air circulation), noise, bad odour, smokes, fumes, etc., which affect the health and efficiency of a worker. (b) Day light should be reinforced with artificial lights, depending upon the nature of work. (c) The environment should be well-ventilated and comfortable. (d) Dust and fume collectors should preferably be attached with the equipments giving rise to them. July 16, 2015 Sri Sai Ram Institute of Technology 104
  • 105. 2. Work place layout Design considerations (a) Materials and tools should be available at their predetermined places and close to the worker. (b) Tools and materials should preferably be located in the order in which they will be used. (c) The supply of materials or parts, if similar work is to be done by each hand, should be duplicated. That is materials or parts to be assembled by right hand should be kept on right hand side and those to be assembled by the left hand should be kept on left hand side. (d) Gravity should be employed, wherever possible, to make raw materials reach the operator and to deliver material at its destination (e.g., dropping material through a chute). (e) Height of the chair and work bench should be arranged in a way that permits comfortable work posture. July 16, 2015 Sri Sai Ram Institute of Technology 105

Editor's Notes

  1. Shows the path the product moves starting from the receiving part (may be as a raw material) up to the shipping area as a finished good Several parts can be shown on one flow diagram Each path is drawn on a layout of the plant