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Method study
This document discusses methods engineering and method study. It describes method study as the systematic analysis and examination of work methods to develop more effective procedures. The key steps of method study include selecting processes to study, recording current methods, examining recordings for inefficiencies, developing improved methods, evaluating changes, defining new standards, installing changes, and maintaining improvements. A variety of charts and diagrams are used to record work including flow diagrams, string diagrams, process charts, and therblings analysis which divides tasks into elemental motions. The overall aim is to eliminate unnecessary steps and make processes more efficient.
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Method study
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- 2. Methods engineering/work design Breakdown of operation into components Systematic analysis of each component Eliminates un-necessary operations According to BSI It is systematic recording & examination of existing methods of doing work and developing more effective methods” ©MGM IOM,A'bad
- 3. SELECT RECORD EXAMINE Procedure for DEVELOPE Method Study EVALUATE DEFINE INSTALL MAINTAIN ©MGM IOM,A'bad
- 4. Recording techniques for Method Study Charts Diagrams Macro Motion Micro Motion 1.Flow Diagram charts charts 2.String Diagram 1.Operations Process Chart SIMO Chart 2.Flow Process Chart 3.Two Handed Process Chart 4.Multiplle Activity Chart ©MGM IOM,A'bad
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- 6. OPERATION INSPECTION TRANSPORTATION DELAY STORAGE ©MGM IOM,A'bad
- 7. 1.Operation Process Chart •Alsocalled Outline process chart •Bird’s eye view of whole process •Records only major activities and inspections •Uses only two symbols i.e. operations & inspection •Constructed by placing symbols one below another Uses •Visualize sequence of operations & inspections in process •Know where operations selected fits into the entire process ©MGM IOM,A'bad
- 8. 2. Flow ProcessChart • Gives sequence of flow of work • Operations, inspection, storage, delay and transportation are represented • Constructed same as operation process chart • Three types 1. Material type 2. Man type 3. Equipment type Uses •Reduce idle time and delays •Reduce distance travelled •Reduce production cycle time •To relocate inspection stages ©MGM IOM,A'bad
- 9. Process chart formaking a cheese sandwich Distance in Symbol Process description meter 10 Move to cabinet - Get loaf of bread - Remove two slices of bread - Lay slices on table top - Close loaf of bread - Replace loaf on shelf - Open butter - Spread butter on top slice - Inspect sandwich - Move to serving area 10 Serve sandwich ©MGM IOM,A'bad
- 10. 3.Two handed processchart •Most detailed type •Activities of workers hand recorded in relation to one another •Confined to work carried out at a single workplace Uses •Visualize complete sequence of activities in repetitive task •Study work station layout 4.Multiple activity chart •Activities of more than one subject each recorded •Common time scale to show inter-relationship Uses •Study idle time •Determine no. of machines handled by one operator •Determine no. of operators required ©MGM IOM,A'bad
- 11. Multiple activity chartfor doing three loads of laundry Time Operator Machine 1 Machine 2 Washer Dryer # Sec Load clothes & detergent Being loaded Idle in machine 1 idle Run Idle - Remove clothes from Being unloaded Idle machine 1 - Load clothes into machine Idle Being loaded 2 - Load clothes & detergent Being loaded Run into machine 1 - Idle Run Run - Remove clothes from Idle Being unloaded machine 2 - Hang clothes Idle Idle ©MGM IOM,A'bad
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- 13. 1.Flow diagram •Drawing of working area & showing location of various activities •Shows the route followed and selects the optimum one •Study different layout and selecting optimum one •Study traffic and frequency over different routes Procedure : •Layout of workplace is drawn to scale •Relative positions of the m/c tools, storage & inspection benches are marked on the scale •Path followed by the subject under study is tracked by drawing lines •Each movement is serially numbered & indicated by arrow for direction •Different colors are used to denote different types of movements ©MGM IOM,A'bad
- 14. 1.String diagram •Scale layout drawing •length of a string is used to record extent & pattern of movements of a worker within a limited area. •Movements difficult to trace on flow diagram can be shown •Shows the route followed and selects the optimum one •Study different layout and selecting optimum one •Study traffic and frequency over different routes Procedure : •A Layout of workplace is drawn to scale •Pins are fixed into boards to mark locations of workstations •Pins are also driven at turning points of the routes •A measured length of thread is taken to trace the movements •The distance covered by object is obtained by measuring the remaining part of the thread and subtracting it from original length ©MGM IOM,A'bad
- 15. •Suggested by Frank o Gilbreth •Technique for recording and timing an activity •Divides human activities in a group of movements or micro motions (called therblings) •Helps to find best pattern of movements for an operator that consumes less time and requires less effort Steps involved •Filming the operation to be studied •Analysis of the data from the film ©MGM IOM,A'bad
- 16. Therblings Sr. Code Name Description Colour 1. SH SEARCH Locate an article Black 2. G GRASP Taking Hold Red 3. H HOLD Prolonged grasp Gold ochre 4. A ASSEMBLE Putting parts Violet together 5. DA DIS- Separating parts Light violet ASSEMBLE 6. U USE Causing a device Purple to perform its function 7. R REST Pause to Orange overcome fatigue ©MGM IOM,A'bad
- 17. •SIMO = SImultaneousMOtion Chart •Recording technique for Micro Motion study •Simultaneous motions are filmed and recorded on a common time scale and analyzed •Therblings performed by different parts of body of one or more operators recorded •Expensive equipments required • used when saving from study is high ©MGM IOM,A'bad
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