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November 5, 2012
Work Study
Work Study is a generic term for management services
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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.
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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
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Methodology (Cont.)
Select Record Examine
OK ? Develop
Install
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Maintain
Pareto Analysis Fish & Bone Diagrams Gantt and PERT charts
Operation Process Chart Flow process chart Flow diagram Worker and Machine Process Charts Gang Process charts Synchronous Servicing
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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.
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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.
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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.
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Some parts require no fabrication steps. These parts are called buyouts. Buyouts are introduced above the operation Tape
Carton
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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
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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.
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75 ft.
You
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Flow Process Types: Product or Material type Worker (Man) type Machine type
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Delay Storage
Inspection
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Operation
Occurs when an object is intentionally changed in
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Transportation
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
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Inspection
Occurs when an object is examined for
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Delay
Occurs when the immediate performance or the
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Storage
Occurs when an object is kept under control such
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Combined Symbols
Two symbols may be combined when two
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Summary
Activity Operation Transport Inspect Delay Store Number of steps 5 9 2 3 Time (min) 23 11 8 8 Distance (ft) 815
(ft)
15 40 40 60 200 200 60 180 20 X X X X X X X X X X X X X X X X X X X
Step description
Enter emergency room, approach patient window Sit down and fill out patient history Nurse escorts patient to ER triage room Nurse inspects injury Return to waiting room Wait for available bed Go to ER bed Wait for doctor Doctor inspects injury and questions patient Nurse takes patient to radiology Technician x-rays patient Return to bed in ER Wait for doctor to return Doctor provides diagnosis and advice Return to emergency entrance area Check out Walk to pharmacy Pick up prescription Leave the building
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
0.50 10.0 0.75 3.00 0.75 1.00 1.00 4.00 5.00 2.00 3.00 2.00 3.00 2.00 1.00 4.00 2.00 4.00 1.00
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Left-Hand-Right-Hand Charts
Useful in analyzing the work performed by one
To assist in finding a better method of performing the task and To train the operator in the preferred method.
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Symbols
Two symbols are used in this chart:
Transportation (either an arrow or a small circle) Action (e.g., grasp, position, use, release)
materials.
Record the motions of one hand at a time Usually necessary to redraw the chart
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Hold Letter
Sign letter
Return pen to holder Release pen in holder Move hand back to letter
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LEFT HAND
Reach for bolt in bin 1 Grasp bolt Carry bolt to work area Position bolt Hold Bolt Carry assembly to bin 3
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RIGHT HAND
Reach for nut in bin 2 Grasp nut Carry nut to work area Position nut Assemble nut
Release nut
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Man-machine chart
The worker and machine process chart (Man-machine
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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.
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Activity Chart
Subject: Semi-Auto Machine Present
Time
1
Operator
Load machine
Machine
Being loaded
2 3
4 5 6
Idle Unload
Run
Being Unloaded
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Any Question
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