Work Study

30th October, 2007

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What is work Study
 Work Study is defined as process which is used
to examine human work in all its contexts.
 It leads to systematic investigations of all
factors which effect the efficiency of situation
being reviewed

To Seek
Improvements
 It aims at finding the best and efficient way of
using :

Men , Material, Money & Machinery

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Elements of Work Study
 Method and Motion Study:
 Systematic investigation of existing method in order to
develop and install an easy ,rapid ,efficient , effective and
less fatiguing procedure for doing same job at lower
costs.
 Done by eliminating unnecessary motions, alteration of
sequence in a process or alteration of process itself

 Work Measurement
 Application of different techniques to measure and
establish the time required to complete the job by a
qualified worker at a defined level of performance

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Work Study – Advantages & Applications
 Advantages:
 Unfiform and improved production flow

 Higher productive efficiency

 Reduced manufacturing costs

 Fast and accurate delivery dates

 Better Wage setting procedures

 Applications of Work Study:

 Industries ( production operations,research and development)

 Marketing,sales and distribution

 Offices,stores and warehouses,

 Material handling

 Building and constructions

 Hospitals and army and agriculture.

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Method Study - Procedure
 Select and set objectives:
 To reduce manufacturing cost
 Reduce bottle neck
 Increase operator efficiency

 Record all data pertaining to existing method by:

 Process Charts :

1. Flow process chart

2. Two handed process chart

3. Multiple activity chart

 Flow Diagrams
 Models
 Motion and film analysis:

1. Simo chart - Simultaneous Motion Chart 5

Flow Process Charts for Data Recording
This chart uses This chart is of 3 types:
circles for operations  Man – Activities of operator
arrows for transports  machine - Manner in which the
squares for inspections equipment is used
 triangles for storage  Material - the changes the material
letter D for delays. undergoes in location or condition
Before Layout Revision Process
Sl.
No Operation M achine

1
.
Storage
From In After Layout Revision Process
trolley
Sl.
2 Coining Press Operation Machine
No.
Storage + Relief
3 Trolley In
Plug Assy. 1 Storage
trolley
4 Ball Pressing Press

On the 2 Coining Press

5 Storage
Machine

6 Leak Check Air Gauge 3 Bearing Pressing Press

7 Storage Table
4 Ball Pressing Press
Poppet
8 Table
assembly Leak Check&
5 Table
9
Bearing
Press Poppet Assy.
Pressing
Thrust washer Poka-
10 Storage Table 6
Assy. Yoke
Thrust washer
11
Assy.
Poka-Yoke Total 1 5 0 0 0

12 Storage --

Total 6 6 0 1 4

Vertical lines connect these symbols in the sequence they are performed. 6
Two handed Process Charts for Data Recording

Two handed process chart records the activities of left and

right hand as related to each other
• Use of human body
Process
• The two hands should begin and LH RH Right hand Operation
Left hand Operation
complete their movements at the same
time Pick up Bolt Idle

• The two hands should not be idle at the Hold Pick up Nut
same time except during periods of rest
Hold to left hand
• Motions of the arms should be
Hold assemble
symmetrical,in opposite direction and
simultaneous
• Continuous curved movements are to Summary of Saving
preferred to straight line motions Activity LH RH
involving sudden and sharp,changes in
Operation 1 2
direction
Transport 0 1
• Work should be arranged so that eye
movements are confined to a Check ing 0 0
comfortable area, without the need for
Storage 3 1
frequent changes of focus
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Multiple Activity Charts for Data Recording
This chart records simultaneously the activities of all the workers and machine on a
common time scale and shows inter- relations between them
To detect idle times and to decide no. of workers

To balance work team and optimize work distributions between workers

Applications:
 Plant repair and
maintenance
 Planning team work

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Flow Diagram for Data Recording
Flow Diagram depicts the probable
movement of materials in the floor plant.
The movement is represented by a line
in the plant drawing.
 This chart indicates the movement of

men and materials

 If these movement are reduced it will

lead to cost and effort reduction

 The path of movements can be

better visualized

 Measures the distances moved and

points out if the work stations are

suitably located 9
Method Study - Procedure
 Examine – asking questions
 Purpose – what is done ?
 Person – Who does it ?
 Place – Where it is done ?
 Means – how is it done ?
 Sequence – When it is done
1. Why is it necessary ,why is it done by that method etc.,
2. Determine alternate ways of doing
3. Determine best method of of doing

Operation Analysis

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Method Study - Operation Analysis
 Detailed study of different operations involved In doing a work
 Some of the work elements to be
 Combined
 Eliminated
 Altered in sequence
 Operation analysis involves in optimizing the processes with regard to:
 Worker in terms of fatigue
 Setup in terms of modification of setup, availability of equipments and number of
setups
 Material specification,cost
 Material handling – backtracking,distance reduction
 Operations
 Tools and fixtures – easy to use
 Work condition – lighting,ventilation
 Analysis of motion :
 Identification of productive and idle motions
 Elimination of unnecessary and non- productive motions
 Redesign of the existing operatios by employing minimum number of motions and
appropriate sequence
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Method Study - Work place Layout design
 Materials and tools to be available in predetermined places closes to
the worler
 To be located in the order of their use
 Use of gravity , for raw material to reach operator wherever possible
 Comfortable posture for operator
 Should be able to operate levers and handles without alteration in
body postures
 Working place classification
 Actual working area – most convenient area to work (1)
 Normal working area – it is within the reach of the operator (2)
 Maximum Working area - It is accessible with full arms stretch (3)

3
1 2

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Method Study - Procedure

 Develop best method which is :

 Practical , feasible, safe and economical

 Acceptable to design and production and quality control and

sales

 Install developed method and examine for

problems

 Maintain new method by periodic checks and

verifications

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Work Measurement

Work measurement is the application of

techniques designed to establish

The time for a qualified worker to

Carry out a specified job at a defined level of

performance
A qualified worker is one who is:
Accepted as having the necessary physical attributes,
Who possesses the required intelligence and education,
Who has acquired the necessary skill and knowledge to carry out the
work in hand to
Satisfactory standards of safety,quantity and quality
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Work Measurement - Application
The uses of work measurement
• To compare the efficiency of alternative methods
• To balance the work of members of teams, in association with
Multiple activity chart
• To determine, in association with man machine multiple activity
charts, the number of machines an operative can run
• The time standards, once set, may then be used:
– For production planning and scheduling
– Determine plant and Labour requirements
– To set standards of machine utilisation and Labour
performance and as a basis for incentive schemes
– To provide information for Labour-cost control
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Work Measurement Technique – Time Study
Time study is a work measurement technique for recording the times and rates
of working for:

 The elements of a specified job

Carried out under specified conditions,

Analysing the data so as to obtain the time necessary for carrying out the job
at a defined level of performance

Basic time study equipment

A stop watch

A study board

time study forms

camera
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Time Study – Procedure
Obtaining and recording all the information available about the job,
the operative and the surrounding conditions
Recording a complete description of the method,breaking down the
operation into elements
An element is a distinct part of a specified job selected for
convenience of observation, measurement and analysis
A work cycle is the sequence of elements which are required to
perform a job or yield a unit of production.The sequence may
sometimes include occasional elements
 Measuring with a timing device(usually a stopwatch) and recording
the time taken for each element
 At same time, assessing the effective speed of working(Rating)
 Extending the observed times to Basic times
 Determining the allowances to be made over and above the basic
time for the operation
 Determining the standard time for the operation 17
Time Study – Rating & Rating Factor
Rating

• Rating is the assessment of the worker’s rate of

working relative to the observer’s concept of the
rate corresponding to standard performance

How the rating factor is used

• Observed Time x Rating = Basic time
Standard Rating(100)
• Basic time is the time for carrying out an
element of work at standard rating
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Time Study – Standard Time

+ CA

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Work Measurement – Other Techniques
Predetermined Motion Time System (PMTS):
 Does not measure elemnt time
 All manual tasks are made up of certain basic human movement
which are common to all jobs
 The average time taken to perform a movement is constant (BS
3138 :1969)
 Basic time can be calculated by summing times of all motions and
applying rating factor

Method Time Measurement (MTM):

 Time measurement unit ( 1 TMU = 0.0006 min.)
 Analyses the human movements , depending on types of motion
and conditions predetermined time values are given for each
motion
 Basic time can be calculated by summing times of all motions and
applying rating factor
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