METHOD STUDY

(AS A TECHNIQUE OF COST

REDUCTION)

Presented by:
Kiran
(202)
Namrata
(212)
Saumya
(139)
Meena (19
3yrs)
CONTENTS
 Definition and Objectives of Method Study
 Method study procedure


 Method Study

 Man, Machines, Materials, Money, Technology and

Time are the main resources required to produce goods
and are to be deployed in the most effective manner

 We have to select the best available combination of these

resources at any point of time.

Method Study helps in analyzing the existing

methods and develop a more efficient
method for future.
 Definition And Objective of 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.
 THE OBJECTIVES OF METHOD STUDY
ARE

 Improvement of processes and procedures

 Improvement in the design of plant and equipment
 Improvement of plant layout.
 Improvement in the use of men, materials and
machines.
 Efficient materials handling
 Improvement in the flow of production and process.
 Economy in human effort and the reduction of
unnecessary fatigue.
 Method Standardization
 Improvement in safety standards.
 Development of a better physical working
environment
 METHOD STUDY PROCEDURE
The basic approach to method study consists of the
following eight steps:

1. SELECT :- the work to be studied and define its

boundaries.

2. RECORD :the relevant facts about the job by direct

observation and collect such additional
data as may be needed from appropriate
sources.

3.EXAMINE the way the job is being performed and

challenge its purpose, place, sequence
and method of performance.

4. DEVELOP the most practical, economic and

effective method.
5.EVALUATE different alternatives to developing
a new improved method, and
compare the cost-effectiveness of
the selected new method with the
current method of performance.
6.DEFINE the new method in a clear manner and
present it to those concerned, management,
supervisors and workers.

7.INSTALL the new method as standard practice

and train the persons involved in applying it.

8.MAINTAIN the new method & introduce control

procedures to prevent a drawback to the previous
method of work.
 These are the seven essential stages in
the application of method study ; none
can be excluded. Strict adherence to
the sequence, as well as to their
content, is essential for the success of
an investigation. They are shown
diagrammatically on the chart.
STEP 1: SELECTING THE WORK TO BE
STUDIED

There are three factors that should be kept in mind when

selecting a job.
1. Economic or cost-effective considerations.
2. Technical considerations.
3. Human considerations.

1. Economic considerations:
It is obviously a waste of time to start or continue a
long investigation if the economic importance of a job
is small.
Questions that should always be asked
 Will it pay to begin a method study of this job? Or

 Will it pay to continue this study?

Obvious choices for study are:
 A. Key profit-generating or costly operations or ones with the largest
Scrap/waste rates.
 B. Bottlenecks which are holding up other production operations, or
lengthy operations that consume a great deal of time.
 C. Operations involving repetitive work using a great deal of labor
and ones that are likely to run for a long time.
 D. Movements of material over long distances between workstations,
those involving the use of a relatively large proportion of labor or
which require repeated handling of material.

 One of the easiest techniques that can be used to identify key

operations as listed in part (A) is the Pareto analysis (sometimes
also referred to as “the ABC analysis of value analysis”).
 The same observation can be extended by saying that among all the
operations in a given plant a small number account for the largest
share of cost or of profit, or the largest percentage of waste.
To illustrate the point we will consider the following
example.
Let us assume that a certain enterprise produces 20
different
products.
Each of these products generates a certain profit.
By listing the annual production and profit contribution
one
obtains the results shown in table 6.
The next step consists of rearranging these items in
descending
order of importance according to profit. The result would
then
appear like the one shown in table 7.
From table 7 it can be seen that three products only,
listed as
“A items”, account for 60 per cent of the profit.
These are the most profitable and any improvement in
methods
of producing these particular products would reflect highly
on
profits. They would be a priority for study.
Products listed under “B”, which are seven in number,
contribute 25 per cent of the profit. They could then
assume a
2. Technical or technological considerations:

One of the important considerations is the desire by management to

acquire more advanced technology, i.e. in equipment or in processes.

 Therefore, management may want to computerize its office paperwork or

its inventory system, or to introduce automation in the production
operations.
 Before such steps are taken, a method study can point out the most
important needs of the enterprise in this respect.
 The introduction of new technology should therefore constitute an
important factor in the choice of methods of work to be investigated.

3. Human considerations:

 Certain operations are often a cause of dissatisfaction by workers.

 They may bring on fatigue or monotony or may be unsafe to operate.
 The level of satisfaction should point to a need for method study. In a
similar fashion, a choice of a particular job for study may lead to anxiety or
ill feeling. The suggestion given here is to leave it alone.
 STEP 2: RECORDING THE FACTS
The next step in the basic procedure, after selecting the work to be
studied,
is to record all the facts relating to the existing method
The success of the whole procedure depends on the accuracy with
which the
facts are recorded, because they will provide the basis of both the
critical
examination and the development of the improved method
 Recording techniques – known as CHARTS and DIAGRAMS
 Charts and diagrams broadly grouped as:
PROCESS SEQUENCES includes the following CHARTS

Operation
Process Chart Flow Process
Chart
Man , Material
and Two Handed
Equipment Type Process Chart
 Process Chart Symbols…

Operation

Indicates the main steps in a process, method or procedure.

Usually the part, material or product concerned is modified or
changed during the operation.

Inspection

Indicates an inspection for quality and / or check for quantity

Transport
Indicates the movement of workers, materials or equipment from place
to place
 Process Chart Symbols…
Temporary Storage or Delay

Indicates a delay in the sequence of events : for example, work waiting

between consecutive operations, or any object laid aside temporarily without
record until required.

Permanent Storage

Indicates a controlled storage in which material is received into or issued

from a store under some form of authorization; or an item is retained for reference
purposes.
 The Outline Process Chart

An outline process chart is a process chart giving an overall

picture by recording in sequence only the main operations and
inspections

 It does not portray the details – delays , movements, and

storage
 It does not go into the details of the details of the place of
activity, the person who performs it, or the physical means of
achievement
 In making an outline process chart we start with a vertical
line down the right hand side of the page to show the
operations and inspections undergone.
 The Outline Process Chart-
Example
For the purpose of illustration , the case of the repair of a
bicycle is taken.

In this example it is assumed that the bicycle had been involved
in a minor accident and required restricted repairs to the
front wheel, the left pedal and the steering handle.

The Outline Process Chart would be

 OBSERVATIONS

After operation number 15, the next operation shown is number 23.
Operations 16 to 22 are covered by the seven repetitions of
operation 15. Similarly , the gap between Inspection number 3 and
11 is accounted for by the seven repetitions of inspection 3.
 FLOW PROCESS CHART (FPC)

It is a process chart setting out the sequence of the flow of a

product or procedure by recording all events under review
using appropriate process chart symbols.

BENEFITS: In identifying ways of improving the process by

eliminating unnecessary idle time, minimizing the distances
things must be moved or rearranging tasks for greater
efficiency
 Three types of flow process charts

MAN TYPE:
Flow chart which shows the actions of a person

MATERIAL TYPE:
Flow chart which shows what happens to a product
or item

EQUIPMENT TYPE:
Flow chart which shows how a tool or other piece of
equipment is used
 Flow Process Charts- Material Type

An FPC (Matrl) sets out the sequence of flow of a product or a

document , recording all the events that affect the material or
document being processed.

Illustration : The process of charging of batteries by Umesh

Motors(P) Ltd. Is as follows.
 Customers deposit discharged automobile batteries at the
Reception Bay of the workshop, and obtain a receipt.
 After three days, they collect their respective batteries from
the Delivery Bay of the workshop, on presentation of the
receipt and payment of service charges.
 The reception clerk marks each battery with a customer-
identification number.
He stacks the batteries on a steel shelf.
The chargeable batteries are collected twice a day from the
Reception Bay by mazdoor Dharam.
 He transports the batteries on a stillage truck , and delivers them to
the charging shop, which is 50 meters away from the Reception Bay.

At the Charging Shop , the battery is tested, cell by cell , for voltage
and specific gravity.
 The cells are ‘topped up’ to the correct level.
 The battery is then moved to the charging bench, and placed on
charge by connecting the terminals to the bus bars. While on charge ,
it is tested every four hours for specific gravity.
On completion of charging, which is determined by the specific
gravity of the electrolyte , the connections to the bus bars are
removed.
The battery is tested for voltage of each individual cell.
It is then placed on a stillage(small wooden platform with low legs)

Mazdoor Dharam collects a stillage of charged batteries and transports

them, by a stillage truck, to the delivery bay , which is 35 meters away
from the charging shop . Here the Delivery Clerk takes over the
batteries and places them on a steel rack.
 Flow Process Charts- Man Type

An FPC(Man), sets out the sequence of activities of an individual

performing a task under study .

Only four symbols are employed- operation , inspection, delay,

transport
 TWO HANDED PROCESS CHARTS

Two handed process charts is a chart in which the activities of a

worker’s hands individually(or limbs) are recorded in the relationship to
one another

SYMBOLS AND THEIR DESCRIPTIONS FOR TWO HANDED CHARTS

Operation

Is used for activities for grasp, position, use, release

etc. of a tool, component or material

Transport

To represent the movement of hand to or

from the work, or a tool, or material
Temporary Storage or Delay

Denotes time during which the hand being

charted is idle (although the others may be in
use)

HOLD

In two handed process chart , hold is used to

represent the activity of holding work , tool or
material i.e when the hand being charted is holding
something
MULTIPLE ACTIVITY CHART

A chart on which the activities of more than

one subject (worker, machine or
equipment) are each recorded on a
common time scale to show their
interrelationship

Useful in organizing teams of operatives on

mass production work and also on
maintenance work when expensive plant
cannot be allowed to remain idle longer
 Time (Hours) WORKER 1 WORKER 2 WORKER 3 WORKER 4
Disassembly of lathe Disassemble lathe. Disassemble head Idle
5 Head stock, bed, fed stock, Remove main
and lead screws, spindle, speed change
carriage and tailstock mechanisms, and
change gears.

10
Inspection to Wash with thinner to Repair carriage bed
determine fault remover grease and and lay out screw,
15 clean parts nuts, etc.
Repair and assembly Repair carriage bed, Repair and assemble Grind lathe beds
of feed gear box check and repair feed feed gear box
20 screw and apron of
the carriage.
25
Fit saddle to bed Assemble and mount Repair carriage way
bed and headstock on and lay out screw,
stand nuts, etc.
30 Assemble tailstock.
Fit cross slide and top
slide
Assemble cooling
35 system
Assemble tailstock
Repair and assembly Install electric motor
of apron Idle
Install feed gear box,
apron and feed rod

Installing feed gear Mount electric motors

box apron and feed and fit reservoirs
red
Running in and Run in and finish Run in and finish
MAN-MACHINE CHART
Variant of Multiple Activity Chart
Present a picture of the operations performed simultaneously
by a man and one or more machines
Useful for
1. Better coordination between man and machine
2. Reduction / elimination of idle times of man and
machine to improve the utilization
3. Exploration of alternative man-machine
arrangements suitable to the plant conditions
 TIME Man Machine
Min.
2 Remove finished casting clean with compressed air

4 Gauge depth on surface plate

5 Break sharp edge and clean with compressed air

6 Idle
8 Place in box obtain new casting

10 Clean machine with compressed air

12 Locate castig in fixture: start machine and

automatic feed
15 Idle Mill second face

20
DIAGRAMS
INDICATING
MOVEMENTS

•String Diagram
•Travel Charts
•Flow Diagrams
STRING DIAGRAM
 Observe the clusters of points, pins, turning points.
 Also observe the grid lines which represent a measure of the
distance between the points.
 Red is the staring point and blue is the ending point
CONSTRUCTION OF A STRING
DIAGRAM

 Step-1
 Produce a scale map of the work area
 Identifying all machines, furniture and other equipments in
the diagram that can be moved. These could be shaped as
pieces of card that can be pinned to the work area map
 Step-2
 Identify the points in the process where actions take place
and also identify the doorways, pillars etc that effect the path
movements and mark the positions of these on the map with
map pins and action symbols.
 Step-3
 Tie the end of a pieces of string to the pin where the process
starts and then wrap it around each pin in turn, following the
movement around the process
CONTINUE………………………..
 Step-4
 Mark the string at the start and finish points, using
a pen.
 Step-5
 Measuring between the pen marks, will give the
total distance travelled during the process.
 Step-6
 Rearrange the movable items on the map, aiming
to reduce the total distance
 Strategies for deciding layouts
include:
 Mobility:- Rearrange items and movements around
fixed or immovable items such as heavy machines.

 Function:- Put machines or people together that

perform the same function. This is useful when
varying loads may be between machines.

 Product:- Put machines or people together that make

the same product. This works well when each machine
is used for only one product.
TRAVEL CHART
 A travel chart is a tabular record for presenting
quantitative data about the movements of workers,
materials or equipment between any number of places
over any given period of time.

 The travel chart also identifies movement, when

movements along complex paths are involved.
WHY TRAVEL CHART ?
 Although the string diagram is a neat and effective way of record
the movement of worker or material

o They take long time to construct ;

o Look increasingly like a complex maze with increasing
complexity of movement paths.

 When the movement patterns are complex, the travel chart is

quicker and more manageable to record.
 Count of occurrence

istance between places

FLOW DIAGRAM
 While the flow process chart describes the flow of a product or
process, it is generally supplemented with a flow diagram.

 While the flow process chart records travel distances and time
taken for various operations, the flow diagram is a plan , drawn
to scale of the work area, correctly indicating the position of
machines and working positions.

 The example indicates the flow diagram of receiving,

inspection, marking and storing materials.
IMPROVED FD OF INSPECTION AND
MARKING
 Suitability of different recording techniques:-
Types of Jobs Examples Recording Technique

Complete Sequence of•Manufacture of an electric motor from rawOutline process chart

manufacture material to dispatch; Flow process chart
•Transformation of thread into cloth fromFlow diagram
preparation to inspection;
• Receipt, packing and dispatch of fruit

Factory layout : movement of•Movements of a diesel engine cylinder headOutline process chart
materials through all machining operations. Flow process chart material type
•Movements of grain between millingFlow diagram
operations. Travel chart
 Continue…………………..
Types of Jobs Examples Recording Technique

Factory layout : Laborers servicing spinning machine Flow process chart-man type
movement of workers Cooks preparing meals in a restaurant kitchen String diagram

Handling of materials Putting materials into and taking them out of stores Flow process chart – material type
Loading lorries with finished products. Flow diagram
String diagram

Workplace layout Light assembly work on a bench Flow process chart-man type.
Typesetting by hand Two-handed process chart.
Multiple activity chart.
 Continue…………………..

Types of Jobs Examples Recording Technique

Gang work or Assembly line Multiple activity chart
automatic machine Operator looking after semi-automatic lathe Flow process chart-equipment
operation type
Movements of Female operatives on short – cycle repetition work Multiple activity chart
operatives at work Operations demanding great manual dexterity Flow process chart – equipment
type
EXAMINE

The questioning technique is the means by which the

critical examination is conducted, each activity being
subjected in turn to a systematic and progressive series
of questions.
 
PRIMARY QUESTIONS

The PURPOSE for which

The PLACE at which

The SEQUENCE in which

The PERSON by whom

The MEANS by which

THIS EXAMINATION SEEKS TO

ELIMINIATING
COMBINING
REARRANGING
Identify possibility the recorded
of OR activities
SIMPLIFING
THE SECONDARY QUESTIONS
 Definition
The secondary questions cover the second
stage of the questioning technique, during
which the answers to the primary questions
are subjected to further query to determine
whether possible alternatives to place,
sequence, persons and/or means are
practicable or preferable as the means of
improvement up on the existing method
Combining the two primary questions with the two
secondary questions under each of the headings
“purpose, place”, etc., yields the following list,
which sets out the questioning technique in full:

PURPOSE: what is done?

why is it done?
what else might be done?
what should be done?
PLACE: where is it done?
Why is it done there?
Where else might it is done?
Where should it be done?
SEQUENCE: When is it done?
Why is it done?
When might it be done?
When should it be done?
PERSON: who does it?
Why does that person do it?
Who else might do it?
Who should do it?
MEANS: How is it done?
Why is it done that way?
How else might it be done?
How should it be done ?

These questions, in the above sequence, must be asked

systematically every time a method study is undertaken.
They are the basis of successful method study.
Remember Rudyard Kipling's
I keep six honest serving men, They taught me all I
knew, Their names are What and Why and How and
Where and When and Who
DEFINING THE IMPROVED METHOD
 The report should show:
Relative costs in material, labour and overheads of
1.    

the two methods, and savings expected.

2.The cost of installing the new method, including the
cost of new equipment and of re-laying out shops
or working areas
3.  Executive actions required to implement the new
method.  

 It should also give details regarding :

1. The tools and equipment to be used
2.  A description of the method
3. A diagram of the work place layout, jigs/fixtures
etc
INSTALLATION OF THE NEW METHOD

 The success of method study is realized when actual change is made

on ground.

 The first part of installation is to define the new method by preparing

‘the written standard practice.

 This method is perhaps the most difficult step of method study

procedure as it needs reassuring, retraining and supporting through
acquisition of new skills.

 New method involves gaining approval of following personnel for the

changes suggested:
1. Concerned department supervision
2. Works and general management
3. Workers and their representatives
 The install Phase in some cases, will require a parallel running of
old and new systems.

 While in other cases it may require the build up of buffer – stocks.

 It may also require changes in procedures, or minor addition of

equipment and process.

 Thus, the successful introduction of new working methods is

extremely important because very often there is only one chance
to make change.
MAINTAIN THE NEW STANDARD

 After the introduction of new working methods, it is necessary to

check and verify that the new method is working and is it bringing
the desired results or not. This is the maintain phase.

 Proper control procedures are used to ensure that new method is

practiced to achieve the benefits of method study and also to
achieve higher productivity.

 One of the common problems of maintaining the new standard is

method drift.

 At last, installation is to be preceded by retraining the workers to

operate new methods. Close contact with the progress of the job
must be maintained, till it is performed.
FINAL EXAMPLE
 Here I took an example of car manufacturing
process.
 As first step is to select the work is to be
studied. Here I select the process of car
manufacturing.
 Step-1 select, manufacturing process of car
STEPS INCLUDE IN MANUFACTURING
PROCESS

Parts are produced in various plants

Start with the frame
Installing the parts
Engine and Transmission Installed
Building the Shell
Final Body Components
Inspection and Washing
Paint
The Inner Workings
The Shell and the Frame
Test the Car
RECORDING OF WORK
 Suppose, here I used string diagram to record the work.

Plants
EXAMINE
 Here assume that total length of thread is
30cm and therefore total distance has to
covered within the process is 30*100= 3000
m. More distance means more time and more
time mean more cost.
 So improvement is required to reduced the
distance.
 After considering all activities. It can be seen
that all machineries are movable. So here we
rearrange all machineries and after that will
see the synergy.
INSTALLATION, MAINTANCE OF NEW
SYSTEM
 Before installation of new plan
 Length of thread
 Distance

 Time

 Cost

 Of the new model should be major and compare with

the original one
 If profitable then install the new plan and
maintain it through regular check on it