WORK STUDY

(METHOD STUDY)
-Bhabajit Baruah,
Assistant Professor,
Department of Mechanical Engineering,
GIMT-Guwahati
INTRODUCTION

 With increasing complexities of the technological world, need to

simplify the work system has been increasing day by day.

 Work study is an area of knowledge that addresses the problem of

work simplification with the basic objectives of productivity
enhancement, human comfort & safety.
EVOLUTION OF WORK STUDY

 F.W.Taylor: Founder of modern method and time study.

 Taylor began his time study work in 1881.

 He established that each job should have a standard time, determined by

time studies.

 In the timing process, Taylor advocated dividing the work into small
divisions of effort known as elements.
 Time was obtained for these element individually and their collective
values were used to determine the allowed time for the task.
WORK OF GILBERTH
 Frank B. Gilbreth and his wife Lillian M. Gilbreth began to develop motion
study in the year 1885. They are considered as the founder of „modern motion
study technique‟ which is defined as the study of body motions used in
performing an operation for the purpose of improving the operation by:

 Eliminating unnecessary motions.

 Simplifying necessary motions.

 Then establishing the most favorable motion sequence for maximum

efficiency.
IMPORTANCE OF WORK STUDY

 Enhancing the production efficiency of the firm.

 Technique to identify non-value operations.

 Only accurate and systematic procedure oriented techniques are adopted.

 Has got universal application.

DEFINATION OF WORK STUDY

 “It is a generic term for those techniques, method study and work
measurement which are used in the examination of human work in all its
context and which lead systematically to the investigation of all the factors
which affect the efficiency and economy of the situation being reviewed, in
order to effect improvement”.

 “It is that body of knowledge concerned with the analysis of the work
methods and the equipment used in performing a job, the design of an
optimum work method and the standardization of proposed work methods”.
WORK STUDY

 Work study has contributed immeasurably to the search for better

method, and the effective utilization of this management tool has
helped in the accomplishment of higher productivity.

 Work study is a management tool to achieve higher productivity in

any organization whether manufacturing tangible products or
offering services to its customers.
 OBJECTIVES OF WORK STUDY
 To analyze the present method of doing a job, systematically in order to develop
a new and better method.
 To measure the work content of a job by measuring the time required to do the
job for a qualified worker and hence to establish a standard time.
 To increase the productivity by ensuring the best possible use of human, machine
and material resources and to achieve best quality product/service at minimum
possible cost.
 To improve operational efficiency.
 To reduce waste through standardization of work elements of a job.
 To improve labor efficiency.
BENIFITS OF WORK STUDY
 Increased productivity and operational efficiency.
 Reduced manufacturing costs.
 Improved work place layout.
 Better manpower planning and capacity planning.
 Fair wages to employees.
 Better working conditions to employees.
 Improved work flow.
 Reduced material handling costs.
 Provides a standard of performance to measure labor efficiency.
 Better industrial relations and employee morale.
 Basis for sound incentive scheme.
 Provides better job satisfaction to employees.
APPLICATION OF WORK STUDY
 Industries:production operations, research and development

 Marketing: sales & distribution.

 Offices: stores & warehouses.

 Material handling

 In designing field

 Building & other construction

 Transport

 Hospital

 Army

 Agriculture
STEPS INVOLVED/ PROCEDURE IN WORK STUDY
1. SELECT
Job Or Process To Be Studied

2. RECORD
All the details concerning job using various Recording Techniques

3. EXAMINE
Recorded facts critically by asking questions like who, what, when, why

4. DEVELOP
Most economical method

5. MEASURE
The amount of work involved and set standard time to do that job

6. DEFINE
The new method for the jobs, process, operation

7. INSTALL
The new method as a standard practice

8. MAINTAIN
New method as agreed standards
PRINCIPLES OF WORK STUDY

 Must come from the top level management.

 People made aware of the objectives and the need of exercising such study.

 Method study must precede work measurement.

NEED OF METHOD STUDY

WORK
STUDY

METHOD STUDY WORK MEASUREMENT

• Motion Study : Examine the • Time Study : Determine the
job and finding more time necessary to perform a
efficient method to perform job and its elements.
it.
COMPONENTS / TECHNIQUES OF METHOD STUDY
 Manufacturing industry uses following resources:

MONEY

MEN MATERIAL

METHOD STUDY

TECHNOLOGY MACHINE

 These resources must be used in most effective and efficient manner.

METHOD STUDY
 It is the systematic recording & critical examination of existing and proposed
ways of doing work, as a means of developing and applying easier and more
effective methods and reducing cost.
 The main purpose of method study is to eliminate the unnecessary
operations and to achieve the best method of performing the operation.
 It aims at improving the present method and developing a new and cheaper
method.
 It is also called as method improvement or work improvement.
 It includes the study of work processes, working conditions and equipments
and tools to carry out the job.
CONCEPT OF METHOD STUDY

Method study are used to analyze:

 Movement of body, people or material.
 Activities of people and machines.
OBJECTIVES OF METHOD STUDY
 To study the existing proposed method of doing any job, operation or
activity.

 To develop an improved method to improve productivity and to

reduce operating costs.

 To reduce excessive material handling or movement and thereby reduce

fatigue to workmen.

 To improve utilization of resources.

 To eliminate wasteful and inefficient motions.

 To standardize work methods or processes, working conditions , machinery,

equipments and tools.
STEPS INVOLVED IN METHOD STUDY
STEP 1
1. SELECT the work or job to be studied and define the objectives to be
achieved by the method study. The job should have scope of work
improvement through reduction of excessive material handling and fatigue
to workmen, scope for improving the working conditions and utilization of
resources.

While selecting a job for doing method study, the following factors are
considered:
(a) Economical factors.
(b) Technical factors.
(c) Human factors.
ECONOMIC CONSIDERATIONS

 Cost effectiveness, i.e. check whether the work study application would pay
or not.
 For this, key profit giving/costlier operations with largest waste/scrap
should be targeted first.
 Next, bottleneck operations, repetitive operations, repeat material handling
operations should be studied.
 For locating most important operations, PARETO ANALYSIS could be used.
TECHNOLOGICAL CONSIDERATIONS

 The analysis involves application of work study for the selection of the
operations/processes where new technology, e.g. automation/robotization
should be introduced.
HUMAN CONSIDERATIONS

 Analysis involves location of these operations which present the sources of

dissatisfaction or annoyance to the workers due to fatigue or monotony or
unsafe environment.
STEP 2
2. RECORD the relevant facts related to existing methods using the recording
techniques such as-
• Process Charts:
1. Outline process charts 5. Two-handed process chart
2. Flow process chart-man type 6. Multiple activity chart
3. Flow process chart-material type 7. Simultaneous Motion Charts
4. Flow process chart-machine type (SIMO) Charts
• Diagrams:
1. Flow diagrams 4. Chronocycligraphs
2. String Diagrams 5. Travel Chart
3. Cycle Graphs
STEP 3
3. EXAMINE the recorded facts critically challenging everything being done
and seeking alternatives, questioning the purpose, the means, sequence,
place, and the person.
STEP 4
4. DEVELOP the improved method by generating several alternatives and
selecting the best method. The factors to be considered while evaluating
alternatives and selecting the best methods are:
1. Cost of implementation.
2. Expected savings in time and cost.
3. Feasibility.
4. Producibility.
5. Acceptance to design, production planning and control, quality control
production and sales departments.
6. Reaction of employees to the new methods.
7. Short term or long term implication of the alternative.
STEP 5
5. INSTALL the new improved method in 3 phases- planning, arranging and
implementing phases. The implementation phase involves the introduction
of the developed methods as standard practice to achieve the desired
results.
STEP 6

6. MAINTAIN the new method by ensuring that the installed method is

functioning well. This is done by periodic checks and verifications at regular
intervals. Proper control procedures are used to ensure that the new
method is practiced to achieve the benefits of methods study and also to
achieve higher productivity.
ADVANTAGES OF METHOD STUDY
 Work simplification  Less fatigue to the operator

 Improved working method  Optimum utilization of all resources

(cheaper method)  Higher safety to work men

 Better product quality  Shorter production cycle time

 Improved work place layout  Higher job satisfaction

 Improved equipment design  Reduced material consumption and

 Better working conditions wastages

 Better material handling  Reduced manufacturing cost

 Improved work flow and higher productivity

RECORDING TECHNIQUES

 After selection of a potential job for study, next step is to record all the
facts related to the job.
 Success of method study depends on the accuracy and correctness of
event/facts related to job as they form basis for critical examination and
development of new method.
 The techniques help in recording the events precisely in standard form which
can be easily understood by all method study analyst all over the world.
 Recording must be: accurate, clear and concise, understandable.
SYMBOLS USED IN RECORDING TECHNIQUES
 ASME has recommended FIVE standard method study symbols.
RECORDING TECHNIQUE SYMBOLS
1. Operation:

 A large circle indicates operation.

 It indicates the main steps in a process, method or procedure. Usually the part,
material or product concerned is modified or changed during the operation.

 An operation takes place when there is a change in physical or chemical

characteristics of an object. An assembly or disassembly is also an operation.

 When information is given or received or when planning or calculating takes

place, it is also called operation.

 Example: Reducing the diameter of an object in a lathe.

Hardening the surface of an object by heat treatment.

RECORDING TECHNIQUE SYMBOLS
2. Transport:

 An arrow indicates transport. This refers to the movement of an object or

operator or equipment from one place to another. When the movement
takes place during an operation, it is not called transport.

 Example: Moving the material by a trolley.

Operator going to the stores to get some tool.

RECORDING TECHNIQUE SYMBOLS
3. Inspection:

 A square indicates inspection.

 Inspection is checking an object for its quality, quantity or identifications.

 Example: Checking the diameter of a rod.

Counting the number of products produced. of an object by heat

treatment.
RECORDING TECHNIQUE SYMBOLS
4. Delay or Temporary Storage:

 A large capital letter D indicates delay. This is also called as temporary

storage.

 Delay occurs when an object or operator is waiting for the next activity.

 Example: An operator waiting to get a tool in the stores.

Work pieces stocked near the machine before the next operation.
RECORDING TECHNIQUE SYMBOLS
5. Permanent Storage:

 An equilateral triangle standing on its vertex represents storage.

 It 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.

 Example: Raw material in the store room.

SYMBOLS USED IN RECORDING TECHNIQUES
(COMBINED ACTIVITIES)
 A combined activity occurs when two activities occur simultaneously.

 In such situations, the symbols for the two activities are combined.

 Example: The circle within the square represents the combined operation
and inspection.
RECORDING TECHNIQUES IN METHOD STUDY

Recording
Techniques

Charts Based Diagram

Charts Based
on Time Based on
on Sequence
Scale Movements

Outline Process Chart Flow Diagram

Flow Process Chart-Man Type String Diagram
Multi Activity Chart
Flow Process Chart-Material Type Cycle Graph
SIMO Chart
Flow Process Chart-Machine Type Chronocycle Graph
Two Handed Process Chart Travel Chart
 OUTLINE PROCESS CHARTS
 A process chart is a graphic means of representing
the sequence of all operations and inspections
taking place in a process.

 It gives a bird„s eye view of the overall activities.

 Entry points of all material, the sequence of all

operations and inspection associated with the
process are noted in the chart.

 The chart is constructed by placing symbols one

below another.
 It is the most popular method of recording the facts.
FLOW PROCESS CHARTS

 A flow process chart is a graphical representation of the sequence of all the

activities (operation, inspection, transport, delay and storage) taking place in a
process.

 It is the detail version of outline process chart recording all the event.

 Process chart symbols are used here to represent the activities.

 FLOW PROCESS CHARTS

 Material Type
 FLOW PROCESS CHARTS

 Man Type
 FLOW PROCESS CHARTS

 Machine Type
TWO-HANDED PROCESS CHARTS
 It is the process chart in which the activities of two hands of the operator are
recorded.

 Motions of both hands of worker are Right hand-Left hand chart recorded
independently.

 It shows whether the two hands of the operator are idle or moving in relation to
one another, in a timescale.

 It is generally used for repetitive operations.

TWO-HANDED PROCESS CHARTS
 Operation: Represents the activities grasp, position, use, release etc. of a tool,
component or material.

 Transport: Represents the movement of the hand or limb to or from the work or
a tool or material.

 Delay: Refers to the time when the hand or limb is idle.

 Storage (Hold): The term „hold‟ is used here instead of storage. This refers to
the time when the work is held by hand.

 The activity ‘inspection’ by hand is considered as an operation. Hence, the

symbol for inspection is not used in this chart.

 Two-handed process chart can be used for assembly, machining and clerical jobs.
TWO-HANDED PROCESS CHARTS
TWO-HANDED PROCESS CHARTS
MULTIPLE ACTIVITY CHARTS
 A Chart in which the activities of more than one item are recorded on a
common time scale to show their inter-relationship.
 It is used when a worker operates a number of machines at a time. It is
also used when a number of workers jointly do a job.

 Multiple Activity Charts are very useful tool for understanding the flow of work
in a cyclic process and as a consequence understanding which resource is
controlling the overall progress of the work.
 The tool can be used to model different scenarios to determine the optimum
mix of resources for the work.
 Man machine chart is the type of multiple activity charts.
EXAMPLE OF MAN-MACHINE CHART (PRESENT METHOD)
EXAMPLE OF MAN-MACHINE CHART
(SUMMARY OF PRESENT METHOD)

Cycle Time (Min) = 2.0

EXAMPLE OF MAN-MACHINE CHART (IMPROVED METHOD)
EXAMPLE OF MAN-MACHINE CHART
(SUMMARY OF IMPROVED METHOD)

Cycle Time (Min) = 1.4

COMPARISION BETWEEN PRESENT & IMPROVED METHOD)
MICRO MOTION STUDY
 It was suggested by Frank Gilbreth.

 It is a 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.
USE OF FILMS IN MICRO MOTION STUDY
Main advantages of films over visual methods are:
 Permit greater detailing than eye observation.

 Provide greater accuracy than pencil, paper and stop watch.

 More convenient.

 Provide a positive record.

 Help in the development of the work study person.

EQUIPMENTS REQUIRED FOR MICRO MOTION STUDY

16 mm FILM MOVIE CAMERA WINK COUNTER

EXPOSURE METER MOTION PICTURE PROJECTOR WITH SCREEN

 THERBLIG-GILBRETH CHART
It deals with the:

 Movement of man who is working, not machine.

 Study of micro motion of body parts and hands.

Gilbreth described 18 motions known as therblig.

USE OF FILMS IN MICRO MOTION STUDY
THERBLIGS
 Search (SH) – attempt to find an object using eyes or hand
 Find (F) – mental reaction at end of search
 Select (ST) – choose among several objects in a group
 Grasp (G) – grasp an object
 Hold (H) – hold an object
 Transport loaded (TL) – move an object with hand and arm
 Transport empty (TE) – reach for an object
 Position (P) – position object in defined location
 Assemble (A) – join two parts
THERBLIGS
 Use (U) – manipulate a tool
 Disassemble (DA) – separate multiple parts that were previously joined
 Inspect (I) – determine quality of object
 Pre-position (PP) – position object for next operation
 Release load (RL) – release control of an object
 Unavoidable delay (UD) – waiting due to factors beyond worker control
 Avoidable delay (AD) – worker waiting
 Plan (PN) – decide on an action
 Rest (R) – resting to overcome fatigue
SIMO CHARTS
 “SIMO” stands for simultaneous-Motion Cycle chart. It is one of micro motion study
devised by Gilbreth.

 It presents graphically the separable steps of each pertinent limb of the operator
under study.

 It is an extremely detailed left and right hand operation chart.

 It records simultaneously the different therbligs performed by different parts of the

body of one more operators on a common time scale.

 The movements are recorded against time measured in “Winks” (1 wink= 1/2000
minute).

 These are recorded by a “Wink Counter” positioned in such a location that it can be
seen rotating during filming process.
SIMO CHARTS
 RECORDING TECHNIQUES – DIAGRAMS BASED ON
MOVEMENTS
 It indicates the path of movement.

 Study of traffic & frequency over different routes of plant.

 Identification of back-tracking & obstacles during movements.

 Study of different layout plans & select optimal layout.

 FLOW DIAGRAMS
A flow diagram is essentially a flow process chart drawn to:
 Show the layout of a facility.
 Show the flow of work through that area.

 Show overcrowding areas, crossing worker paths, total travel.

 Identify how layout can be redesigned to reduce travel, motion, collisions, etc.
 Store materials near where they are used.
 Increase efficiency and safety.
STEPS INVOLVED IN FLOW CHARTS

 Layout of work station is drawn to scale.

 Relative positions of machine tools, work benches, etc are marked.

 Path followed by the subject under study is traced by drawing lines.

 Each movement is serially numbered and indicated by arrow for direction.

 Different colors are used to denote different types of movements.

EXAMPLE OF FLOW DIAGRAMS
EXAMPLE OF FLOW DIAGRAMS
STRING DIAGRAM
 String/Thread is used to measure the distance.

 Records the pattern of movement of a worker working within a limited area

during a certain period of time.

 Repetitive movements can be conveniently traced.

 It is used for recording the complex movements of material or men.

 Back tracking, congestion, bottlenecks, under utilized paths are easily found out.

 It is used to check whether the work station is correctly located.

 Used to record irregular movements.

 Used to find out the most economical route.

STEPS INVOLVED IN STRING DIAGRAM

 Layout of the work station or factory is drawn to scale on a soft board.

 Pins are fixed into boards to mark the location of work stations.

 Pins are also driven at the turning point of the routes.

 A measured length of thread is taken to trace the movement(path).

 The distance covered by the object is obtained by measuring the remaining

part of the thread and subtracting it from the original length.
EXAMPLES OF STRING
DIAGRAM
CYCLE GRAPH
 This is the photographic techniques for the study of path of movements of an
operator‟s hands and fingers.

 These are used especially for those movements which are too fast to be traced
by human eye.

 The technique was first used in 1890 by Marley to study the movements of
athletes and later developed by Gilbreth in the study of work.

 Electric light bulbs are attached to the hands, arms or feet of the subject whose
work is being analyzed.
CYCLE GRAPH
 A record of path of movements, usually traced by the continuous source of a light
on a photograph.

 A photograph showing the movement depicted as a continuous pattern of light

and it is made by exposing a film or plate for the period of cycle of the activity
being analyzed.

 Later it is used with a stereoscopic camera to show the path in three dimensions.

 One of the difficulties in the cycle graph is that it does not indicate the direction or
the speed of the movement.
 METHOD FOR CYCLE GRAPH
 To make a cycle graph, a small electric bulb is attached to the finger, hand or any
other part of the body whose motion is to be recorded.

 By using still photography, the path of light of bulb (in other words that of the body
member) is photographed by keeping the working area relatively less illuminated.

 The resulting picture (cycle graph) shows a permanent record of the motion pattern
employed in the form of closed loop of white continuous line with the working area
in the background.

 Alternatively, such a light maybe attached to a worker‟s helmet if the purpose is to

obtain a record of the path over which he or she moves during the performance of
the task.
EXAMPLE OF CYCLE GRAPH
Light (Bulb)
attached to
the hand
USES OF CYCLE GRAPH
 Improving the motion pattern.

 Training purposes also in which two cycle graphs may be shown with one
indicating a better motion pattern than the other.
CHRONOCYCLE GRAPH
 This is the photographic techniques for the study of path of movements of an
operator‟s hands and fingers.

 These are used especially for those movements which are too fast to be traced
by human eye.

 The chronocycle graph is a special form of cycle graph in which the light source
is suitably interrupted so that the path appears as a series of pear-shaped dots,
the pointed end indicating the direction of the movement and the spacing
indicating the speed of the movement.

 Sports professionals use this analysis extensively for the purpose of training in the
development of their skills for enhancing their performance.
CHRONOCYCLE GRAPH-HOW IT WORKS?
 A flash bulb is attached to the object which the
path has to be traced out and analyzed and a
camera is used to record the traces in the long
exposure.

 The white lines that can be seen are the traces of

the movement recorded by the camera and the
light source has been attached to the fingers.

 So the LED light source is attached to the finger

and this is recorded with the help of a camera.
INTERPRETATION OF CHRONOCYCLE GRAPH
 It shows the short dashes of line spaced in proportion to speed of the body
member or the object being photographed.

 Wide spacing would represent fast movement while close spacing would
represent slow movement.

 The jumbling of the dots at one point would indicate fumbling or hesitation of
the body member.

 A chronocycle graph can thus be used to study the motion pattern as well as to
compute the velocity, acceleration and retardation experienced by the body
member at different locations.
USES OF CHRONOCYCLE GRAPH
 Developing a better work place-chronocycle graph reveals obstructions and
bad locations.

 Analysis of a complex movement.

 An aid to training.

 Comparison of two methods.

 Design of a new equipment.

TRAVEL CHART
 The chart which gives an estimate about the amount of materials handling
between various work stations is known as “Travel Chart”.

 The aim of travel chart is to decide such layout where overall materials handling
function is performed at minimum cost.

 Movement of workers, material & equipment at any time and any workstation is
shown numerically by two way matrix.

 Travel chart is square tabular where each column and row represents single work
station.
TRAVEL CHART
 Construction of travel chart depends on the “from-to” chart. Once the frequency
& distance travelled between workstations is measured, the total distance
travelled is placed in terms of each distance travelled.

 According to that, change the layout design of the plant with the aim to reduce
the total distance travelled.
TRAVEL CHART
 As shown in the diagram, travelling
from one station to other is
represented as “X”.

 So there is high work load on the

station no. 4 & 6, almost from all
department.

 So, if the layout is changed in a such

reducing the travel distance, then it is
possible to reduce travelling cost as
well as travelling time.
 PRINCIPLES OF MOTION ECONOMY
These principles can be considered under three different groups:

 Those related to the use of the human body.

 Those related to the workplace arrangement.

 Those related to the design of tools & equipment.

PRINCIPLES OF MOTION ECONOMY
Principles related to the use of human body:

 Both hands should begin and end their basic divisions of activity simultaneously
& should not be idle at the same instant, except during the rest periods.

 Momentum should be employed to assist the worker wherever possible, and it

should be reduced to a minimum if it must be overcome by muscular effort.

 Continuous curved motions should be preferred to straight line motions involving

sudden and sharp changes in the direction.

 Work that can be done by the feet should be arranged so that it is done together
with work being done by the hands.

 Twisting motions should be performed with the elbows bent.

PRINCIPLES OF MOTION ECONOMY
Principles related to the arrangement & conditions of workplace:

 Fixed locations should be provided for all tools and materials so as to permit the
best sequence and eliminate search and select.

 Gravity bins and drop delivery should be used to reduce reach and move times.

 Use may be made of ejectors for removing finished parts.

 Work table height should permit work by the operator in alternately sitting
and standing posture.

 Glare-free adequate illumination, proper ventilation and proper temperature

should be provided.
 PRINCIPLES OF MOTION ECONOMY
Principles related to the design of tools and equipment:
 Use colour, shape or size coding to maximize speed and minimize error in finding
controls.
 Use simple on/off, either/or indicators whenever possible.
 All levers, handles, wheels and other control devices should be readily accessible to
the operator and should be designed so as to give the best possible mechanical
advantage.
 Use quick acting fixture to hold the part/material upon which the work is being
performed.
 Use stop guides to reduce the control necessary in positioning motions.
 Operating, set-up and emergency controls should be grouped according to the
function.
PRINCIPLES OF MOTION ECONOMY