METHODS

ENGINEERING

Raden M. Manlambus
College of Engineering
First Asia Institute of Technology and Humanities
 Methods engineering
 The history of industry has been one of
never-ending search for more efficient
manufacturing methods.
 This field is frequently referred to as
«motion study», «methods design»,
«operations analysis», «work study», or
«job design». It is closely affiliated with the
function of «work measurement» or «time
study».
 Areas of application
 The application of methods engineering
ranges from of the design of a new plant,
to the design of a new process, to the
improvement of an existing process.
 Wherever work is being done, methods
engineering is a desirable function to
insure that the work is being done in the
easiest, safest, and most productive way.
 Origin of Methods Engineering
 Methods engineering
grew out of the
pioneering
developments of the
Gilbreths, who
developed many of the
tools of «motion study»
as a part of formulating
a systematic approach
to the analysis of work
methods.
 Frank B. Gilbreth
 Frank B. Gilbreth, who in 1885 was
employed as an apprentice
bricklayer, soon observed that a
journeyman bricklayer used one set of
motions when laying bricks slowly, another
set when working at average speed, and
still a different set when working at rapid
speed. As a result of his observations, he
invented an adjustable scaffold and
developed a set of motions that greatly
increased the number of bricks that could
be laid in a day.
Lillian Gilbreth
 His wife, Lillian Gilbreth, who was
a psychologist, proved to be a
capable partner in the development of
many motion study techniques credited to
them. The Gilbreths had developed many
of the analysis techniques in use today. In
their quest for the «one best way» the
Gilbreths made use of the process chart,
the right- and left-hand operation chart,
micromotion study, and the
chronocylegraph.
Organization for methods engineering
In attempting to determine how much
engineering time and effort can be
justified on a methods project, the
following factors should be taken into
account:
1. the volume of production to be scheduled
of the job,
2. the anticipated life of the job.
3. the current investment in machines,
tools, and equipment, and
4. personnel conditions (union requirements,
retraining time, and so forth).
Approaches to Method Designs
Charles E. Geisel states that in order to
design a system (method) thoroughly
there are eight elements that must be
considered namely:
1. Purpose: The function, mission, aim or
need for the mission.
2. Input: The physical items people, and/or
information that enter the system to be
 processed into the output.
3. Output. That which the system producers
to accomplish its purpose, such as
finished steel, assembled toasters, boxes
and so forth.
4. Sequence. The steps required to
convert, transform, or process the input
to the output.
5. Environment. Condition under which the
system operates, including physical,
attitudinal, organizational, contractual,
 cultural, political, and legal (environments).
6. Human Agents (workers). The people who
aid in the steps of the sequence without
becoming a part of the output.
7. Physical Catalysts (Equipment). The
equipment and physical resources that aid
in the steps of the sequence without
becoming part of the output.
8. Information Aids. Knowledge and
information resources that aid in the steps
of the sequence without becoming part of
the output.
Methods Study (Method Engineering)
Methods Study is a systematic procedure to
develop a work center, produce a product or
provide a service.
Methods
Engineering/Analysis
is the systematic
recording and critical
examination of the
way tasks are
completed in order to
make improvements.
 Methods analysis is concerned with
the reduction of the work content of a
job or operation, while work
measurement is typically concerned
with any ineffective time associated
with the method and subsequent
establishment of time standards for
the operation.
Methods Analysis Objectives are:
 The improvement of processes and
procedures.
 The improvement of plan, office or service
area layout.
 Economy in human effort and the
reduction of unnecessary fatigue.
 Improvement in the use of materials,
machines and manpower.
 Development of a better physical working
environment.
In methods analysis, the following six
questions can help to pinpoint areas for
improvement. For each operation performed
on every part ask:
 Why?
 What?
 When?
 Who?
 Where?
 How?
Steps in Methods Study Program
Select Project

Get and Present Data

Analyze Data

Develop Ideal Method

Present And Install Method

Develop Job Analysis

Establish Time Standards

Follow up
 Select Project
New plant and plant
Get and Present Data expansion
New products, new
Analyze Data methods
Products with high cost/
Develop Ideal Method low profit
Products unable to meet
Present And Install Method competition
Manufacturing difficulties
Develop Job Analysis Bottleneck operations/
exploratory tools
Establish Time Standards

Follow up
 Select Project
Obtain production
Get and Present Data requirements
Procure engineering
Analyze Data data
Procure manufacturing
Develop Ideal Method and cost data
Develop description and
Present And Install Method Sketches of workstation
and tools
Develop Job Analysis Construct operation
process charts
Establish Time Standards Construct flow process
for individual items
Follow up
 Select Project

Get and Present Data

Analyze Data Use 9 primary

approaches to operation
Develop Ideal Method analysis
Question every detail
Present And Install Method Use : why, where, what,
who, when, how
Develop Job Analysis

Establish Time Standards

Follow up
 Select Project

Get and Present Data Worker and machine

process chart
Analyze Data Mathematical techniques
Eliminate, combine,
Develop Ideal Method simplify, rearrange step
Principles of work design
Present And Install Method With respect to:
- Motion economy,
Develop Job Analysis manual work, workplace
- Equipment, tools, safety,
Establish Time Standards work environment

Follow up
 Select Project

Get and Present Data

Analyze Data
Use decision-making tools
Develop Ideal Method Develop written and oral
presentation
Present And Install Method Overcome resistance
Sell method to operators,
Develop Job Analysis supervisor, and
management
Establish Time Standards Put method to work

Follow up
 Select Project

Get and Present Data

Analyze Data

Develop Ideal Method

Present And Install Method

Job analysis
Develop Job Analysis Job description
Accommodation of
Establish Time Standards differently able
to workers
Follow up
 Select Project

Get and Present Data

Analyze Data

Develop Ideal Method

Present And Install Method

Stopwatch time study
Develop Job Analysis Work sampling
Standard data
Establish Time Standards Formulas
Predetermined time
Follow up system
 Select Project

Get and Present Data

Analyze Data

Develop Ideal Method

Present And Install Method

Verify saving
Develop Job Analysis Assure that installation is
correct
Establish Time Standards Keep everyone sold
Repeat methods
Follow up procedure